1998 Gmt-98 Ck-1 Service Manual-Volume 1 of 4

BM
C5MC-
CHEVRD LET
VOLUME 1 OF 4
Includes: General Information,
HVAC, Body Accessories^,
and Restraints
G M T/98-C K-1
C A U TIO N
In order to reduce the chance of personal injury and/or property damage, carefully observe
the in stru ction s that follow :
S ervice in fo rm a tio n p rovided by General M otors C orporation is intended fo r use by

professional, qualified technicians. A ttem pting repairs or service w ithout the appropriate
training, tools, and equipm ent could cause injury to you or others. This could also damage
the vehicle, or cause the vehicle to operate im properly.
Proper vehicle service and repair are im portant to the safety of the service technician and to
the safe, reliable operation of all m otor vehicles. If you need to replace a part, use the same
part num ber or an equivalent part. Do not use a replacement part of lesser quality.
The service procedures we recommend and describe in this manual are effective m ethods of
perform ing service and repair. Some of the procedures require the use of too ls that are
designed fo r specific purposes.
t A ccordingly, any person who intends to use a replacem ent part, a service procedure, or a
tool that is not recommended by General Motors, m ust firs t establish that there is no
jeopardy to personal safety or the safe operation o f the vehicle.
This manual contains CAUTIONS that you m ust observe carefully in order to reduce the risk
o f in ju ry to yo urself or others. This manual also contains NOTICES that m ust be carefully
follow ed in order to avoid im proper service that may damage the vehicle, or damage too ls or
equipm ent. These CAUTIONS and NOTICES are not exhaustive. General M otors can not
p ossib ly warn o f all the potentially hazardous consequences of your failure to fo llo w these
in stru ction s.
If the vehicle being serviced is equipped with a Supplem ental Inflatable Restraint (SIR), refer
to the CAUTIONS in the follow ing service manual section/service category type before
perform ing a service on or around SIR Com ponents or w iring:
• S u b -S e ctio n 9J - S u p p le m e n ta l In fla ta b le R e s tra in ts , re fe r to CAUTIONS u nd e r

On-Vehicle Service and the SIR Com ponent W iring Location view, or,
• Section - Body and Accessories, Sub-Section - Restraints, refer to CAUTIONS under
On-Vehicle Service and the SIR Com ponent W iring Location view.
Failure to fo llo w these CAUTIONS could cause air bag deploym ent, personal injury, or
otherw ise unneeded SIR repairs.
In order to help avoid accidental air bag deploym ent and personal injury, w henever you
service a vehicle that requires repair o f the SIR and another vehicle system , we recommend
| tha t you firs t repair the SIR, then go on to the other system.
k
Mixed Style Service Manual Structure
This service manual is a mix of the old style GM service manual and the new style that
will be completely transitioned for the 1999 model year. For 1998 this manual consists
of three volumes. The following table shows the section content by volume and the
style the information was written in.
Volum e 1 Volum e 2 Volum e 3

0 - General Information New 2 - Steering Old 6 - Engine New
1 - HVAC Old 3 - Suspension New Volum e 4
8 - Chassis/Body Electrical Old 4 - Driveline/Axle New 6 - Engine - Continued New
9 - Accessories Old 5 - Brakes New 7 - Transmission/Transaxle New
10 - Body Old
Another change to the old style sections is that all of the sub-section Table of Contents
have been brought forward to the front of the section and the information is listed in
book order for that section. These Table of Contents have been enhanced and are to
be used to locate information in those sections as there are not index entries in the
Index for the old style sections.
The following table gives the previous service manual sub-sections with the name of
the new section and sub-section. If a section is new style, it will contain the diagnosis
that was previously in Section 8A. Also, Seat Belts and SIR is found in Sub-Section 9J
in Accessories this year.
Please bear with us through this transition year. W e hope the information found in the
following tables and the enhanced Table of Contents will enable you to more easily find
the information you need.
Truck Service Manual Sub-Section to Section
and Sub-Section Conversion Table
O ld New
Sub-Section O ld Sub-Section Section Section Nam e Sub-Section Nam e
OA General Information Preface Cautions and Notices Cautions and Notices
OA General Information 0 General Information General Information
OB Maintenance and Lubrication 0 General Information Maintenance and Lubrication
OC Vibration Diagnosis 0 General Information Vibration Diagnosis
1A Heating and Ventilation 1A HVAC Heating and Ventilation
Heating, Ventilation, and Heating, Ventilation, and
1B Air Conditioning 1B HVAC Air Conditioning
1D2 A/C Compressors 1D2 HVAC A/C Compressors
2A Frame and Bumpers 10A5 Body Frame and Bumpers
2B Sheet Metal 10A6 Body Sheet Metal
3A Front Wheel Alignment 3 Suspension Wheel Alignment
Power Steering Gear Power Steering Gear and
3B and Pump 2B Steering Pump
Power Steering Gear Unit Power Steering Gear Unit
3B1A Repair 2B1A Steering Repair
Power Steering Pump Unit Power Steering Pump Unit
3B1B Repair 2B1B Steering Repair
3B3 Steering Linkage 2B3 Steering Steering Linkage
3C Front Suspension 3 Suspension Front Suspension
3D Rear Suspension 3 Suspension Rear Suspension
3E Tires and Wheels 3 Suspension Tires and Wheels
3F Steering Columns 2F Steering Steering Wheel and Column
4A Propeller Shaft 4 Driveline/Axle Propeller Shaft
4B1, 4B2,
4B3, 4B4,
4B5, 4B7 Rear Axle and Differential 4 Driveline/Axie Rear Drive Axle
Front Drive Axles Front Wheel Drive Shafts
4C, 4C2 and Differential 4 Driveline/Axle and Front Drive Axle
4D1 Drive Axle Unit Repair 4 Driveline/Axle Rear Drive Axle
5A Hydraulic Brakes 5 Brakes Hydraulic Brakes
5A1, 5A1A Master Cylinder 5 Brakes Hydraulic Brakes
5B1 Front Disc Brakes 5 Brakes Disc Brakes
5B2 Rear Disc Brakes 5 Brakes Disc Brakes
Leading/Trailing Drum
5C1 Brakes 5 Brakes Drum Brakes
5C2 Duo-Servo Brakes 5 Brakes Drum Brakes
5D1, 5D2,
5D2A Hydraulic or Vacuum Booster 5 Brakes Hydraulic Brakes
5F Parking Brake 5 Brakes Parking Brake
5E Antilock Brakes 5 Brakes Antilock Brakes
Truck Service Manual Sub-Section to Section
and Sub-Section Conversion Table (cont’d)
Old New
Sub-Section Old Sub-Section Section Section Nam e Sub-Section Name
6, 6A Engine Mechanical 6 Engine Engine Mechanical
6B Engine Cooling and Radiator 6 Engine Engine Cooling
6D Engine Electrical 6 Engine Engine Electrical
— Driveability and Emissions 6 Engine Engine Controls
6F Exhaust System 6 Engine Exhaust System
6H Vacuum Pump 6 Engine Vacuum Pump
6J Turbocharger 6 Engine Turbocharger
Automatic Transmission, and
Transmission/Transfer Case
7A Automatic Transmission 7 T ransmission/Transaxle Unit Repair Manual
Manual Transmission, and
7B Manual Transmission 7 Transmission/Transaxle Unit Repair Manual
7C Clutch 7 T ransmission/Transaxle Clutch
Transfer Case, and
7D Transfer Case 4 Driveline/Axle Unit Repair Manual
8A Electrical Diagnosis 8A Electrical Diagnosis Electrical Diagnosis
8B Lighting Systems 8B Body Lighting Systems
Instrument Panel and Instrument Panel and
8C Gauges 8C Body Gauges
8D Chassis Electrical 8D Body Chassis Electrical
8E1 Windshield Wiper/Washers 8E1 Body Wiper/Washer Systems
Rear Window Wiper Washer Rear Window Wiper Washer
8E2 System 8E2 Body System
9A Audio Systems 9A Body Audio Systems
9B Cruise Control 9B Body Cruise Control
9E Engine Coolant Heater 9E Engine Engine Cooling
9F Luggage Carrier 9F Body Luggage Carrier
Supplemental Inflatable Supplemental inflatable
9J Restraint 9J Restraints Restraints
9K Remote Keyless Entry 9K Body Remote Keyless Entry
10A1 Doors 10A1 Body Doors
10A2 Body Seats
10A2 Seats 9J Restraints Seat Belts
10A3 Stationary Windows 10A3 Body Windows
10A4 Interior Trim 10A4 Body Interior Trim
10A5 Endgate 10A7 Body Body Rear End
10B Cab and Body Maintenance 10B Body Sheet Metal
1<J8 C/K TVuc';
Service Manual
Volume 1
This manual provides information on the diagnosis, the service procedures, the adjustments, and the
specifications for the 1998 C/K Truck.
Information on transmission unit repair (overhaul) can be found in the 1998 Transmission/Transaxle/Transfer Case
Unit Repair Manual (TURM), GMPT/98-TURM, available seperately. The TURM manual contains information on
automatic and manual transmissions and transaxles, and transfer cases for all GM passenger cars and light duty
trucks, including the fluid flow and circuit description information.
The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better
service the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in
place of the recommended item. All information, illustrations and specifications in this manual are based on the
latest product information available at the time of publication approval. General Motors reserves the right to make
changes at any time without notice.
Published by
NORTH AMERICAN OPERATIONS

General Motors Corporation
Warren, Michigan 48090
©1997 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

The information cutoff date is 3/26/97. LITHO IN U.S.A.
No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means
(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of
General Motors Corporation. This applies to all text, illustrations, and tables.
Table of Contents
V o lu m e 1 V o lu m e 2
P re fa c e P re fa c e
Cautions and Notices................................................ 1 Cautions and Notices................................................ 1
G e n e ra l I n f o r m a t io n ............................................0-1 S te e r in g ........................................................................ 2
General Information................................................0-3 Power Steering Gear and Pum p....................... 2B-1
Maintenance and Lubrication..............................0-41 Power Steering Gear Unit Repair..................2B1A-1
Vibration Diagnosis and Correction................... 0-85 Power Steering Pump Unit Repair................2B1B-1
H V A C ..............................................................................1 Steering Linkage.................................................2B3-1
Heater and Ventilation......................................... 1A-1 Speed Dependent Steering Electronic
Heater, Ventilation and Air Conditioning............1B-1 Variable Orifice (EVO )................................... 2B5-1
HD6/HT6 Air Conditioning Compressor Steering Wheel and Column On Vehicle
Service or Unit Repair R-134a..................... 1D2-1 Service............................................................... 2F-1
E le c tr ic a l...................................................................... 8 Supplemental Inflatable Restraint (SIR)
Electrical Diagnosis............................................. 8A-1 Standard Steering Column Unit Repair...... 2F4-1
Lighting Systems................................................. 8B-1 Supplemental Inflatable Restraint (SIR)
Instrument Panel and Gauges........................... 8C-1 Tilt Steering Column Unit Repair................. 2F5-1
Chassis Electrical................................................ 8D-1 S u s p e n s io n ..............................................................3-1
Windshield Wiper/Washer System..................... 8E-1 Suspension General Diagnosis............................. 3-3
Rear Window Wiper/Washer System...... .......... 8E-2 Wheel Alignment.................................................. 3-17
A c c e s s o r ie s ................................................................9 Front Suspension................................................. 3-35
Audio Systems......................................................9A-1 Rear Suspension.................................................. 3-93
Cruise Control.......................................................9B-1 Tires and W heels............................................... 3-113
Passlock System................................................. 9D-1 D r iv e lin e /A x le ......................................................... 4-1
Engine Coolant Heater........................................ 9E-1 Propeller Shaft........................................................ 4-5
Luggage Carrier....................................................9F-1 Wheel Drive Shafts..............................................4-29
Running Boards................................................... 9G-1 Front Drive A x le ................................................... 4-49
Restraints...............................................................9J-1 Rear Drive A xle.................................................. 4-103
Seat Belts...........................................................9J-1 Rear Drive Axle - Locking/Limited Slip
Supplemental Inflatable Restraints (SIR).... 9J-47 Rear A xle ........................................................ 4-169
Remote Keyless Entry......................................... 9K-1 Transfer Case..................................................... 4-181
B o d y .............................................................................10 B r a k e s ....................................................................... 5-1
Doors................................................................. 10A1-1 Hydraulic Brakes....................................................5-5
Seats..................................................................10A2-1 Disc Brakes............................................................5-89
Windows.............................................................10A3-1 Drum Brakes....................................................... 5-123
Interior Trim....................................................... 10A4-1 Park Brake.......................................................... 5-145
Frame and Bumpers........................................ 10A5-1 Antilock Brake System...................................... 5-163
Sheet Metal....................................................... 10A6-1
Endgate..............................................................10A7-1
Cab and Body Maintenance..............................10B-1
Table of Contents - Continued
V o lu m e 3 Volume 4
P re fa c e Preface
Cautions and Notices............................................... 1 Cautions and Notices................................................1
E n g in e ...................................................................... 6-1 Engine.............................................................6-1
Engine Mechanical - 4.3L....................................6-23 Engine Controls - 6.5L.................................... 6-2279
Engine Mechanical - 5.0L, 5.7L....................... 6-237 Engine Controls - 7.4L.................................... 6-2677
Engine Mechanical - 6.5L..................................6-455 Turbocharger.....................................................6-3239
Engine Mechanical - 7.4L..................................6-687 Vacuum Pump...................................................6-3253
Engine Cooling....................................................6-927 Engine Exhaust.................................................6-3259
Engine Electrical................................................ 6-991 Transmission/Transaxle...............................7-1
Engine Controls - 4 .3 L ....................................6-1089 Manual Transmission - New Venture................... 7-7
Engine Controls - 5.0, 5.7L.............................6-1643 Automatic Transmission - 4L60-E...................... 7-39
Automatic Transmission - 4L80-E.................... 7-269
Clutch.................................................................. 7-593
REPORTING ERRORS AND SUGGESTIONS
If you find an error in a GM Service manual, or if you have a suggestion about a GM service manual, we
want to hear from you.
When calling, be prepared with the following information:

• Your name
• Your dealership’s name
• Your dealership’s phone number
• The model year and the vehicle line
• The publication part number (if present)
• The vehicle identification number of the vehicle being worked on
• The service manual section and page number(s)
• Any applicable electronic information element identification numbers
• A descriptive explanation of your concern
The GM service manual phone personnel will respond to your concerns in the following ways:
• By delivering your concern to the manual’s author.
• By eliciting a response from the author.
• By supplying you with an answer to your concerns.
For paper manual users: The GM service manual phone personnel will also explain how to send in examples
or marked-up pages.
For electronic manual users: Be prepared to provide any applicable identification numbers pertaining to the
electronic information that you are questioning.
The GM service manual comment telephone numbers do not provide technical assistance. For technical
assistance, contact your regular technical assistance source.
United States and Canada General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-828-6860,
fax number 810-265-9327, 8:00 a.m.-8:00 p.m. Eastern Time Zone.
Canada, French Speaking General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-503-3222,
International English Speaking General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 810-265-0840,
United States and Canadian Vehicle Owner/Operator

Vehicle owners or operators are encouraged to address their comments and concerns to the applicable
Customer Assistance Center. The phone number and address of the Customer Assistance Centers are in the
Owner’s Manual.
GM | ServiceTechnology Group
Preface Table of Contents -1
Preface
Cautions and Notices ............................................3 SIR Inflator Module Disposal Caution.................5

Definition of Caution, Notice, and Important..... 3 SIR Inflator Module Handling and
ABS Handling Caution..........................................3 Storage Caution................................................ 5
Battery Disconnect Caution................................. 3 SIR Special Tool Caution......................................5
Brake Dust Caution............................................... 3 Vehicle Lifting Caution..........................................5
in co co co co co
Brake Fluid Caution.............................................. 4 Window Removal Caution..
Clutch Dust Caution..............................................4 Window Retention Caution.
Electric Coolant Fan Caution............................... 4 Work Stall Test Caution.....
Fuel and EVAP Pipe Caution.............................. 4 Defective Scan Tool Notice
Fuel Pipe Fitting Caution..................................... 4 Fastener Notice...................
Fuel Storage Caution............................................4 Fuel Pressure Notice.........
Gasoline/Gasoline Vapors Caution......................4 Handling ESD Sensitive Parts Notice................ 6
Lower O-Ring Removal Caution..........................4 Handling IAC Valve Notice.................................. 7
Ignition OFF When Disconnecting Battery
Moving Parts and Hot Surfaces Caution........... 4
Notice.................................................................7
Relieving Fuel Pressure Caution.........................4
Latched DTC B1018, B1024 Notice
Road Test Caution................................................ 4 (SDM-RSD)....................................................... 7
Safety Glasses and Compressed Air Caution...5 Nylon Fuel Lines Notice.................... 7
Safety Goggles and Fuel Caution.......................5 OBDII System Description Notice.......................7
Seat Belt Replacement Caution..........................5 PCM and ESD Notice...........................................7
Shop Towel Fuel Link Caution............................ 5 Servicing and Replacing Seat Belts Notice...... 7
SIR Caution............................................................5 Single Cylinder Flooding Notice.......................... 7
SIR Handling Caution...........................................5
2 - Table of Contents Preface
BLANK
Preface Cautions and Notices - 3
Cautions and Notices

Definition of Caution, Notice, and • Damage to fasteners, basic tools, or
Important special tools
• The leakage of coolant, lubricant, or other vital
C autions, N otices, and Im portants in the fluids
S ervice M anual IMPORTANT Defined
The diagnosis and repair procedures in the GM IMPORTANT statements emphasize a necessary
Service Manual contain both general and specific characteristic of a diagnostic or repair procedure.
Cautions, Notices, and Importants. GM is dedicated IMPORTANT statements are designed to do the
to the presentation of service information that helps following:
the technician to diagnose and repair the systems • Clarify a procedure
necessary for the proper operation of the vehicle, • Present additional information for accomplishing
however, certain procedures may present a hazard a procedure
to the technician if they are not followed in the • Give insight into the reason or reasons for
recommended m anner. Cautions, Notices, and performing a procedure in the manner
Importants are elements designed to prevent these recommended
hazards, however, not all hazards can be foreseen. • Present information that will help to accomplish
This information is placed at strategic locations within a procedure in a more effective manner
the service manual. This information is designed to
prevent the following from occurring: • Present information that gives the technician
the benefit of past experience in accomplishing
• Serious bodily injury to the technician a procedure with greater ease
• Damage to the vehicle
• Unnecessary vehicle repairs ABS Handling Caution
• Unnecessary component replacement Caution: Certain components in the Antilock
Brake System (ABS) are not intended to be
• Improper repair or replacement of vehicle
serviced individually. Attempting to remove or
components. Any caution or notice that appears
disconnect certain system components may
in general information is referenced from the result in personal injury andlor improper system
individual service categories. operation. Only those component with approved
CAUTION Defined removal and installation procedures should be
When encountering a CAUTION, you will be asked serviced.
to take a necessary action or not to take a
prohibited action. If a CAUTION is not heeded, the Battery Disconnect Caution
following consequences may occur: Caution: Disconnect the negative battery cable
1. Serious bodily injury to the technician under the following circumstances:
2. Serious bodily injury to other technicians in the • When installing an electrical unit.
workplace area • When a tool or equipment could easily come
3. Serious bodily injury to the driver and/or into contact with "live" exposed electrical
passenger(s) of the vehicle, if the vehicle has terminals.
been improperly repaired Failure to disconnect the negative battery
NOTICE Defined terminal may result in personal injury or damage
Notices call special attention to a necessary action to the vehicle’s components. Turn OFF the
vehicle ignition, unless instructed otherwise.
or to a prohibited action. If a NOTICE is not heeded,
the following consequences may occur:
Brake Dust Caution
• Damage to the vehicle
Caution: Avoid taking the following actions when
• Unnecessary vehicle repairs you service wheel brake parts:
• Unnecessary component replacement • Do not grind brake linings.
• Improper operation or performance of the • Do not sand brake linings.
system or component under repair
• Do not clean wheel brake parts with a dry
• Damage to any systems or components which brush or with compressed air.
are dependent upon the proper operation of the Many earlier model or aftermarket brake parts
system or component under repair may contain asbestos fibers which can become
• Improper operation or performance of any airborne in dust. Breathing dust with asbestos
systems or components which are dependent fibers may cause serious bodily harm. Use a
upon the proper operation or performance of water-dampened cloth in order to remove any
the system or component under repair dust on brake parts. Equipment is available
4 - Cautions and Notices Preface
commercially in order to to perform this washing Fuel Pipe Fitting Caution
function. These wet methods prevent fibers from
Caution: Always apply a few drops o f clean
becoming airborne.
engine oil to the male pipe ends before
Brake Fluid Caution connecting fuel pipe fittings in order to reduce
the risk of fire and personal injury.
Caution: Brake fluid may be irritating to the skin
or eyes. In case of contact, take the following This will ensure proper reconnection and prevent
actions: a possible fuel leak.
• Eye contact - rinse eyes thoroughly with During normal operation, the O-rings located in
water. the female connector will swell and may prevent
proper reconnection if not lubricated.
• Skin contact - wash skin with soap and
water. Fuel Storage Caution
Clutch Dust Caution Caution: Do not drain the fuel into an open
container. Never store the fuel in an open
Caution: Avoid taking the following actions when container due to the possibility o f a fire or an
you service wheel brake parts: explosion.
• Do not grind brake linings.
• Do not sand brake linings.
Gasoline/Gasoline Vapors Caution
• Do not clean wheel brake parts with a dry Caution: Gasoline or gasoline vapors are highly
brush or with compressed air. flammable. A fire could occur if an ignition
Many earlier model or aftermarket brake parts source is present. Never drain or store gasoline
may contain asbestos fibers which can become or diesel fuel in an open container, due to the
airborne in dust. Breathing dust with asbestos possibility of fire or explosion. Have a dry
fibers may cause serious bodily harm. Use a chemical (Class B) fire extinguisher nearby.
water-dampened cloth In order to remove any Lower O-Ring Removal Caution
dust on brake parts. Equipment is available
commercially in order to to perform this washing Caution: Verify that the lower (small) O-ring o f
function. These wet methods prevent fibers from each Injector does not remain in the lower
becoming airborne. manifold in order to reduce the risk o f fire and
personal Injury.
Electric Coolant Fan Caution If the O-ring is not removed with the injector, the
Caution: An electric fan under hood can start replacement injector with new O-rings will not
even when the engine is not running and can seat properly in the Injector socket. Improper
Injure you. Keep hands, clothing and tools away seating could cause a fuel leak.
from any underhood electrical fan.
Moving Parts and Hot Surfaces Caution
Fuel and EVAP Pipe Caution Caution: While working around a running engine,
Caution: In order to Reduce the Risk o f Fire and avoid contact with moving parts and hot surfaces
Personal Injury observe the following items: to prevent possible bodily Injury.
• Replace all nylon fuel pipes that are nicked, Relieving Fuel Pressure Caution
scratched or damaged during Installation, Do
Not attempt to repair the sections o f the Caution: Relieve the fuel system pressure before
nylon fuel pipes servicing fuel system components in order to
• Do Not hammer directly on the fuel harness reduce the risk o f fire and personal Injury.
body clips when installing new fuel pipes. After relieving the system pressure, a small
Damage to the nylon pipes may result In a amount o f fuel may be released when servicing
fuel leak. the fuel lines or connections. In order to reduce
• Always cover nylon vapor pipes with a wet
the chance of personal Injury, cover the regulator
towel before using a torch near them. Also, and the fuel line fittings with a shop towel before
never expose the vehicle to temperatures disconnecting. This will catch any fuel that may
higher than 115°C (239°F) for more than one leak out. Place the towel In an approved
hour, or more than 90°C (194°F) for any container when the disconnection Is complete.
extended period. Road Test Caution
• Apply a few drops o f clean engine oil to the
male pipe ends before connecting fuel pipe Caution: Road test a vehicle under safe
fittings. This will ensure proper reconnection conditions and while obeying a ll traffic laws. Do
and prevent a possible fuel leak. (During not attempt any maneuvers that could Jeopardize
normal operation, the O-rings located in the vehicle control. Failure to adhere to these
female connector will swell and may prevent precautions could lead to serious personal injury.
proper reconnection If not lubricated.)
Safety Glasses and Compressed Air SIR Inflator Module Disposal Caution
Caution Caution: In order to prevent accidental
Caution: Wear safety glasses when using deployment o f the a ir bag which could cause
compressed a ir in order to prevent eye injury. personal injury, do not dispose of an undeployed
inflator module as normal shop waste. The
Safety Goggles and Fuel Caution undeployed inflator module contains substances
Caution: Always wear safety goggles when that could cause severe illness or personal injury
working with fuel in order to protect the eyes if the sealed container is damaged during
from fuel splash. disposal. Use the following deployment
procedures to safely dispose of an undeployed
Seat Belt Replacement Caution inflator module. Failure to dispose o f an inflator
module as instructed m ay be a violation of
Caution: Replace belts, retractors, and hardware federal, state, province, or local laws.
In use during all but a m inor collision. Also,
restraint systems should be replaced and SIR Inflator Module Handling and Storage
anchorage’s properly repaired if they were in Caution
areas damaged by collision, whether the belt was
In use or not. If there is any question, replace Caution: When you are carrying an undeployed
the belt system. Damage, whether visible or not, inflator module:
could result in serious personal Injury in the • Do not carry the inflator module by the
event o f an accident. wires or connector on the inflator module
• Make sure the bag opening points away
Shop Towel Fuel Link Caution
from you
Caution: Wrap a shop towel around the fuel When you are storing an undeployed Inflator
pressure connection in order to reduce the risk module, make sure the bag opening points away
o f fire and personal Injury. The towel will absorb from the surface on which the inflator module
any fuel leakage that occurs during the rests. When you are storing a steering column,
connection o f the fuel pressure gauge. Place the do not rest the column with the bag opening
towel In an approved container when the facing down and the column vertical. Provide free
connection o f the fuel pressure gauge is space for the a ir bag to expand in case of an
complete. accidental deployment. Otherwise, personal Injury
may result.
SIR Caution
Caution: This vehicle has a Supplemental SIR Special Tool Caution
Inflatable Restraint (SIR) System. Refer to SIR Caution: In order to avoid deploying the air bag
Component Location View In order to determine when troubleshooting the SIR system, use only
whether you are performing service on or near the equipment specified in this manual and the
the SIR components or the SIR wiring. When you Instructions given In this manual. Failure to use
are perform ing service on or near the SIR the specified equipment as instructed could
components or the SIR wiring, refer to SIR cause a ir bag deployment, personal injury to you
On-Vehlcle Service information. Failure to follow or someone else, or unnecessary SIR system
the CAUTIONS could cause a ir bag deployment, repairs.
personal Injury, or unnecessary SIR system
repairs. Vehicle Lifting Caution
SIR Handling Caution Caution: To help avoid personal Injury, when a
vehicle Is on a hoist, provide additional support
Caution: When you are carrying an undeployed for the vehicle a t the opposite end from which
Inflator module: you are removing components. The additional
• Do not carry the Inflator module by the support will reduce the possibility o f the vehicle
wires or connector on the inflator module falling off the hoist. When you are removing
• Make sure the bag opening points away major components from the vehicle while the
from you vehicle is on a hoist, chain the vehicle frame to
the hoist pads at the same end from which you
When you are storing an undeployed Inflator
are removing the m ajor components to prevent
module, make sure the bag opening points away
tip-off. If you fail to follow these precautionary
from the surface on which the Inflator module
measures, vehicle damage, serious personal
rests. When you are storing a steering column, injury, or death m ay result.
do not rest the column with the bag opening
facing down and the column vertical. Provide free Window Removal Caution
space for the a ir bag to expand In case o f an
accidental deployment. Otherwise, personal Injury Caution: When working with any type o f glass,
may result. use approved safety glasses and gloves to
reduce the chance o f personal injury.
Window Retention Caution locking compound or sealant are identified in the

service procedure. Do not use paints, lubricants, or
Caution: When replacing stationary windows, corrosion inhibitors on fasteners or fastener joint
Urethane Adhesive Kit GM P/N 12346284, or a surfaces unless specified. These coatings affect
urethane adhesive system meeting GM fastener torque and joint clamping force and may
Specification GM3651M, must be used to damage the fastener. Use the correct tightening
maintain original installation integrity. Failure to sequence and specifications when installing fasteners
use the urethane adhesive kit will result in poor in order to avoid damage to parts and systems.
retention o f the window which may allow
unrestrained occupants to be ejected from the Fuel Pressure Notice
vehicle resulting in personal injury.
Notice: Do not allow the fuel pressure to exceed the
Work Stall Test Caution specified value because damage to the fuel pressure
regulator or the fuel pressure gauge may result.
Caution: One or more o f the following guidelines
may apply when performing specific required Handling ESD Sensitive Parts Notice
tests in the work stall:
1. When a test requires spinning the drive
wheels with the vehicle jacked up, adhere to
the following precautions:
NOTICE
• Do not exceed 56 km/h (35 mph) when
spinning one drive wheel with the other
drive wheel stopped. This lim it is
necessary because the speedometer
Indicates only one-half the actual vehicle
speed under these conditions. Personal
injury may result from excessive wheel
spinning.
• If all of the drive wheels are spinning at
the same speed, do not exceed 112 km/h
(70 mph). Persona! injury m ay result from
excessive wheel spinning. CONTENTS SENSITIVE
• A ll persons should stay clear o f the TO
rotating components and the balance STATIC ELECTRICITY
weight areas in order to avoid possible
personal injury. 6392
• When running an engine in the repair stall
Electrostatic discharge (ESD) can damage many
for an extended period o f time, use care
solid state electrical components. Not all components
not to overheat the engine and the
that are susceptible to damage from ESD are
transmission.
labeled with the ESD symbol. Exercise caution when
2. When a test requires jacking up the vehicle handling all solid state electrical components.
and running with the wheels and brake
Avoid damaging solid state electrical components by
rotors removed, adhere to the following
taking the following precautions:
precautions:
• Discharge personal electricity by touching a
• Do not apply the brake with the brake
metal ground point after each of the following
rotors removed.
activities:
• Do not place the transmission in Park
- sliding across the vehicle seat
with the drive wheels still spinning.
- sitting or rising
• Turn O ff the ignition in order to stop the
powertrain components from spinning. - walking
• Do not touch the exposed electric terminals on
Defective Scan Tool Notice a component with your finger or a tool. The
Notice: Do not use a scan tool that displays faulty connector that you are checking may be tied
data. Report the scan tool problem to the into a circuit that is susceptible to damage by
manufacturer. Use of a faulty scan tool can result in ESD.
misdiagnosis and unnecessary parts replacement. • Do not allow a screwdriver or a similar tool to
contact exposed terminals when disconnecting
Fastener Notice a connector.
Notice: Use the correct fastener in the correct • Do not remove the protective packing of the
location. Replacement fasteners must be the correct solid state component until you are ready to
part number for that application. Fasteners requiring install the solid state component.
replacement or fasteners requiring the use of thread
• Unless specified in a particular diagnostic OBDII System Description Notice
procedure, avoid the following activities:
Notice: The OBD II symbol is used on the circuit
- jumpering components or connectors
diagrams in order to alert the technician that the
- grounding components or connectors circuit is essential for proper OBD II emission control
- using test equipment probes on components circuit operation. Any circuit which, if it fails causes
or connectors the Malfunction Indicator Lamp (MIL) to turn on, is
• When a diagnosis requires the use of test identified as an OBDII circuit.
equipment probes, connect the ground
lead first. PCM and ESD Notice
• Touch the solid state component’s package to a Notice: Do not touch the connector pins or soldered
ground before opening. components on the circuit board in order to prevent
• Do not lay the solid state component in any of possible electrostatic discharge (ESD) damage to
the following locations: the PCM.
- On a metal work bench Servicing and Replacing Seat Belts Notice
- On top of an electrically operating appliance
Notice: To prevent possible seat belt damage, refer
or piece of equipment, like a TV, radio or
to the following items before servicing or replacing
oscilloscope
lap and shoulder belts, including single loop belt
• Do not drop the solid state component. systems:
Handling IAC Valve Notice 1. Lap and shoulder belts will be serviced as
follows:
Notice: If the IAC valve has been in service: DO 1.1. Replace only the part in question.
NOT push or pull on the IAC valve pintle. The force
required to move the pintle may damage the threads 1.2. All belts need to be serviced as a set to
on the worm drive. Also, DO NOT soak the IAC assure the belt components are from the
valve in any liquid cleaner or solvent, as damage same supplier.
may result. 1.3. Do not intermix standard and deluxe
belts on front or rear seats.
Ignition OFF When Disconnecting Battery 1.4. All attachment hardware must be
Notice replaced, not reused.
Notice: Always turn the ignition OFF when 2. Keep sharp edges and damaging objects away
connecting or disconnecting battery cables, battery from belts.
chargers, or jumper cables. Failing to do so may 3. Avoid bending or damaging any portion of the
damage the Powertrain Control Module (PCM) or belt buckle or latch plate.
other electronic components.
4. Do not bleach or dye belt or strap webbing.
Latched DTC B1018, B1024 Notice Clean with a mild soap solution and water.
(SDM-RSD) 5. When installing lap or shoulder belt anchor
bolts, start the bolts by hand to ensure that the
Notice: When DTC B1018 or B1024 has been set it bolts are threaded straight.
is necessary to replace the inflatable restraint
Sensing and Diagnostic Module (SDM). Setting DTC 6. Do not attempt repairs on lap or shoulder belt
retractor mechanisms to lap belt retractor
B1018 or B1024 will also cause DTC B1071 to set.
covers. Replace defective assemblies with new
When a scan tool clear codes command is issued
and the malfunction is no longer present, DTC service replacement parts.
B1018 or B1024 and DTC B1071 will remain current. 7. Do not attempt to remove the seat belt retractor
Make sure that the short to ground condition is cover. The cover and the long rivet securing the
repaired prior to installing a replacement SDM to cover to the retractor are not available as
avoid damaging the SDM. service replacement parts.
Nylon Fuel Lines Notice Single Cylinder Flooding Notice

Notice: Do not attempt to straighten the kinked Notice: In order to prevent flooding of a single
nylon fuel lines. Replace any kinked nylon fuel feed cylinder and possible engine damage, relieve the fuel
or return pipes in order to prevent damage to the pressure before performing the fuel injector coil test
vehicle. procedure.
BLANK
General Information Table of Contents 0-1
Section 0
General Information
General Inform ation ............................................0-3 M aintenance........................................................ 0-45

In tro d u c tio n ........................................................... 0-3 Maintenance Schedule.................................... 0-45
English/Metric Conversion................................. 0-3 Short Trip/City Maintenance
Decimal and Metric Equivalents.......................0-3 Schedule (Gasoline)................................... 0-46
How to Use the Paper Version of Short Trip/City Maintenance
the Service Manual....................................... 0-4 Schedule (Diesel)........................................ 0-53
Description of Arrows and Symbols................ 0-5 Long Trip/Highway Maintenance
Schedule (Diesel)........................................ 0-66
Special Tools Ordering Information................. 0-6
Long Trip/Highway Maintenance
Diagnostic Work Sheets.................................... 0-6 Schedule (Gasoline)................................... 0-72
Vehicle Identification.......................................... 0-6 Owner Checks and Services..........................0-75
VIN Derivative...................................................0-10 Explanation of Scheduled Services............... 0-76
Vehicle Certification Label............................... 0-11 Inspections and Other Services.....................0-81
Tire Placard......................................................0-12 Periodic Maintenance Inspection
Engine ID and VIN Derivative (General Maintenance)............................... 0-83
Location........................................................ 0-12 Periodic Maintenance Inspection (Cooling
Transmission ID and VIN Derivative System Maint Recommend).......................0-84
Location (Transmission ID).........................0-15
V ib ra tio n D ia g n o s is an d C o rre c tio n ........ o-85
Anti-Theft Labeling.......................................... 0-17
S pecifications...................................................... 0-85
Service Parts ID Label.................................... 0-17
Specifications.................................................... 0-85
RPO Code List.................................................0-17
Diagnostic Inform ation and P rocedures...... 0-86
How to Obtain Replacement Labels............. 0-22
Vibration Diagnosis......................................... 0-86
Exterior and Interior Colors.............................0-22
Road Test......................................................... 0-87
Fasteners.......................................................... 0-22
Classifying the Vibration................................. 0-89
Thread Inserts..................................................0-26
Tire and Wheel Vibration................................ 0-92
Proper Use of Torque Wrenches................... 0-26
Tire and Wheel Runout Measurement.......... 0-92
Abbreviations and Their Meanings................ 0-29
Driveline Vibration Analysis with EVA........... 0-94
Coding Keys and Lock Cylinders.................. 0-34
Engine Related Vibration................................ 0-99
Vehicle Lifting and Jacking.............................0-37
Repair Instructio n s...........................................0-104
Special Tools and Equipm ent..........................0-40
General Service Precautions........................0-104
Special Tools.................................................... 0-40
Correcting Tire and Wheel Vibration........... 0-104
Maintenance and Lubrication .......................0-41 Balancing Tires and Wheels.........................0-108
S pecifications...................................................... 0-41 Correcting Non-Uniform Tires....................... 0-112
Drive Belt Tension Specifications.................. 0-41 Correcting Driveline Vibration -
Approximate Fluid Capacities.........................0-41 RWD and 4W D..........................................0-113
Recommended Fluids and Lubricants........... 0-42 Description and O peration............................. 0-130
Tire Inflation Pressure Specifications............ 0-43 General Description....................................... 0-130
Maintenance Items...........................................0-44 Special Tools and Equipment.......................0-142
0-2 Table of Contents General Information
BLANK
General Information General Information 0-3
General Information
Introduction English/M etric C onversion (co n t’d)
M ultiply/ Divide
English by Metric
E nglish/M etric Conversion
LIGHT
M ultiply/ Divide
English by Metric Foot Candle 10.764 lm/m2
LENGTH VELOCITY
in 25.4 mm mph 1.6093 km/h
ft 0.3048 TEMPERATURE
m
yd 0.9144 5/9( * F-32) = *C
mi 1.609 km *F = 9/5( * C+32)
AREA FUEL PERFORMANCE
645.2 sq mm 235.215/mpg = L/100 km

sq in
6.45 sq cm
Refer to the following table for equivalent of fractions
sq ft 0.0929
sq m to decimals in English (inches), to metric (millimeters).
sq yd 0.8361
VOLUME Decim al and M etric Equivalents
16,387.0 cu mm Fraction (in) Decimal (in) Metric (mm)
cu in 16.397 cu cm 1/64 0.015625 0.39688
0.0164 1/32 0.03125 0.79375
qt 0.9464 L 3/64 0.046875 1.19062

gal 3.7854 1/16 0.0625 1.5875
cu yd 0.746 cu m 5/64 0.078125 1.98437
MASS 3/32 0.09375 2.38125
lb 0.4536 7/64 0.109375 2.77812
kg
907.18 1/8 0.125 3.175
ton
0.907 tonne (t) 9/64 0.140625 3.57187
FORCE 5/32 0.15625 3.96875
kg 9.807 11/64 0.171875 4.36562

oz 0.2780 newtons (N) 3/16 0.1875 4.7625
lb 4.448 13/64 0.203125 5.15937
ACCELERATION 7/32 0.21875 5.55625
ft/s2 0.3048 15/64 0.234375 5.95312
m/s2
in/s2 0.0254 1/4 0.25 6.35
TORQUE 17/64 0.265625 6.74687
lb in 0.11296 9/32 0.28125 7.14375
N-m
lb ft 1.3558 19/64 0.296875 7.54062
POWER 5/16 0.3125 7.9375
hp 0.745 kW 21/64 0.328125 8.33437
PRESSURE (STRESS) 11/32 0.34375 8.73125
inches of H 20 0.2491 23/64 0.359375 9.12812

kPa
Ib/sq in 6.895 3/8 0.375 9.525
ENERGY (WORK) 25/64 0.390625 9.92187
Btu 1055.0 13/32 0.40625 10.31875
lb ft 1.3558 J (J= one Ws) 27/64 0.421875 10.71562
kW hour 3,600,000.0
0-4 General Information General Information
Decim al and M etric Equivalents (cont’d) How to Use the Paper Version of the
Fraction (in) , Decimal (in) Metric (mm) Service Manual
0.4375 11.1125
Construction
7/16
This service manual is constructed with the following
29/64 0.453125 11.50937 10 Service Category Types:
15/32 0.46875 11.90625
31/64 0.484375 12.30312 Major Section
Number Major Section Name
1/2 0.5 12.7
0 General Information
33/64 0.515625 13.09687
Heating, Ventilation, and Air
17/32 0.53125 13.49375 1
Conditioning (HVAC)
35/64 0.546875 13.89062 2 Steering
9/16 0.5625 14.2875 3 Suspension
37/64 0.578125 14.68437 4 Driveline/Axle
19/32 0.59375 15.08125 5 Brakes
39/64 0.609375 15.47812 6 Engine
5/8 0.625 15.875 7 T ransmission/T ransaxle
41/64 0.640625 16.27187 8 Body and Accessories
21/32 0.65625 16.66875 9 Restraints
43/64 0.671875 17.06562
11/16 0.6875 17.4625 Information Flow
With few exceptions, the information flow within a
45/64 0.703125 17.85937
Service Category Type is as follows:
23/32 0.71875 18.25625 1. Table of Contents for the entire Service
47/64 0.734375 18.65312 Category Type
3/4 0.75 19.05 2. Service Categories
49/64 0.765625 19.44687 The information within each Service Category will be
ordered as follows:
25/32 0.78125 19.84375
1. Specifications
51/64 0.796875 20.24062
2. Diagnosis
13/16 0.8125 20.6375
3. Repair Procedures
53/64 0.828125 21.03437 4. General Description and System Operation
27/32 0.84375 21.43125 5. Special Tools
55/64 0.859375 21.82812 Improvements Made
7/8 0.875 22.225 This service manual provides many more illustrations
than in earlier manuals. Illustrations serve as the
57/64 0.890625 22.62187
primary source for repair procedures. These
29/32 0.90625 23.01875 illustrations will be supplemented with text
59/64 0.921875 23.41562 descriptions. In the previous service manuals, text
was the primary source of information for repair
15/16 0.9375 23.8125 procedures and illustrations provided support.
61/64 0.953125 24.20937 Repair procedures, illustrations, and the descriptive
31/32 0.96875 24.60625 text have been arranged so that they will correspond
with the way you work. This manual provides
63/64 0.984375 25.00312
disassembled views, wherever possible, so that it will
1 1.0 25.4 be easy to look up parts, names, and order of
assembly. The text descriptions have been rewritten
into simple, complete sentences.
Suggestions Welcome
Our goal is to help you to do your job more
effectively. After using this manual for a time, please
call in with your comments at 1-800-828-6860. In
Canada, in order to speak to someone in French,
please call 1-800-503-3222.
Description of Arrows and Symbols • Do not touch the exposed electric terminals
on a component with your finger or a tool. The
connector that you are checking may be tied
into a circuit that is susceptible to damage
NOTICE by ESD.
• Do not allow a screwdriver or a similar tool to
contact exposed terminals when disconnecting
a connector.
• Do not remove the protective packing of the
solid state component until you are ready to
install the solid state component.
• Unless specified in a particular diagnostic
procedure, avoid the following activities:
- jumpering components or connectors
- grounding components or connectors
CO NTENTS SENSITIVE - using test equipment probes on components
TO or connectors
STATIC ELECTRICITY • When a diagnosis requires the use of test
equipment probes, connect the ground
lead first.
6392
• Touch the solid state component’s package to a
Electrostatic discharge (ESD) can damage many ground before opening.
solid state electrical components. Not all components
that are susceptible to damage from ESD are • Do not lay the solid state component in any of
labeled with the ESD symbol. Exercise caution when the following locations:
handling all solid state electrical components. - On a metal work bench
Avoid damaging solid state electrical components by - On top of an electrically operating appliance
taking the following precautions: or piece of equipment, like a TV, radio
or oscilloscope
• Discharge personal electricity by touching a
metal ground point after each of the following • Do not drop the solid state component.
activities:
- sliding across the vehicle seat
- sitting or rising
- walking
Special Tools Ordering Information

The special service tools shown in this service Vehicle Identification
manual that have product numbers beginning with
J or BT are available for worldwide distribution from:
OE Tool Equipment Group
Kent-Moore
28635 Mound Road
Warren, Ml., U.S.A. 48092-3499
Phone: 1-800-345-2233
Monday through Friday
8:00 a .m -7:00 p.m. Eastern Standard Time
Fax: 800-578-7375
The TECH 2® scan tool and accessories can be
purchased through:
Dealer Equipment and Services
5775 Enterprise Dr.
Warren, Mi., U.S.A. 48092-3463
Phone: 1-800-GM-TOOLS
Monday through Friday
8:00 a.m.-6:00 p.m. EST
Fax: 1-810-578-7205
Diagnostic Work Sheets
The GM Diagnostic Worksheet has been designed to
improve communications between the service customer The vehicle identification number (VIN) plate is the
and the technician. The diagnostic worksheet can legal identifier of the vehicle. The VIN plate is
provide the technician with more information than the located on the upper LH corner of the Instrument
conventional repair order, since it is filled out by the Panel and can be seen through the windshield from
service customer. The GM Diagnostic Worksheets the outside of the vehicle:
are available to you at no cost. GM Service
Bulletin 58-01-01 has information on how to
order this diagnostic worksheet.
Vehicle Identification Number (VIN) System
Position Definition Character Description
1 United States
1 Country of Origin 2 Canada
3 Mexico
2 Manufacturer G General Motors
B Chevrolet
C Incomplete Chevrolet Truck
3 Make
D GMC
T Incomplete GMC Truck
B 3001-4000/Hydraulic
C 4001-5000/Hydraulic
D 5001-6000/Hydraulic
E 6001-7000/Hydraulic
4 GVWR/Brake System F 7001 -8000/Hydraulic
G 8001-9000/Hydraulic
H 9001 ‘ 10000/Hydraulic
J 10001-14000/Hydraulic
K 14001 -16000/Hydraulic
C Conventional Cab/4x2
5 Truck Line/Chassis Type D Military Truck/4x4
K Conventional Cab/4x4
1 V2 Ton
6 Series 2 3/4 Ton
3 1 Ton
3 Crew Cab
4 Two-Door Cab
7 Body Type 6 Suburban
8 Utility
9 Extended Cab
F (L65) 6.5L Diesel
M (L30) 5.0L Gas
R (L31) 5.7L Gas
8 Engine Type
J (L29) 7.4L Gas
S (L56) 6.5L Diesel
W (L35) 4.3L Gas
9 Check Digit — —
10 Model Year w 1998
1 Oshawa, Ontario
E Pontiac, Ml
Z Fort Wayne, Indiana
11 Plant Location
J Janesville, Wl
G Silao, Mexico
R Arlington, TX
12-17 Plant Sequence Number — —
C/K Model Identification
186742
Legend
(1) Regular Cab Pickup
(2) Extended Cab Pickup
(3) Regular Cab Chassis
(4) Extended Cab Chassis
(5) Crew Cab Pickup
(6) 2 Door Utility
(7) Suburban
(8) 4 Door Utility
Vehicle Identification
E n g in e T ra n s m is sio n
M odel
B ase O p tio n B ase O p tio n
C105 (16) 5.7L V8 (L31) — 4 Spd. Auto. (M30) —

5.0L (L30)
C107 (03) 4.3L V6 (L35) 5 Spd. Manual (MG5) 4 Spd. Auto. (M30)
5.7L V8 (L31)
C107 (06) 5.7L V8 (L31) - 4 Spd. Auto. (M30) -
4 Spd. Auto. (MT1)
5.0L (L30)
5.7L V8 (L31)
5 Spd. Manual (M50)
4 Spd. Auto. (MT1)
5.0L (L30)
5.7L V8 (L31)
5 Spd. Manual (M50)
C109 (06) 5.7L V8 (L31) 6.5L V8 (L65) 4 Spd. Auto. (M30) 4 Spd. Auto. (MT1)
Vehicle Identification (cont’d)
E ngine T ran sm issio n
M odel
B ase O p tio n B ase O p tio n
4 Spd. Auto. (MT1)
C109 (53) 5.0L (L30) 5.7L V8 (L31) 5 Spd. Manual (MG5) 4 Spd. Auto. (M30)
5 Spd. Manual (M50)
4 Spd. Auto. (MT1)
5.7L V8 (L31)
C207 (53) 5.0L (L30) 5 Spd. Manual (MG5) 4 Spd. Auto. (M30)
6.5L V8 (L56)
5 Spd. Manual (M50)
5.7L V8 (L31)
7.4L V8 (L29)
C209 (03) 5.0L (L30) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L56)
6.5L V8 (L65)
7.4L V8 (L29)
C209 (06) 5.7L V8 (L31) 4 Spd. Auto. (MT1) -
6.5L V8 (L65)
7.4L V8 (L29)
C209 (53) 5.7L V8 (L31) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
C309 (43) 5 .7 L V 8 (L31) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L65)
7.4L V8 (L29)
C309 (53) 5 .7 L V 8 (L31) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
C318 (03) 7.4L V8 (L29) 6.5L V8 (L65) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
K105 (16) 5.7L V8 (L31) 6.5L V8 (L56) 4 Spd. Auto. (M30) 4 Spd. Auto. (MT1)
5.0L V8 (L30)
K107 (03) 4.3L V6 (L35) 5 Spd. Manual (MG5) 4 Spd. Auto. (M30)
5.7L V8 (L31)
K107 (06) 5.7L V8 (L31) - 4 Spd. Auto. (M30) -
5.0L V8 (L30) 4 Spd. Auto. (MT1)
K107 (53) 4.3L V6 (L35) 5.7L V8 (L31) 5 Spd. Manual (MG5) 4 Spd. Auto. (M30)
6.5L V8 (L56) 5 Spd. Manual (M50)
4 Spd. Auto. (MT1)
5.0L V8 (L30)
5.7L V8 (L31)
5 Spd. Manual (M50)
K109 (06) 5.7L V8 (L31) 6.5L V8 (L65) 4 Spd. Auto. (M30) 4 Spd. Auto. (MT1)
4 Spd. Auto. (MT1)
5.7L V8 (L31)
6.5L V8 (L56)
5 Spd. Manual (M50)
7.4L V8 (L29)
K207 (53) 5.7L V8 (L31) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
K209 (06) 5.7L V8 (L31) 4 Spd. Auto. (MT1) -
6.5L V8 (L65)
Vehicle Identification (co n t’d)
Engine Transmission
Model
Base Option Base Option
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
K309 (53) 5 .7 L V 8 (L31) 5 Spd. Manual (MW3) 4 Spd. Auto. (MT1)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
7.4L V8 (L29)
6.5L V8 (L65)
Model Codes: C-Rear Wheel Drive

K-Selectable Four Wheel Drive
03-Two Door Cab
06-Suburban or Four Door Utility
16-Two Door Utility
43-Four Door Cab
53-Two Door Extended Cab
VIN Derivative
All engines and transmissions are stamped or laser
etched with a partial Vehicle Identification Number
(VIN), which was derived from the complete VIN. A
VIN derivative contains the following nine positions:
Position Definition Character Description

1 GM Division Identifier G General Motors
2 Model Year W 1998
Oshawa, Ontario
Pontiac, Ml
Fort Wayne, IN
3 Assembly Plant I.E.Z.J.G.R
Janesville, Wl
Silao, Mexico
Arlington, TX
4 -9 Plant Sequence Number — —
A VIN derivative can be used to determine if a

vehicle contains the original engine or transmission,
by matching the VIN derivative positions to their
accompanying positions in the complete VIN:
VIN Derivative Position Equivalent VIN Position

1 2
2 10
3 11
4 -9 12-17
Vehicle Certification Label Gross vehicle weight (GVW) is the weight of the
vehicle and everything it carries. Include the
following items when figuring the GVW:
• The base vehicle weight (factory weight)
• The weight of ail vehicle accessories, like the
winches or the plows
• The weight of the driver and the passengers
• The weight of the cargo
The gross vehicle weight must not exceed the Gross
Vehicle Weight Rating.
The front gross axle weight (GAW) is the weight
exerted on the front axle. The rear gross axle weight
(GAW) is the weight exerted on the rear axle. The
front and rear gross axle weights must not exceed
the front and rear gross axle weight ratings.
The payload rating defines the vehicle’s maximum
allowable cargo load. The cargo load includes the
driver and the passengers. The payload rating is
based on the vehicle’s factory installed equipment.
Deduct from the payload rating the weight of
6472
accessories added to the vehicle after the final date
of manufacture.
The vehicle may have a Gross Combination Weight
Rating (GCWR). The Gross Combination Weight
Rating refers to the total maximum weight of the
C loaded tow vehicle (including driver and passengers)
and a loaded trailer.
The vehicle’s tires must be the proper size and
properly inflated for the load the vehicle is carrying.
For more information on tires, refer to Tire Inflation
Pressure Specifications in General Information.
6473
The vehicle certification label displays the following

assessments:
• The Gross Vehicle Weight Rating (GVWR)
• The Gross Axle Weight Rating (GAWR)
• The vehicle’s payload rating
• The original equipment tire sizes and the
recommended tire pressures
Tire Placard Engine ID and VIN Derivative Location
Legend
(1) Engine Identification Number
(2) Alternative Engine Identification Number
(1) Specified Occupant Seating Positions

(2) Total Occupant Seating
(3) Maximum Vehicle Capacity Weight
(4) Tire Pressures, Front, Rear, and Spare
(5) Tire Speed Rating, Front, Rear, and Spare
(6) Tire Label Code
(7) Engineering Model Minus First Character
(8) Tire Sizes, Front, Rear, and Spare
(9) Vehicle Identification Number*•
The Tire Placard is permanently located on the edge

of the driver’s door. Refer to the placard to obtain:
• The maximum vehicle capacity weight
• The cold tire inflation pressures
• The tire sizes (original equipment tires)
• The tire speed ratings (original equipment tires)
4.3L Engine
181920 181924
7.4L Engine
Located on the VIN plate, the VIN provides detailed
engine identification and code information by liter
and by the engine code letter.
Legend
(1) Source Code
(2) Month of Build
(3) Date of Build
(4) Broadcast Code
The engine unit number or date code is either laser

etched or stamped into the engine block.
All engines are stamped with an eight digit engine
identification number.
Transmission ID and VIN Derivative
Location (Transmission ID)
8 YD D 3 187 A
174101
8 XX P 3 187
181926
The transmission model identification is located on a

label or tag on the transmission case. If this label is
missing or unreadable, use the service parts
identification label in order to identify the vehicle’s
transmission.
186748
Anti-Theft Labeling The service parts identification label is placed on the
vehicle in order to help service and parts personnel
identify the vehicle’s original parts and the vehicle’s
original options.
RPO Code List

AE7: 60/40 Front Split Bench Seat, Driver,
Passenger Easy Entry
AG2: Seat Adjuster: Power, 6-way, Passenger
AG9: Seat Adjuster: Power, 6-way, Driver
AJ1: Windows: Deep Tint
AJ3: Restraint: Front Seat, Driver Inflatable
AL3: Restraint: Front Seat, Driver Inflatable, Delete
AM7: Seat, Rear Folding
APC: Provisions, Front Bucket Seating
APD: Provisions, Front Bench Seating
APR: Sales Incentive, 2500 Work Truck
175291 AS3: Seat, Rear Suburban
Federal law requires that General Motors label ATZ: Seat, Rear Delete
certain body parts on this vehicle with the VIN. The AT5: Seat, Center
purpose of the law is to reduce the number of motor
vehicle thefts by helping in the tracing and AU0: Lock Control: Remote Entry
recovering of parts from stolen vehicles. AU3: Locks, Power Door
The labels are permanently affixed to an interior AU6: Electric End Gate Lock Release
surface of the part. The label on a replacement part A20: Window: Rear Quarter Swing Out
contains the letter R, the manufacturer’s logo, and A21: Window: Non Encapsulated Glass
the "DOT" symbol.
A28: Window: Rear, Full Width, Sliding
Service Parts ID Label A31: Windows: Power
A50: Seat, Front Bucket
A52: Seat, Front Bench
A95: Seat: Front Bucket, High Back, Pass and
Driver Reclining
BAG: Parts Package, Export
BG9: Floor Covering, Rubber
BNP: Molding Wheel Opening Delete
BVE: Steps, Running Board
BYP: Sales, Sport Equipment Package
BZY: Liner, Pickup Box
B30: Floor Covering, Carpet
B32: Auxiliary Floor Covering, Front Floor Mats
B33: Auxiliary Floor Covering, Rear Floor Mats
B34: Carpeted Front Floor Mats
B35: Carpeted Rear Floor Mats
B37: Floor Covering, Auxiliary Front and Rear
6480 B39: Floor Covering, Carpeted Floor Mat
Legend B4L: Label Price, Refer Geographic Chart
(1) Vehicle Identification Number B71: Molding, Wheel Opening Colored
(2) Wheel Base B85: Molding, Body Side, Exterior
(3) Part Number Location B96: Molding, Wheel Opening
(4) Model Designation CMD: Plant Code, Flint, Ml
(5) Order Number
C25: Wiper System, Rear Window
(6) Exterior Color
C3F: 7700 Lbs. GVW Rating
(7) Paint Technology
C36: Auxiliary Heater
C49: Rear Window Defogger GTY: Axle Wide Track
C5B: 15000 Lbs. GVW Rating GT4: Rear Axle: 3.73 Ratio
C5I: 8050 Lbs. GVW Rating GT5: Rear Axle: 4.10 Ratio
C5M: 6100 Lbs. GVW Rating GU4: Rear Axle: 3.08 Ratio
C5P: 6250 Lbs. GVW Rating GU6: Rear Axle: 3.42 Ratio
C5Q: 6300 Lbs. GVW Rating G80: Rear Axle: Positraction
C5S: 6600 Lbs. GVW Rating HC4: Rear Axle: 4.56 Ratio
C5U: 6800 Lbs. GVW Rating HC7: Rear Axle: 5.13 Ratio
C5Z: 7200 Lbs. GVW Rating JAN: Plant Code, Janesville, Wl, GM NATG
C6P: 8600 Lbs. GVW Rating JB5: Brake System: Power, Front Disc, Rear Drum,
C6U: 9000 Lbs. GVW Rating 6400 Lbs.
C6W: 9200 Lbs. GVW Rating JB6: Brake System: Power, Front Disc, Rear Drum,
7200 Lbs.
C6Y: 9600 Lbs. GVW Rating
JB7: Brake System: Power, Front Disc, Rear Drum,
C60: HVAC System, Front Air Conditioning 8400 Lbs.
C69: HVAC System, Rear Air Conditioning JB8: Brake System: Power, Front Disc, Rear Drum,
C7A: 10000 Lbs. GVW Rating 10000 Lbs.
C7E: 11000 Lbs. GVW Rating JD5: Brake System: Dual Power, Front Disc, Rear
C7I: 6450 Lbs. GVW Rating Drum, 6400 Lbs.
C7L: 12000 Lbs. GVW Rating JD6: Brake System: Hydraulic Power, Front Disc,
DD0: Mirror, Outside, LH and RH, Electric, Heated, Rear Drum, 7200 Lbs.
Electrochromic JD7: Brake System: Hydraulic Power, Front Disc,
DD7: Mirror: l/S, Rearview Light Sensitive, Compass Rear Drum, 8400 Lbs.
DE2: Mirror: O/S, LH & RH, Folding, Painted JF9: Brake System: Hydraulic Power, Four
Wheel Disc
DF2: Mirror: O/S, LH & RH, Camper Style,
Stainless Steel KA1: Heated Seats, DR/PS, High Back Buckets
w/Leather
DF5: Mirror: l/S, Rearview, Electrochromic, Compass
and Outside Temperature KC4: Cooling System, Engine Oil
DG5: Mirror: O/S, LH & RH, Large Stainless Steel KG9: Generator, 140 Amp
KL5: Modification Engine, Natural Gas
DK6: Console: Roof, Interior
DR1: Mirror: O/S, LH & RH, Manual Control KL6: Provisions, Natural Gas
KNP: Transmission, Heavy Duty Cooling System
D44: Mirror: Outside, Painted
D45: Mirror: Outside, Stainless Steel KW2: Generator, 124 Amp
D48: Mirror: Outside, Remote Control, Electric KXB: Dual Generator, 100 Amp
D55: Console, Front Compartment, Floor K02: Fan: Radiator Booster
EF1: Bumper Provisions, Rear, Delete K05: Heater: Engine Block
EXP: Export, International Sales K34: Cruise Control: Automatic, Electronic
E24: Door, Rear Side Hinged K47: Air Cleaner, High Capacity
E55: Body Equipment End Gate K60: Generator: 100 Ampere
E62: Body Equipment, Stepside Pickup Box K68: Generator: 105 Ampere
E63: Body Equipment, Fleetside Pickup Box L29: Engine: 7.4 Liter V8, MFI
FE9: Certification: Emission, Federal L30: Engine: 5.0 Liter V8, CPI
FG5: Shock Absorbers: Front & Rear, Gas, L31: Engine: 5.7 Liter V8, CPI
Delco/Bilstein, 46MM L35: Engine: 4.3 Liter V6, CPI
FW1: Plant Code, Fort Wayne, IN, GM NATG L56: Engine Diesel: 6.5 Liter V8, Turbo
F44: Chassis, Heavy Duty L65: Engine Diesel: 6.5 Liter V8, Turbo
F48: Chassis, Manual Select Dampening MG5: Transmission: Manual 5 Speed,
F51: Shock Absorbers, Front and Rear, Heavy Duty New Venture Gear
F60: Spring, Front, Heavy Duty MSL: Plant Code, Silao, Mexico
F61: Stabilizer Shaft: Rear MT1: Transmission: 4L80-E, 4-Speed Automatic,
Electronic
GAM: Vehicle Government
MW3: Transmission: Manual 5 Speed,
GK9: Rear Axle: 4.63 Ratio New Venture Gear
M30: Transmission: 4L60-E, 4-Speed Automatic, RSB: Restraint: Front Seat, 208, Auto, Manual,
Electronic Active
M50: Transmission: Manual 5 Speed, R04: Wheel, Single Rear
New Venture Gear R05: Wheel, Dual Rear
NA1: Emission System: GVW Less than 8500 lbs TP2: Battery Auxiliary, Camper
NA4: Emission System: GVW Above 8500 lbs TL1: Grille: Special
NA5: Emission System: Federal, Tier 0 T62: Lighting, Daytime Running, Delete
NB2: Emission System: California, Tier 0 T85: Headlamps: LH Rule of Road, E Mark
NB6: Emission System: California, Tier 1 UC2: Speedometer: Instrument, Kilometers & Miles,
NB8: Emission Override: California System Kilometer Odometer, Positive Bias
NC1: Emission System: California, LEV UD4: Alarm: Vehicle Speed, 120 K/H
NC7: Emission Override: Federal System UG1: Homelink™ 3-Channel Transmitter
NF2: Emission System: Federal, Tier 1 UK1: Radio, Frequencies, Japanese
NG1: Certification Emission, Geographically UL0: Radio: AM/FM Stereo, Seek/Scan, Auto
Restricted Registration Reverse Cassette, Music Search
NM8: Leaded Fuel System Compatible UL2: Radio, Frequencies, European
NN8: Emission Override Unleaded Fuel, Export UL5: Radio: Delete
NP1: Transfer Case, Electronic Shift, Two Speed UM6: Radio: AM/FM Stereo, Seek/Scan, Auto
NP5: Steering Wheel: Leather Wrapped Reverse Cassette, Clock, ETR
NQZ: Fuel Tank, Auxiliary, Rear Mounted, 18 Gallon, UM7: Radio: AM/FM Stereo, Seek/Scan, Clock, ETR
Delete UNO: Radio: AM/FM Stereo, Seek/Scan, Compact
NRQ: Exhaust Close Coupled Disc, Auto Tone
NY1: Shield, Fuel Tank UP0: Radio: AM/FM Stereo, Seek/Scan, Auto
Reverse, Music Search, Cassette, Compact Disc
NZZ: Sales Package, Skid Plate, Off Road Sport
Player, Auto Tone
N33: Steering Column: Tilt Type
UQ3: Speaker System, Performance Enhanced
N83: Wheel: 1 5 x 7 , Chrome Styled Radio
N90: Wheel: 1 5 x 7 , Aluminum Cast, 4.75 Inch Bolt UQ5: Speaker System 4, Dual Front Door Mounted,
Circle Dual Extended Range, Quarter Mounted
OSG: Plant Code, Oshawa, Ontario, GM of Canada UW3: Radio: AM/FM Stereo, Seek/Scan, Auto
PF4: Wheel: 1 6 x 7 , Aluminum Cast Reverse, Music Search
P06: Wheel, Trim Discs UY1: Wiring Provisions, Camper
QBN: Tire: All, LT245/75R16/C BW R/PE ST U01: Roof Marker Lamp, Five
TBL OOR U19: Speedometer Inst, Kilo and Miles
QBX: Tire: All, LT245/75R16/C WOL R/PE ST VB1: Label Shipping, Japan
TBL OOR VB3: Bumper, Rear Step, Chrome, Impact Strip
QFL: Tire: All, P235/75R15 BW R/PE ST TL VC0: Vehicle Label, Noise Control Information
ALS 105S
VC4: Label Price/Fuel Econ, Puerto Rico
QFN: Tire: All, P235/75R15 WL R/PE ST TL
ALS 105S VC5: Label Shipping, Except for US, US
Possessions, Or Japan
QGA: Tire: All, P245/75/R16 BW R/PE ST TL
ALS 109S VC7: Label Price/Fuel Econ, Guam
QGB: Tire: All, P245/75/R16 WOL R/PE ST TL VG3: Bumper, Front Impact Strip
ALS 109S VG8: Vehicle Label, Notice to Buyer
QGC: Tire: All, P265/75/R16 BW R/PE ST TL VK3: License Plate, Front Mounting Package
ALS 114S VK5: Seat: Temporary, For Shipping
QGD: Tire: All, P265/75/R16 WOL R/PE ST TL VPH: Vehicle Preparation Overseas Delivery
ALS 114S
VL3: Label: Mirror, O/S Warning
QHA: Tire: All, P235/75/R15/X BW R/PE ST TL ALS
VR4: Trailer Hitch: Weight Distributing Platform
QIW: Tire: All, P245/75/R16 BL R/PE ST TL OOR
VR6: Hook: Tie Down
QIZ: Tire: All, P245/75/R16 BL R/PE ST TL ALS
VS7: Vehicle Non-Saleable
Q4B: GVW Rating 6200 lbs.
VYU: Provisions, Snow Plow Prep
RHD: Right Hand Drive
V10: Provisions: Cold Climate
RSA: Restraint: Front Seat, 208, Auto, Passive
V22: Grille Chrome, Radiator
V27: Guards, Front Bumper YD7: Axle for Scheduling GVW Plate, Used with R05
V43: Bumper, Rear Step, Painted YE9: Convenience Package Comfort and Decor
V54: Luggage Carrier, Roof, Painted Level #3
V60: Vehicle Statement Gulf States Organization, YFL: Tire: Rear, P235/75R15 BW R/PE ST TL ALS
Incomplete Vehicle YFN: Tire: Rear, P235/75R15N RWL R/PE ST TL
V73: Vehicle Statement US/Canada ALS 105S
V76: Tow Hook YF2: Sales Package, Ambulance Upfitter
V78: Vehicle Statement Delete YF4: Vehicle Engineering, Hold Order
V87: Vehicle Statement Gulf States Organization YF5: California Emission Certificate
V98: Factory Delivery Processing YF7: Sales Package, Recreational Vehicle Upfitter
WD1: Identification Pilot Vehicle YGA: Tire: Rear, P245/75R16 BW R/PE ST TL
AT 109S
W99: Equipment Misc Equip For Venez
YGB: Tire: Rear, P245/75R16 WOL R/PE ST TL
XBN: Tire: Front, LT245/75/R16/C BL R/PE ST
AT 109S
TBL OOR
YGC: Tire: Rear, P265/75R16 BW R/PE ST TL
XBX: Tire: Front, LT245/75/R16/C WOL R/PE ST
AT 114S
TBL OOR
YGD: Tire: Rear, P265/75R16 WOL R/PE ST TL
XFL: Tire: Front, P235/75/R15 ST TL ALS B/W
AT 114S
XFN: Tire: Front, P235/75/R15/N WL R/PE ST TL
YGK: Tire: Rear, P245/75R16E BL R/PE ST
ALS 105S
OOR (9591214)
XGA: Tire: Front, P245/75/R16 BW R/PE ST TL
YG4: Optional Seats Not Desired
AT 109S
YHA: Tire: Rear, P235/75R15X BL R/PE ST TL ALS
XGB: Tire: Front, P245/75/R16 WOL R/PE ST TL
AT 109S YHH: Tire: Rear, P245/75R16E BL R/PE ST ALS
XGC: Tire: Front, P265/75/R16 BW R/PE ST TL YHM: Tire: Rear, P235/75R15 WOL R/PE ST TL
AT 114S ALS 108S (X/LOAD)
XGD: Tire: Front, P265/75/R16 WOL R/PE ST TL YHP: Tire: Rear, LT225/75R16D BL R/PE ST
AT 114S TL ALS
XGK: Tire: Front, LT245/75/R16 BL R/PE ST OOR YHR: Tire: Rear, LT225/75R16D BL R/PE ST
TL OOR
XHA: Tire: Front, P235/75/R15X BL R/PE ST
TL ALS YTN: Tire: Rear, LT225/70R19.5 BW R/ST ST
TL HWY
XHE: Tire: Front, LT235/75/R16C BL R/PE ST ALS
YYK: Tire: Rear, LT215/85R16D BL R/PE ST
XHH: Tire: Front, LT245/75/R16E BL R/PE ST ALS
TL HWY
XHM: Tire: Front, P235/75/R15 WOL R/PE ST TL
YYL: Tire: Rear, LT215/85R16D BL R/PE ST
ALS 108S (X/LOAD)
TL OOR
XHP: Tire: Front, LT225/75/R16D BL R/PE ST
Y91: Sales Package, Luxury (GMT 425)
TL ALS
ZA6: Package Price Leader, Canadian
XHR: Tire: Front, LT225/75/R16D BL R/PE ST
TL OOR ZA7: Package Value Leader, Canadian
XTN: Tire: Front, 225/70R9.5F BW R/ST ST ZBN: Tire: Spare LT245/75R16C BL R/PE ST
TL HWY TBLE OOR
XYK: Tire: Front, LT215/85/R16D BL R/PE ST ZBX: Tire: Spare LT245/75R16C WOL R/PE ST
TL OOR TBLE OOR
XYK: Tire: Front, LT215/85/R16D BL R/PE ST ZFL: Tire: Spare P235/75R15 BW R/PE ST TL
TL HWY ALS 105S
X81: Sales Incentive Price Leader ZFN: Tire: Spare P235/75R15N RWL R/PE ST TL
ALS 105S
X88: Conversion Name Plate — CHEVROLET
ZGA: Tire: Spare P245/75R16 BW R/PE ST TL
YA7: Assembly Line Emission Test, California
ALS 109S
YA9: Axle, 3400 lbs
ZGB: Tire: Spare P245/75R16 WOL R/PE ST TL
YBN: Tire: Rear, LT245/75R16C BL R/PE ST AT 109S
TBL OOR
ZGC: Tire: Spare P265/75R16 BW R/PE ST TL
YBX: Tire: Rear, LT245/75R16C WOL R/PE ST AT 114S
TBL OOR
ZGD: Tire: Spare P265/75R16 WOL R/PE ST TL
YD3: Front Axle For Scheduling GVW Plate AT 114S
YD6: Rear Spring, Base Equipment
ZGK: Tire: Spare LT245/75R16E BL R/PE ST OOR 262: Trim Combination Leather, Navy
ZHA: Tire: Spare P235/75R15X BW R/PE ST 27A: Stripe Color Accent, Light Indigo/Dark Indigo
TL ALS 29U: Primary Color Exterior, Dark Blue
ZHH: Tire: Spare LT245/75R16E BL R/PE ST ALS 31 A: Stripe Color Accent, Light Sllver/Dark Indigo
ZHM: Tire: Spare P235/75R15 WOL R/PE ST TL 35L: Secondary Color Exterior, Laguna Green
ALS 108S (X/LOAD)
35U: Primary Color Exterior, Laguna Green
ZHP: Tire: Spare LT225/75R16D BL R/PE ST
39L: Secondary Color Exterior, Indigo Blue Metallic
TL ALS
ZHR: Tire: Spare LT225/75R16D BL R/PE ST 39U: Primary Color Exterior, Indigo Blue Metallic
TL OOR 41L: Secondary Color Exterior, Black
ZM9: Sates Package Comfort and Convenience 41U: Primary Color Exterior, Black
(Utility/Suburban Feature Package) 43L: Secondary Color Exterior, Emerald Green
ZP6: Sales Package Combination, Rear Window 43U: Primary Color Exterior, Emerald Green
Wiper/Rear Window Defogger 46U: Primary Color Exterior, Dark Green
ZTN: Tire: Spare LT225/70R19.5F BW R/ST ST 50L: Secondary Color Exterior, Olympic White
TL HWY
50U: Primary Color Exterior, Olympic White
ZW9: Body Equipment, Base Body or Chassis Cab
51 A: Stripe Color Accent, Gunmetal/Ultra Silver
ZYK: Tire: Spare LT215/85R16D BL R/PE ST
TL HWY 51L: Secondary Color Exterior, Dark Toreador Metallic
ZYL: Tire: Spare LT215/85R16D BL R/PE ST 51U: Primary Color Exterior, Dark Toreador Metallic
TL OOR 52C: Trim Combination Cloth, Light Neutral
ZY1: Color Combination, Solid 52D: Trim Combination Cloth, Light Neutral
ZY2: Color Combination, Two Tone 52I: Interior Trim, Light Neutral
ZY4: Color Combination, Deluxe Two Tone 52V: Trim Combination Vinyl, Light Neutral
Z49: Export, Canadian Modified Mandatory 522: Trim Combination Leather, Light Neutral
Base Equipment 56A: Stripe Color Accent, Medium Beige/Black
Z71: Chassis Package Off-Road 61U: Primary Color Exterior, Tan
Z81: Camper Special 65L: Secondary Color Exterior, Smokey Carmel
Z82: Trailer Provisions Special equipment, Metallic
Heavy Duty 65U: Primary Color Exterior, Smokey Carmel Metallic
Z88: Conversion Name Plate, GMC TRUCK 69L: Secondary Color Exterior, Copper Metallic
01L: Exterior Color Secondary, Special 69U: Primary Color Exterior, Copper Metallic
01U: Exterior Color Primary, Special 71U: Primary Color Exterior, Red Orange
11L: Secondary Color Exterior, Pewter Metallic 72U: Primary Color Exterior, Standard Red
11U: Primary Color Exterior, Pewter Metallic 74L: Secondary Color Exterior, Victory Red
12U: Primary Color Exterior, Linen White 74U: Primary Color Exterior, Victory Red
13C: Trim Combination Cloth, Light Gray 79C: Trim Combination Cloth, Ruby Red
13D: Trim Combination Cloth, Light Gray 79D: Trim Combination Cloth, Ruby Red
131: Interior Color, Light Gray 79I: Interior Trim, Ruby Red
13V: Trim Combination Vinyl, Light Gray 79V: Trim Combination Vinyl, Ruby Red
132: Trim Combination Leather, Light Gray 792: Trim Combination Leather, Ruby Red
19U: Primary Color Exterior, Lamp Black 80A: Stripe Color Accent, Gunmetal/Light Silver
23U: Primary Color Exterior, Ocean Blue 82A: Stripe Color Accent, Light Silver/Dark Green
24L: Secondary Color Exterior, Opal Blue 83A: Stripe Color Accent, Green/Ultra Silver
24U: Primary Color Exterior, Opal Blue 84A: Stripe Color Accent, Light Silver/Dark Indigo
24U: Primary Color Exterior, Medium Blue Metallic 87A: Stripe Color Accent, Light Silver/Medium Red
25L: Secondary Color Exterior, Bright Blue Metallic 90U: Primary Color Exterior, Gray Metallic
26C: Trim Combination Cloth, Navy 91L: Secondary Color Exterior, Dark Argent
26D: Trim Combination Cloth, Navy
26I: Interior Trim, Navy
26V: Trim Combination Vinyl, Navy
How to Obtain Replacement Labels Fasteners

Obtain replacements for the following labels through Metric Fasteners
the GM Service Parts Operations:
This vehicle is dimensioned in the metric system.
• The vehicle emission control information Most metric fasteners are very close in diameter to
(exhaust emission tune-up) label well known fasteners in the English (inch) system.
• The spare wheel caution label Replace fasteners with those of the same nominal
• The jacking label diameter, thread pitch, and strength.
• The serpentine belt routing label A number marking identifies the OE metric fasteners
• The engine fan caution label (except cross-recess head screws). The number also
indicates the strength of the fastener material. A
• The spare tire storage label Posidriv® or Type 1A cross-recess identifies a metric
The following labels are not available as cross-recess screw. For best results, use a Type 1A
service parts: cross-recess screwdriver, or equivalent, in Posidriv®
• The vehicle certification label recess head screws.
• The tire pressure placard GM Engineering Standards and North American
• The service parts identification label Industries have adopted a portion of the ISO-defjned
standard metric fastener sizes. The purpose was to
Exterior and Interior Colors reduce the number of fastener sizes used while
retaining the best thread qualities in each thread
Exterior Colors size. For example, the metric M6.0 X 1 screw, with
nearly the same diameter and 25.4 threads per inch
GM Code WA No. Color replaced the English 1/4-20 and 1/4-28 screws. The
24 305D Opal Blue Metallic thread pitch is midway between the English coarse
and fine thread pitches.
Bright Blue
25 303D
Metallic
Lt. Stellar Blue
27 146B
Metallic
35 304D Laguna Green
39 9792 Indigo Metallic
41 8555 Black
Emerald Green
43 177B
Metallic
50 8624 White
Dk. Toreador
51 334D
Metallic
Lt. Autumnwood
55 228A
Metallic
Red Maple
59 225C
Metallic
65 333D Smokey Caramel
74 9260 Victory Red
Dk. Cherry
77 9800
Metallic
Dk. Hunt Club
84 9927
Red
Ultra Silver
96 8867
Metallic
Interior Colors
GM Code WA No. Color
131 9779 Medium Gray
261 173B Navy Blue
521 195A Neutral
791 9933 Ruby Red
Fastener Strength Identification
171891
Legend
(1) English Bolt, Grade 2 (Strength Class) (5) Metric Nut, Strength Class 9
(2) English Bolt, Grade 5 (Strength Class) (6) Metric Bolts, Strength Class Increases as
(3) English Bolt, Grade 7 (Strength Class) Numbers Increase
(4) English Bolt, Grade 8 (Strength Class)
The most commonly used metric fastener strength standards of countries other than the United States,
property classes are 9.8 and 10.9. The class and may exhibit the following defects:
identification is embossed on the head of each bolt. • Lower strength
The English (inch) strength classes range from
• No numbered head marking system
grade 2 to grade 8. Radial lines are embossed on
the head of each bolt to identify the strength class. • Wrong thread pitch
The number of lines on the head of the bolt is two The metric fasteners on GM products are designed
lines less than the actual grade. For example, a to new, international standards. Following are the
grade 8 bolt will have 6 radial lines on the bolt head. common sizes and pitches, except for special
Some metric nuts are marked with a single digit applications:
strength identification number on the nut face. . M6.0 X 1
The correct fasteners are available through GM . M8 X 1.25
SPO. Many metric fasteners available in the
• M10 X 1.5
aftermarket parts channels were designed to metric
. M12 X 1.75
Prevailing Torque Fasteners A prevailing torque nut is designed to develop an

interface between the nut and bolt threads. Distortion
of the top of a metal nut or using a nylon patch
on the threads in the middle of the hex flat causes
that interface.
A prevailing torque bolt/nut that is clean and free of
rust can be reused as follows. If there is any doubt,
replace the fastener:
1. Clean away all dirt or foreign material.
2. Inspect the fastener for signs of overtightening.
3. Handstart the fastener at the original location.
4. Inspect the fastener for torque development,
referring to the table below.
5. Tighten the fastener within specifications.
Legend
(1) Prevailing Torque Nut, Center Lock Type
(2) Prevailing Torque Nut, Top Lock Type
(3) Prevailing Torque Nut, Nylon Patch Type
(4) Prevailing Torque Nut, Nylon Washer
Insert Type
(5) Prevailing Torque Nut, Nylon Insert Type
(6) Prevailing Torque Bolt, Dry Adhesive
Coating Type
(7) Prevailing Torque Bolt, Thread Profile
Deformed Type
(8) Prevailing Torque Bolt, Nylon Strip Type
(9) Prevailing Torque Bolt, Out-of-Round Thread
Area Type
Metric-Size Fasteners
Com ponent Size (in mm) N-m Lb in
6 0.4 4
6.3 0.4 4
8 0.6 7
10 1.4 12
Nuts and All Metal Bolts/Screws
12 2.2 18
14 3.0 27
16 4.2 37
20 7.0 82
6 0.4 4
6.3 0.4 4
8 0.6 5
10 1.2 11
Adhesive or Nylon Coated Bolts/Screws
12 1.6 14
14 2.4 21
16 3.4 30
20 5.6 50
English-Size Fasteners
Com ponent Size (in inches) N-m Lb in
0.250 0.4 4
0.312 0.6 5
0.375 1.4 12
0.437 1.6 16
Nuts and All Metal Bolts/Screws
0.500 2.4 21
0.562 3.2 28
0.625 4.2 37
0.750 7.0 62
0.250 0.4 4
0.312 0.6 5
0.375 1.0 9
0.437 1.4 12
Adhesive or Nylon Coated Bolts/Screws
0.500 1.8 16
0.562 2.6 23
0.625 3.4 30
0.750 5.2 49
Thread Inserts
Repair Procedure
Tools Required
General purpose thread repair kits. These kits are
available commercially.
Caution: Wear safety glasses in order to avoid
eye damage.
4. Thread the thread insert onto the mandrel of

the installer. Engage the tang of the insert onto
the end of the mandrel.
Important: The insert should be flush to one
turn below the surface.
5. Lubricate the insert with light engine oil
(except when installing in aluminum) and
4962 install the insert.
Important: Refer to the thread repair kit 6. If the tang of the insert does not break off
manufacturer’s instructions regarding the size of the when backing out the installer, break the tang
drill and tap to use. off with a drift.
Avoid any buildup of chips. Back out the tap every Proper Use of Torque Wrenches
few turns and remove the chips.
Torque Defined
1. Determine the size, the pitch, and the depth of Torque is defined as the measurement of resistance
the damaged thread. If necessary, adjust the to turning or rotating. Torque, often called torsional or
stop collars on the cutting tool and tap to the twisting movement, tends to twist a body about an
required depth. axis of rotation. A typical application is the tightening
2. Drill out the damaged threads. Clean out of a screw.
any chips. Torque applied in tightening a common bolt, nut, or
3. Lubricate the tap with light engine oil. Tap the screw is expended in three areas:
hole. Clean the threads. • the head
• bearing surface
• clamp load
Clamp Load
About 50% of applied torque is used in overcoming
bearing friction. This is the friction between the
bearing surface of the bolt head, screw head or nut
face, and the base material or washer (the surface
the fastener is rotating on). Approximately 40% of
the applied torque is used in overcoming thread
friction, this leaves only about 10% of the applied
torque to develop useful clamp load. Clamp load is
the force that holds a joint together. Friction can
account for as much as 90% of the applied torque
on a fastener.
Torque Wrenches and Techniques
The term "torque wrench" is commonly used to
describe a type of measuring tool. The tool is set or
calibrated in such a way as to make possible the
measurements of the resistance to turning (torque).
The torque wrench measures this resistance to
turning and, therefore, is the method used to obtain
objective tightening data used in the assembly of
fasteners. A torque wrench is a gage tool that can
be compared with micrometers, dial indicators,
vernier calipers, levels, and other measuring devices.
6487
Tapered Beam Model Torque Wrench Click-type Torque Wrench

Of the many different types of torque wrenches Another type of torque wrench is the "Click" type
available, the most popular in the service field is the which is adjusted to a predetermined torque. Once
tapered beam model. This model uses a pointer the designated torque has been reached, the wrench
attached to the head that runs the length of the has a reflex signalling feature that causes a
flexible beam (shaft) to a scale located near the momentary breakaway of the body of the torque
handle. As the wrench is pulled, the beam bends wrench. This feature has the effect of sending a
and the pointer indicates the torque on the scale. strong impulse to the technician’s hand. Although
once quite popular, these wrenches are not the
preferred method for torque applications.
6485
Pivoted Handle Torque Wrench accurate within 2% of the indicated reading from
Some types of torque wrenches are equipped with a 20% of full scale to full scale. For example, a
pivoted handle. If used properly, this handle permits 200 N.m (148 lb ft) full scale torque wrench is
the accurate and correct use of the torque wrench. guaranteed to be accurate from 40 N.m to
In order to hold a pivoted type handle, it should be 200 N.m (30-148 lb ft) (20-100% of full scale).
floated on the pivot point. This concentrates your Using this wrench below 40 N.m (30 lb ft) (its
pulling force. If the pivoting handle comes in contact guaranteed operating range) could result in
with the yoke extension during the process of pulling, inaccurate torque readings and possible
there is a very good chance the torque readings will joint failure due to either an overtorque or
be inaccurate because this could alter the wrench undertorque condition.
loading point. The design of the handle, however, Torque Wrench Selection
makes it inconvenient to deliberately use the floating Since it is not possible to purchase one wrench to fit
principle improperly. the widest range of torque specifications in the
service environment, the following guidelines should
be used for torque wrench selection:
• 0-20 N-m Full Scale (177 lb in). Accurate from
4-20 N-m (35-177 lb in).
• 0-75 N-m Full Scale (55 lb ft). Accurate from
15-75 N.m (11-55 lb ft).
• 0-250 N-m Full Scale (185 lb ft). Accurate from
50-250 N-m (37-185 lb ft).
Torque Wrench Calibration
This is a general guideline and is published to
facilitate the selection of a range or torque wrenches
that would cover most applications and would remain
in the guaranteed accuracy ranges of the wrenches.
Once a wrench is put into service, nothing
guarantees that the wrench will remain calibrated
within its accuracy range. It is recommended,
therefore, that torque wrenches be calibrated a
minimum of twice annually. Once again, the torque
wrench is a precision measuring device. The torque
wrench is exposed to a rugged working conditions.
Direct Reading Torque Wrench Precautions must be taken in order to protect against
Some of the newer model wrenches, such as the inaccurate measurements.
Snap-on® Direct Reading Torqometer wrench (Model Continuous Pull Method
TES or equivalent) can be held at any position on Once a torque wrench is selected, you will use a
the wrench without affecting accuracy, these technique called the "continuous pull method" in
wrenches are preferred over the flexible beam types order to increase accuracy during torquing. Pull the
because of their greater degree of accuracy, torque wrench in one continuous, smooth action until
compact design, and scales that are easily readable. the specified torque is reached. There is no jerking
Torque Wrench Accuracy or wratcheting during this final tightening effort. The
Selecting the proper size and range of a torque continuous pull method is an excellent way to
wrench is important in obtaining accurate results. develop consistency.
The best quality torque wrenches (the Snap-on®
Direct Reading Torqometer models or equivalent) are
Abbreviations and Their Meanings A bbreviations Table (cont’d)
The following abbreviations may appear in this A bbreviation M eaning
manual.
BLK Black
A bbreviations Table BLU Blue
Abbreviation M eaning BP Back Pressure
A BPM Brake Pressure Modulator
A Ampere(s) BPP Brake Pedal Position
ABS Antilock Brake System BRN Brown
A/C Air Conditioning BTDC Before Top Dead Center
AC Alternating Current BTSI Brake Transmission Shift Interlock
ACC Accessory, Automatic Climate Control Btu British thermal units
ACL Air Cleaner C
ACR4 Air Conditioning Refrigerant, Recovery, •c Degrees Celsius

Recycling, Recharging CAC Charge Air Cooler
A/D Analog to Digital CAFE Corporate Average Fuel Economy
Adj Adjust Cal Calibration
ADL Automatic Door Lock Cam Camshaft
A/F Air/Fuel (Ratio) CARB California Air Resources Board
AIR Secondary Air Injection cc cubic centimeters
ALC Automatic Level Control CCM Central Control Module
Alt Altitude CCOT Cycling Clutch Orifice Tube
AM/FM Amplitude Modulation/Frequency CCP Climate Control Panel
Modulation
CD Compact Disc
Ant Antenna
CE Commutator End
AP Accelerator Pedal
CEAB Cold Engine Air Bleed
API American Petroleum Institute
CEMF Counter Electromotive Force
APP Accelerator Pedal Position
cfm cubic feet per minute
APT Adjustable Park Throttle
eg center of gravity
ARS Automatic Restraint System
CID Cubic Inch Displacement
ASR Acceleration Slip Regulation
CKP Crankshaft Position
A/T Automatic Transmission/Transaxle
CKT Circuit
ATC Automatic Temperature Control
CL Closed Loop
ATC Automatic Transfer Case
C/Ltr Cigar Lighter
ATDC After Top Dead Center
cm3 cubic centimeters
Auto Automatic
CMP Camshaft Position
avg average
CNG Compressed Natural Gas
AWD All Wheel Drive
CO Carbon Monoxide
AWG American Wire Gage
C 02 Carbon Dioxide
A4WD Automatic Four W heel Drive
Coax Coaxial
B
COMM Communication
B+ Battery Positive Voltage
Conn Connector
B- Battery Negative Voltage
Conv Converter
BARO Barometric (pressure)
CPA Connector Position Assurance
batt battery
CPP Clutch Pedal Position
BBV Brake Booster Vacuum
CPS Central Power Supply
BCM Body Control Module
CPU Central Processing Unit
BHP Brake Horsepower CRT Cathode Ray Tube
A bbreviations Table (cont’d) A bbreviations Table (cont’d)

A bbreviation M eaning Abbreviation Meaning
CRTC Cathode Ray Tube Controller EEVIR Evaporator Equalized Values

in Receiver
CS Charging System
EFE Early Fuel Evaporation
CTP Closed Throttle Position
EGR Exhaust Gas Recirculation
cu ft cubic foot/feet
EGR TW Exhaust Gas Recirculation Thermal
cu in cubic inch/inches
Vacuum Valve
CV Contant Velocity Goint)
El Electronic Ignition
CVRSS Continuously Variable Road
ELAP Elapsed
Sensing Suspension
ELC Electronic Level Control
Cyl Cylinder(s)
E/M English / Metric
D
EMF Electromotive Force
DAB Delayed Accessory Bus
Eng Engine
dB decibels
EOP Engine Oil Pressure
dBA decibels on A-weighted scale
EOT Engine Oil Temperature
DC Direct Current
EPA Environmental Protection Agency
DCM Door Control Module
EPR Exhaust Pressure Regulator
DE Drive End
EPROM Erasable Programmable Read
DEC Digital Electronic Controller
Only Memory
DERM Diagnostic Energy Reserve Module
ESC Electronic Suspension Control
DFI Direct Fuel Injection
ESD Electrostatic Discharge
Dl Distributor ignition
ETC Electronic Throttle Control, Electronic
dia diameter Temperature Control
DIC Driver Information Center ETCC Electronic Touch Climate Control
Diff Differential ETR Electronically Tuned Receiver
DK Dark EVAP Evaporative Emission
DLC Data Link Connector EVO Electronic Variable Orifice
DMM Digital Multimeter Exh Exhaust
DOHC Dual Overhead Camshafts F
DR Driver *F Degrees Fahrenheit
DRL Daytime Running Lamps FC Fan Control
DTC Diagnostic Trouble Code FDC Fuel Data Center
DVM Digital Voltmeter FED Federal (all United States
DVOM Digital Voltmeter/Ohmmeter except California)
E FEDS Fuel Enable Data Stream
EBCM Electronic Brake Control Module FF Flexible Fuel
EBTCM Electronic Brake and Traction FI Fuel Injection

Control Module FMVSS Federal Motor Vehicle Safety Standards
EC Electrical Center F/P Fuel Pump
ECC Electronic Climate Control ft foot/feet
ECI Extended Compressor at Idle FT Fuel Trim
ECL Engine Coolant Level F4WD Full Time Four W heel Drive
ECM Engine Control Module 4WAL Four Wheel Antilock
ECS Emission Control System 4W D Four W heel Drive
ECT Engine Coolant Temperature FW Flat Wire
EEPROM Electronically Erasable Programmable FWD Front W heel Drive
Read Only Memory
General Information General Information 0*31
Abbreviations Table (cont’d) Abbreviations Table (cont’d)
A b b rev iatio n M ean in g A b b rev iatio n M ean in g
G IDI Integrated Direct Ignition
g grams, gravitational accelaration ign ignition
GA Gage ILC Idle Load Compensator
gal gallon in inch/inches
gas gasoline INJ Injection
GCW Gross Combination Weight inst instantaneous
Gen Generator int intake
GL Gear Lubricant l/P Instrument Panel
GM General Motors IPC Instrument Panel Cluster
GM SPO General Motors Service l/PEC Instrument Panel Electrical Center
Parts Operations
ISC Idle Speed Control
gnd ground
ISO International Standards Organization
gpm gallons per minute
ISS Input Speed Shaft
GRN Green
K
GRY Gray KAM Keep Alive Memory
GVWR Gross Vehicle Weight Rating
KDD Keyboard Display Driver
H
kg kilogram
H Hydrogen
kHz kilohertz
H 20 W ater kilometer
km
Ham Harness
km/h kilometers per hour
HC Hydrocarbons km/l kilometers per liter
H/CMPR High Compression
kPa kilopascals
HD Heavy Duty
KS Knock Sensor
HDC Heavy Duty Cooling
kV kilovolts
hex hexagon
L
Hg Mercury
L Liter
Hi Alt High Altitude L4 Four Cylinder Engine, In-line
H 02S Heated Oxygen Sensor
L6 Six Cylinder Engine, In-Line
hp horsepower
lb pound
HPL High Pressure Liquid
lb ft pound feet (torque)
HPS High Performance System
lb in pound inch (torque)
HPV High Pressure Vapor
LCD Liquid Crystal Display
Htd Heated
LDCL Left Door Closed Locking
HTR Heater
LDCM Left Door Control Module
HUD Head-up Display
LED Light Emitting Diode
HVAC Heater-Vent-Air Conditioning
LF Left Front
HVACM Heater-Vent-Air Conditioning Module
LH Left Hand
HVM Heater Vent Module Im lumens
Hz Hertz
LR Left Rear
I
It left
IAC Idle Air Control
LT Light
IAT Intake Air Temperature
LTPWS Low Tire Pressure Warning System
IC Integrated Circuit, Ignition Control M
ICM Ignition Control Module MAF Mass Air Flow
ID Identification, Inside Diameter
Man Manual
A bbreviations Table (co n t’d) A bbreviations Table (cont’d)

A b b rev iatio n M eaning A b b rev iatio n M ean in g
MAP Manifold Absolute Pressure OSS Output Shaft Speed

MAT Manifold Absolute Temperature oz ounce(s)
max maximum P
M/C Mixture Control PAG Polyalkylene Glycol
MDP Manifold Differential Pressure PAIR Pulsed Secondary Air Injection
MFI Multiport Fuel Injection PASS Passenger
mi miles PASS-Key® Personalized Automotive
Security System
MIL Malfunction Indicator Lamp
P/B Power Brakes
min minimum
PC Pressure Control
ml milliliter
PCB Printed Circuit Board
mm millimeter
PCM Powertrain Control Module
mpg miles per gallon
PCS Pressure Control Solenoid
mph miles per hour
PCV Positive Crankcase Ventilation
ms millisecond
PID Parameter Identification
MST Manifold Surface Temperature
PM Permanent Magnet (Generator)
M /T Manual Transmission/Transaxle
P/N Part Number
MV Megavolt
PNK Pink
mV millivolt
PNP Park/Neutral Position
N
PNRDL Park, Neutral, Reverse, Drive, Low
NAES North American Export Sales
POA Pilot Operated Absolute (Valve)
NC Normally Closed
POS Positive
NEG Negative
POT Potentiometer (Variable Resistor)
Neu Neutral
PPL Purple
NLGI National Lubricating Grease Institute
ppm parts per million
N-m Newton-meter (torque)
PROM Programmable Read Only Memory
NO Normally Open
P/S Power Steering
NOx Oxides of Nitrogen
PSD Power Sliding Door
NPTC National Pipe Thread Coarse
PSP Power Steering Pressure
NPTF National Pipe Thread Fine
psi pounds per square inch
NVRAM Non Volatile Random Access Memory
psia pounds per square inch absolute
0
psig pounds per square inch gage
02 Oxygen
Pt pint
02S Oxygen Sensor
PWM Pulse Width Modulated
ODB On-Board Diagnostics
Q
OBD II On-Board Diagnostics II
qt quart(s)
OC Oxidation Converter (Catalytic)
R
OD Outside Diameter
R-12 Refrigerant-12
ODO Odometer
R-134a Refrigerant-134a
OE Original Equipment
RAM Random Access Memory
OEM Original Equipment Manufacturer
(non permanent memory devise,
OHC Overhead Camshaft memory contents are lost when power
OL Open Loop is removed)
ORC Oxidation Reduction RAP Retained Accessory Power

Converter (Catalytic) RAV Remote Activation Verification
ORN Orange RCDLR Remote Control Door Lock Receiver
A bbreviations Table (cont’d) A bbreviations Table (cont’d)
Abbreviation M eaning A bbreviation Meaning
RDCM Right Door Control Module Sw Switch
Ref Reference syn synchronizer
Rev Reverse T
RF Right Front, Radio Frequency TAC Throttle Actuator Control
RFA Remote Function Actuation Tach Tachometer
RFI Radio Frequency Interference TAP Transmission Adaptive Pressure
RH Right Hand TBI Throttle Body Fuel Injection
RKE Remote Keyless Entry TC Turbocharger
Rly Relay TCC Torque Converter Clutch
ROM Read Only Memory (permanent TCS Traction Control System
memory devise, memory contents are
TDC Top Dead Center
retained when power is removed)
TEMP Temperature
RPM Engine Speed (Revolutions Per Minute)
Term Terminal
RPO Regular Production Option
TFP Transmission Fluid Pressure
RR Right Rear
TFT Transmission Fluid Temperature
rt right
THM Turbo Hydra-Matic
RTD Real Time Damping
TP Throttle Position
RTV Room Temperature Vulcanizing (sealer)
TPA Terminal Positive Assurance
RWAL Rear Wheel Antilock
TPM Tire Pressure Monitoring
RWD Rear W heel Drive
TR Transmission Range
S
TRANS T ransmission/Transaxle
s second(s)
TV Throttle Valve
SAE Society of Automotive Engineers
TVRS Television and Radio Suppression
SC Supercharger
TVV Thermal Vacuum Valve
SCB Supercharger Bypass
TWC Three Way Converter (Catalytic)
SCM Seat Control Module
TW C+OC Three Way + Oxidation Converter
SCPI Sequential Central Port Injection (Catalytic)
SDM Sensing and Diagnostic Module TXV Thermal Expansion Valve
SEO Special Equipment Option U
SFI Sequential Multiport Fuel Injection UART Universal Asynchronous Receive and
SI System International (modem version Transmit
of metric system)
U/H Underhood
SIR Supplemental Inflatable Restraint U/HEC Underhood Electrical Center
SLA Short/Long Arm (suspension)
U-joint Universal Joint
sol solenoid UTD Universal Theft Deterrent
S02 Sulfur Dioxide UV Ultraviolet
SP Splice Pack V
SPO Service Parts Operations V Volt(s), Voltage
sq ft square foot/feet V6 Six Cylinder Engine, V-Type
sq in square inch/inches V8 Eight Cylinder Engine, V-Type
SRC Service Ride Control Vacuum
Vac
SRI Service Reminder Indicator VAC Vehicle Access Code
SS Shift Solenoid VATS Vehicle Anti-Theft System
ST Scan Tool
VCM Vehicle Control Module
Stat Status VDOT Variable Displacement Orifice Tube
S4W D Selectable Four W heel Drive
Abbreviations Table (cont’d) Cutting Keys

A bbreviation Meaning
VDV Vacuum Delay Valve
vel velocity
VES Variable Effort Steering
VF Vacuum Fluorescent
VIO Violet
VIN Vehicle Identification Number
VMV Vacuum Modulator Valve
VR Voltage Regulator
Vacuum Regulator
V ref Voltage Reference
VSS Vehicle Speed Sensor
W
w/ with
W/B W heel Base
65495
W HL W heel
After the code has been determined from the
W HT White code list or the key code diagram, perform the
w/o without following steps:
W OT Wide Open Throttle 1. Cut a blank key to the proper level (1) of each
W /P W ater Pump
of the tumbler positions (2).
2. Inspect the key operation in the lock cylinder.
W /S Windshield
W SS Wheel Speed Sensor Replacement Lock Cylinders
W U-OC Warm Up Oxidation Converter New lock cylinders (except ignition lock cylinders) are
(Catalytic) available from the service parts warehouse with new
lock cylinder locking bars. The tumblers are also
W U-TW C Warm Up Three Way Converter available and must be assembled into the cylinder
(Catalytic) as recommended. For additional information, refer to
X the following.
X-valve Expansion valve Lock Cylinder Tumbler Operation
Y All lock tumblers are shaped alike with the exception
yd yard(s) of the notched position on one side. As the key is
inserted into the lock cylinder, the tumblers are
YEL Yellow
lowered to the correct height so that notches on
each tumbler are at the same level. When the
Coding Keys and Lock Cylinders notches on all six tumblers line up, two small springs
push the side bar into the notches, allowing the
Key Identification and Usage cylinder to turn in the cylinder bore. Five types of
The lock cylinder keyway is designed so that tumblers are used in making the lock combinations,
other model keys will not enter a current model and each is coded and stamped with a number
lock cylinder. A single key is used for all locks between 1 and 5.
on the vehicle.
The key identification is obtained from the
four-character key code stamped on the knockout
portion of the key head. Knock the plugs out of the
key head after code numbers have been recorded.
The code list, available to owners of key cutting
equipment from equipment suppliers, determines the
lock combinations from the code numbers.
If the code numbers are not available from the
records or from the knockout plug, lay the key on
the key code diagram in order to determine the
lock combinations (the tumbler numbers and the
position arrangement).
A ssem bling and Coding Ignition 4. Insert one tumbler spring (2) above each
Lock C ylinders tumbler (4).
T o o ls R e q u ire d 5. Lubricate the tumblers using Superlube® GM
J 41340 Lock Cylinder Staking and Holding Fixture P/N 12346241 or equivalent.
6. Insert the spring retainer (1) prongs into the
slots at the end of each cylinder.
1. Determine the tumbler numbers/arrangement:

1.1. Place the tip of the key directly over the
tip of the illustrated key. 7. Press down the retainer (1) until fully seated in
the depression.
1.2. Inspect that the diagram outlines the key.
1.3. Starting with position 1 (open end of
cylinder), find and record the lowest level
(tumbler number) that is visible.
1.4. Repeat the previous step for
positions 2-10.
8.1. Hold the spring retainer (2) in position.

8.2. Insert the key (1) into the cylinder.
8.3. The side bar (3) should drop down
65498 flush with the cylinder diameter if
2. Starting with position 1, insert the tumblers (4) properly installed.
into their corresponding slots in the 8.4. Disassemble and assemble properly
coded order. as needed.
3. Using your fingers, pull out the side bar (3) until 9. Remove the key.
the tumblers fall completely into place.
65504
12. Stake the other end of the retainer:

10.1. Inspect that the spring retainer is facing 12.1. Remove the punch, part of J 41340.
up and positioned directly under the 12.2. Rotate the punch, part of J 41340,
punch slots. 180 degrees.
10.2. Push the cylinder into the J 41340 until 12.3. Hold the punch, part of J 41340,
butted with the cylinder bezel. squarely against the end of the punch
10.3. Tighten the holding screw. slot on J 41340.
12.4. Stake the metal over the other end of
the retainer.
65503
11. Stake the bezel end of the retainer in place:

11.1. Hold the flat side of the punch, part of
J 41340, squarely against the face of the
cylinder bezel. 14. Remove the cylinder from the J 41340.
11.2. Stake the lock cylinder metal over the 15. Inspect that the retainer is properly staked.
retainer corners. Restake as needed.
16. Lubricate the cylinder retainer slot.
17. Insert the following parts into the cylinder Frame Contact Hoist
retainer slot: Front Hoist Pads
• The retainer spring (2)
Important: The front hoist pads must not contact the
• The retainer (3) rocker panels, the front fenders, or the floor pan.
Important: Use a paste type grease, not a Position the (frame contact) front hoist pads
spray, for the following step. as follows:
18. Lubricate the following parts with GM
P/N 12345996 or equivalent as needed:
• The detent pins (1)
• The cylinder retainer (3)
Side Door Lock Cylinder Coding
The side door lock cylinder has five snap-in
tumblers. The number 1-5 positions (beginning
closest to the cylinder head) is a brass retainer
tumbler. The 6-10 positions are standard tumbler
positions. Therefore, only the 6-10 positions
are required.
Vehicle Lifting and Jacking

Caution: To help avoid personal Injury, always
use Jack stands when you are working on or
under any vehicle that Is supported only by
a Jack.
Caution: To help avoid personal Injury, when a
vehicle is on a hoist, provide additional support
for the vehicle a t the opposite end from which • The front frame between the lower control arm
you are removing components. The additional and the frame pad or the front frame pad when
support will reduce the possibility o f the vehicle using a tip-up hoist pad.
falling off the hoist. When you are removing
m ajor components from the vehicle while the Rear Hoist Pads
vehicle Is on a hoist, chain the vehicle frame to Important: The rear hoist pads must not contact the
the hoist pads a t the same end from which you body rocker panels or the floor pan.
are removing the m ajor components to prevent
tip-off. If you fall to follow these precautionary Position the (body/frame contact) rear hoist pads
measures, vehicle damage, serious personal as follows:
Injury, or death m ay result.
Notice: When you are jacking or lifting a vehicle at
the frame side rails or other prescribed lift points, be
certain that the lift pads do not contact the catalytic
converter, the brake pipes or the fuel lines. If such
contact occurs, vehicle damage or unsatisfactory
vehicle performance may result.
For lifting the vehicle, various lift points are
recommended. Before you begin any lifting
procedure, be sure the vehicle is on a clean, hard,
level surface. Be sure all the lifting equipment meets
weight standards and is in good working order. Be
sure all the vehicle loads are equally distributed and
secure. If you are only supporting the vehicle at the
frame side rails, make sure the lifting equipment
does not put too much stress on or weaken the
frame side rails.
If you use any other hoisting methods than those
called out, take special care not to damage the fuel
174087
anks, the exhaust system or the underbody.
• Under the rear spring, just behind the hanger,
for the tip-up pad only.
Suspension Contact Hoist Under the Frame Rails
Front Lift Important: The floor jack pad must not contact
Position the (suspension contact) front lift as follows: rocker panel or the floor pan.
under the outer edge of the front suspension lower
control arms.
Position the floor jack pad under the frame rail pad.
175244
Under the Front Suspension Crossmember
• Under the outer areas of the lower control arm.
Rear Lift
Position the (suspension contact) rear lift as follows:
175243
Position the floor jack pad under the center of the

front suspension crossmember.
Under the axle housing tubes on each side of

the differential.
Jacking
When you are lifting a vehicle with a vehicle jack or
a floor jack, block the wheels at the opposite end
from which you are lifting. Use jack stands to provide
additional support.
Under the Rear Differential Under the Rear Spring Hanger
175241 175237
Position the floor jack pad under the center of the Position the jack under the rear spring hanger.
rear axle differential.
Jack Stands
Important: When supporting the vehicle with jack
stands, the jack stands should be placed under the
frame, the front suspension crossmember, or the
rear axle.
Special Tools and Equipment

Tool Illustration Tool No. and D escription
JNS J 35819
Companion Flange
Runout Gage
1512
j||p> J 38792
Electronic Vibration
Analyzer (EVA)
6826
v. mfjj J 41340
Ignition Lock Holding Fixture
65540
General Information Maintenance and Lubrication 0-41
Maintenance and Lubrication

Specifications
Drive Belt Tension Specifications
Serpentine Belt
Belt tension is maintained by a spring tensioned
idler pulley.
No adjustment of the serpentine belt is necessary.
Approximate Fluid Capacities

Liters Quarts
Engine Cooling System
4.3L (VIN W)
12.3 13.0
With Air Conditioning
4.3L (VIN W)
12.3 13.0
Without Air Conditioning
5.0L (VIN M)
17.0 18.0
5.0L (VIN M)
16.6 17.5
5.7L (VIN R)
19.0 20.0
5.7L (VIN R)
16.6 17.5
5.7L (VIN R)
25.5 27.0
With Air Conditioning - C 3500 HD
5.7L (VIN R)
25.0 26.5
Without Air Conditioning - C 3500 HD
6.5L (VIN F and S)
26.0 27.5
6.5L (VIN F and S)
26.0 27.5
7.4L (VIN J)
26.0 27.5
7.4L (VIN J)
23.5 25.0
7.4L (VIN J)
27.0 28.5
With Air Conditioning - C 3500 HD
7.4L (VIN J)
25.0 26.5
Without Air Conditioning - C 3500 HD
Engine Crankcase
4.3L (VIN W) With Filter 4.3 4.5
5.0L (VIN M) With Filter 4.8 5.0
5.7L (VIN R) With Filter 4.8 5.0
6.5L (VIN F and S) Roth Filter 6.5 7.0
7.4L (VIN J) Roth Filter 6.5 7.0
0-42 Maintenance and Lubrication General Information
Approximate Fluid Capacities (cont’d)
Liters Quarts
Transmission
4L60-E 4.7 5.0
After Complete Overhaul 10.6 11.0
4L80-E 7.3 7.7
After Complete Overhaul 12.8 13.5
New Venture Gear 3500 Manual Transmission 2.0 2.2
New Venture Gear 4500 Manual Transmission 3.78 4.0
Transfer Case
New Venture 241 2.13 2.25
New Venture 243 2.13 2.25
Borg W arner 4401 3.1 3.28
Borg Warner 4470 3.1 3.28
Approximate Fluid Capacities

Fuel Tank Liters Gallons
Short Bed Models 98.0 26.0
Long Bed Models 128.0 34.0
Crew Cab Models 128.0 34.0
Chassis-Cab (Standard Side Tank) 87.0 23.0
Chassis-Cab (Optional Rear Tank) 68.0 18.0
C 3500 HD (Standard Side Tank) 87.0 23.0
C 3500 HD (Optional Rear Tank) 68.0 18.0
Two-Door Utility 113.0 30.0
Four-Door Utility 113.0 30.0
Suburban 44.0 166.6
Suburban (Diesel) 159.0 42.0
Recommended Fluids and Lubricants

USAGE FLUID/LUBRICANT
Engine Oil Engine oil with the American Petroleum Institute Certified For Gasoline Engines
"Starburst" symbol of the proper viscosity. To determine the preferred viscosity for your
vehicle’s engine, refer to the Owner’s Manual
Engine Coolant 50/50 mixture of clean water (preferably distilled) and use only GM Goodwrench®
DEX-COOL® or Havoline® DEX-COOL® coolant.
Hydraulic Brake System Delco Supreme 11® Brake Fluid (GM P/N 12377967 or equivalent DOT-3 brake fluid).
Parking Brake Cable Guides Chassis lubricant (GM P/N 12377985 or equivalent) meeting requirements of NLGI
Grade 2, Category GC or GC-LB
Power Steering System GM Hydraulic Power Steering Fluid (GM P/N 1052884 - 1 pint, 1050017 - 1 quart,
or equivalent).
Automatic Transmission DEXRO N® -lll Automatic Transmission Fluid
Key Lock Cylinders Multi-Purpose Lubricant, Superlube® (GM P/N 12346241 or equivalent).
Chassis Lubrication Chassis lubricant (GM P/N 12377985 or equivalent) or lubricant meeting requirements of
NLGI Grade 2, Category GC or GC-LB.
Front W heel Bearings-RWD Wheel bearing lubricant (GM P/N 1051344) or equivalent) or lubricant meeting
requirements of NLGI Grade 2, Category GC or GC-LB
Differential, Standard, Front and Axle Lubricant (GM P/N 1052271) or SAE 80W -90 GL-5 Gear Lubricant.
Rear Axle
Recommended Fluids and Lubricants (cont’d)
USAGE FLUID/LUBRICANT
Differential, Locking Axle Lubricant (GM P/N 1052271) or SAE 80W -90 GL-5 Gear Lubricant.
Transfer Case DEXRO N®-lll Automatic Transmission Fluid
Windshield Washer Solvent GM Optikleen® Washer Solvent (GM P/N 1051515) or equivalent
Hood Latch Assembly Lubriplate lubricant aerosol (GM Part No. 12346293 or equivalent) or lubricant meeting
• Pivots and Spring Anchor requirements of NLGI Grade 2, Category LB or GC-LB.
• Release Pawl
Hood and Door Hinges Multi-Purpose lubricant, Superlube® (GM P/N 12346241 or equivalent).
Weatherstrip Conditioning Dielectric Silicone Grease (GM P/N 12345579 or equivalent).
Tire Inflation Pressure Specifications Tires with a higher than recommended pressure can
cause the following conditions:
When you inflate the tires to the recommended
inflation pressures, the factory-installed wheels and • A hard ride
tires are designed to handle loads to the tire’s rated • Tire bruising
load capacity. Incorrect tire pressures, or under-inflated • Rapid tread wear at the center of the tire
tires, can cause the following conditions:
Tires with a lower than recommended pressure can
• Vehicle handling problems cause the following conditions:
• Poor fuel economy • A tire squeal on turns
• Shortened tire life • Hard steering
• Tire overloading • Rapid wear and uneven wear on the edge of
Check the tire pressure when the following apply: the tread
• The tires are cool. • Tire rim bruises and tire rim rupture
• The vehicle has not been driven for more than • Tire cord breakage
3 hours. • High tire temperatures
• The vehicle has been driven less than • Reduced vehicle handling
1.6 km (1 mi).
• High fuel consumption
Check the tires monthly or before any extended trip.
Adjust the tire pressure to the specifications on the • Soft riding
tire placard. Refer to Tire Placard in General Unequal pressure on the same axle can cause the
Information. Install the valve caps or extensions on following conditions:
the valves. These keep out dust and water. • Uneven braking
The kilopascal (kPa) is the metric term for tire • Steering lead
inflation pressure. The tire pressure may be printed
• Reduced vehicle handling
in both kilopascal (kPa) and psi. One psi equals
6.9 kPa.
Inflation Pressure Conversion Chart

(Kilopascals to PSI)
kPa psi kPa psi
140 20 215 31
145 21 220 32
155 22 230 33
160 23 235 34
165 24 240 35
170 25 250 36
180 26 275 40
185 27 310 45
190 28 345 50
200 29 380 55
205 30 415 60
Conversion: 6.9 kPa=1 psi
0<44 Maintenance and Lubrication General Information
Maintenance Items
Usage Type
Air Cleaner
4.3L (VIN W) AC Type A1300C
5.0L (VIN M) AC Type A1300C
5.7L (VIN R) AC Type A1300C
6.5L (VIN F and S) AC Type A1300C/A1306C
7.4L (VIN J) AC Type A1300C
Engine Oil Filter
4.3L (VIN W ) AC Type PF-52
RWD AND S4W D
5.0L (VIN M) AC Type PF-1218
RWD
5.0L (VIN M) AC Type PF-52
S4WD
5.7L (VIN R) AC Type PF-1218
RWD
5.7L (VIN R) AC Type PF-52
S4W D
6.5L (VIN F and S) AC Type PF-1218
RWD AND S4W D
7.4L (VIN J) AC Type PF-1218
RWD AND S4WD
PCV Valve
4.3L (VIN W ) AC Type CV746C
5.0L (VIN M) AC Type CV796C
5.7L (VIN R) AC Type CV796C
7.4L (VIN J) AC Type CV774C
Spark Plugs and Gaps
4.3L (VIN W) AC Type 41-932
(GAP 1.52 mm, 0.060 in)
5.0L (VIN M) AC Type 41-932
(GAP 1.52 mm, 0.060 in)
5.7L (VIN R) AC Type 41-932
(GAP 1.52 mm, 0.060 in)
7.4L (VIN J) AC Type 41-932
(GAP 1.52 mm, 0.060 in)
Fuel Filter
4.3L (VIN W) AC Type GF-626
5.0L (VIN M) AC Type GF-626
5.7L (VIN R) AC Type TP-1006
7,4L (VIN J) AC Type GF-626
Radiator Cap
4.3L (VIN W ) AC Type RC-36
5.0L (VIN M) AC Type RC-36
5.7L (VIN R) AC Type RC-36
6.5L (VIN F and S) AC Type RC-33
7.4L (VIN J) AC Type RC-36
Maintenance Every 25 000 km (15,000 miles)

• Shields and underhood insulation inspection
Maintenance Schedule (GVWR above 8600 lbs only).
Using The Maintenance Schedule • Thermostatically controlled engine cooling
Because of the different ways GM vehicles are used, fan check.
maintenance needs vary. More frequent maintenance • Air Filter Inspection (if driving in
intervals than found in these manual may by dusty conditions)
needed. When reading this section, keep in mind the
conditions under which the vehicle is operated, and • Front Wheel Bearing Repack (RWD Only)
adjust the maintenance intervals accordingly. Every 50 000 km (30,000 miles)
The proper fluids and lubricants to use are listed in • Air Filter Replacement
Recommended Fluids and Lubricants. Use the proper • Fuel Filter Replacement
fluids and lubricants whenever servicing this vehicle. Every 83 000 km (50,000 miles)
The maintenance schedules found in this manual are Automatic Transmission fluid and filter change if
for vehicles that: the vehicle is driven under one or more of
• Carry passengers and cargo within the following:
recommended limits. Refer to Vehicle • In heavy city traffic where the outside
Certification Label in General Information temperature regularly reaches 90 * F (32 * C)
• Are driven on reasonable road surfaces within or higher.
legal driving limits. • In hilly or mountainous terrain
• Are driven off-road in the recommended • When doing frequent trailer towing
manner. Refer to the Owner’s Manual.
• Uses such as found in taxi, police, or
• Use recommended unleaded fuel. delivery service. If you do not use your
Selecting The Right Schedule vehicle under any of these conditions, the
First you will need to decide which of the two fluid and filter change should be changed
schedules is right for your vehicle. Diesel engine every 50,000 miles.
vehicles have different maintenance requirements. If Every 100 000 km (60,000 miles)
your vehicle has a diesel engine, follow a schedule
• Engine Drive Belt Inspection
designated for diesel engine vehicles only.
• Fuel Tank, Cap and Lines Inspection
Short Trip/City Definition
Follow the Short Trip/City maintenance schedule if • Exhaust Gas Recirculation System Inspections
any one of these are true: • Evaporative Control System Inspection
• Most trips are less than 5 to 10 miles (8 to Every 161 000 km (100,000 miles)
16 km). This is particularly important when • Spark Plug Replacement
outside temperatures are below freezing.
• Spark Plug Wire Inspection
• Most trips include extensive idling (such as
• Engine Timing Check
frequent driving in stop and go traffic).
• Positive Crankcase Ventilation (PCV)
• The vehicle is operated in dusty areas, or
Valve Inspection
off-road frequently.
Every 240 000 km (150,000 miles) or Every
• Trailer towing or using a carrier on top of the 60 months
vehicle frequently.
Drain, flush and fill the cooling system.
• The vehicle is used for delivery service, police,
taxi, or other commercial application. Long Trip/Highway Definition
Follow the Long Trip/Highway maintenance schedule
Short Trip/City Maintenance Schedule Summary ONLY if none of the conditions from the Short
These intervals summarize the Short Trip/City Trip/City maintenance schedule are true.
Maintenance Schedule. Refer to Short Trip/City
Maintenance Schedule (Gasoline) for the complete Long Trip/Highway Schedule Summary
maintenance schedule. Follow the Long Trip/Highway maintenance schedule
ONLY if none of the conditions from the Short
Every 5 000 km (3,000 miles) or 3 months Trip/City maintenance schedule are true. Do not use
• Engine Oil and Filter Change this section if the vehicle is used for trailer towing,
• Chassis Lubrication driven in a dusty area or used off paved roads. Use
• Drive Axle Service. Refer to Footnotes. the Short Trip/City schedule for these conditions.
Every 10 000 km (6,000 miles) Then Every These service intervals summarize the Long
19 000 km (12,000 miles) Trip/Highway Maintenance Schedule. Refer to Long
Trip/Highway Maintenance Schedule (Gasoline) for
Tire Rotation
the complete maintenance schedule.
Every 12 500 km (7,500 miles) 10 000 km (6,000 miles)

• Engine and Oil Filter Change (or every • Change the engine oil and the filter every
12 months) 10 000 km (6,000 miles) or every 3 months,
• Chassis Lubrication (or every 12 months) whichever occurs first. An Emission
Control Service *
• Drive Axle Service.
• Lubricate the following vehicle components:
At 12 500 km (7,500 miles) Then Every 25 000 km
(15,000 miles) - The front suspension
Tire Rotation - The steering linkage
Every 25 000 km (15,000 miles) - The transmission shift linkage
• Shields and underhood insulation inspection - The parking brake cable guides
(GVWR above 8600 lbs only). - The rear driveline center splines
• Thermostatically Controlled Engine Cooling - The brake pedal springs
Fan Check • Do not lubricate the bail joints unless the ball
Every 50 000 km (30,000 miles) joint temperature is -12* C (10‘ F) or higher.
• Air Filter Replacement • Verify the rear fluid level. Add fluid as needed.
• Fuel Filter Replacement • Inspect the constant velocity joints for leaks.
• Front Wheel Bearing Repack (RWD Only) • Inspect the axle seals for leaks.
Every 100 000 km (60,000 miles) • Rotate the tires. Refer to Tires and Wheels
• Exhaust Gas Recirculation System Inspection in Suspension.
• Engine Drive Belt Inspection 15 000 km (9,000 miles)
• Fuel Tank, Cap and Lines Inspection • Change the engine oil and the filter every
• Evaporative Control System Inspection 15 000 km (9,000 miles) or every 3 months,
whichever occurs first. An Emission
Every 161 000 km (100,000 miles)
Control Service *
• Spark Plug Replacement
• Spark Plug Wire Inspection
- The front suspension
• Engine Timing Check
- The steering linkage
• Positive Crankcase Ventilation (PCV)
- The transmission shift linkage
Valve Inspection
Every 240 000 km (150,000 miles) or Every - The parking brake cable guides
60 m onths - The rear driveline center splines
Drain, flush and fill the cooling system. - The brake pedal springs
• Do not lubricate the ball joints unless the ball
Short Trip/City Maintenance joint temperature is -12* C (10* F) or higher.
Schedule (Gasoline) • Verify the rear fluid level. Add fluid as needed.
Perform the services shown in this schedule up to • Inspect the constant velocity joints for leaks.
166 000 km (100,000 miles) and after
166 000 km (100,000 miles) at the same intervals. • Inspect the axle seals for leaks.
5 000 km (3,000 miles) 20 000 km (12,000 miles)
• Change the engine oil and the filter every • Change the engine oil and the filter every
5 000 km (3,000 miles) or every 3 months, 20 000 km (12,000 miles) or eveiy 3 months,
whichever occurs first. An Emission whichever occurs first. An Emission
Control Service * Control Service *
• Lubricate the following vehicle components: • Lubricate the following vehicle components:
- The front suspension - The front suspension
- Trie steering linkage - The steering linkage
- The transmission shift linkage - The transmission shift linkage
- The parking brake cable guides - The parking brake cable guides
- The rear driveline center splines - The rear driveline center splines
- The brake pedal springs - The brake pedal springs
• Do not lubricate the ball joints unless the ball • Do not lubricate the ball joints unless the ball
joint temperature is -12* C (10* F) or higher. joint temperature is -12*C (10*F) or higher.
• Verify the rear fluid level. Add fluid as needed. • Verify the rear fluid level. Add fluid as needed.
• Inspect the constant velocity joints for leaks. • Inspect the constant velocity joints for leaks.
• Inspect the axle seals for leaks. • Inspect the axle seals for leaks.
General Information Maintenance and Lubrication (M 7
25 000 km (15,000 miles) 35 000 km (21,000 miles)
25 000 km (15,000 miles) or every 3 months, 35 000 km (21,000 miles) or eveiy 3 months,
- The steering linkage - The steering linkage
- The parking brake cable guides
- The rear driveline center splines
- The brake pedal springs
• Do not lubricate the ball joints unless the ball joint temperature is -12* C (10* F) or higher.
joint temperature is -12* C (10* F) or higher.
• Verify the rear fluid level. Add fluid as needed.
• Inspect the constant velocity joints for leaks.
• Inspect the axle seals for leaks.
• Inspect the axle seals for leaks. 40 000 km (24,000 miles)
• Inspect the air cleaner filter. • Change the engine oil and the filter every
• Clean the front wheel bearings (or each brake 40 000 km (24,000 miles) or eveiy 3 months,
relining, whichever occurs first). whichever occurs first. An Emission
Control Service *
• Repack the front wheel bearings (or each brake
relining, whichever occurs first). • Lubricate the following vehicle components:
• For vehicles with GVWR above - The front suspension
3 855 kg (8,500 lbs), inspect the following - The steering linkage
vehicle components for looseness: - The transmission shift linkage
- The shields - The parking brake cable guides
- The underhood insulation - The rear driveline center splines
• Adjust or replace these components as - The brake pedal springs
specified. • Do not lubricate the ball joints unless the ball
30 000 km (18,000 miles) joint temperature is -12* C (10* F) or higher.
• Change the engine oil and the filter every • Verify the rear fluid level. Add fluid as needed.
30 000 km (18,000 miles) or every 3 months, • Inspect the constant velocity joints for leaks.
whichever occurs first. An Emission • Inspect the axle seals for leaks.
Control Service *
45 000 km (27,000 miles)
• Lubricate the following vehicle components: • Change the engine oil and the filter every
- The front suspension 40 000 km (27,000 miles) or every 3 months,
- The steering linkage whichever occurs first. An Emission
Control Service *
• Lubricate the following vehicle:
joint temperature is -1 2 *6 (10* F) or higher.
• Inspect the axle seals for leaks. joint temperature is -12* C (10*F) or higher.
• Rotate the tires. Refer to Tires and Wheels • Verify the rear fluid level. Add fluid as needed.
in Suspension.
50 000 km (30,000 miles) • Do not lubricate the ball joints unless the ball
• Change the engine oil and the filter every joint temperature is -12*6 (10*F) or higher.
50 000 km (30,000 miles) or eveiy 3 months, • Verify the rear fluid level. Add fluid as needed.
whichever occurs first. An Emission • Inspect the constant velocity joints for leaks.
Control Service *
• Lubricate the following vehicle components: 60 000 km (36,000 miles)
- The front suspension • Change the engine oil and the filter every
- The steering linkage 60 000 km (36,000 miles) or every 3 months,
- The transmission shift linkage whichever occurs first. An Emission
- The parking brake cable guides Control Service *
- The rear driveline center splines • Lubricate the following vehicle components:
- The brake pedal springs - The front suspension
• Do not lubricate the ball joints unless the ball - The steering linkage
joint temperature is -12* C (10* F) or higher. - The transmission shift linkage
• Verify the rear fluid level. Add fluid as needed. - The parking brake cable guides
• Inspect the constant velocity joints for leaks. - The rear driveline center splines
• Inspect the axle seals for leaks. - The brake pedal springs
• Clean the front wheel bearings (or each brake • Do not lubricate the ball joints unless the ball
relining, whichever occurs first). joint temperature is -1 2 *6 (10* F) or higher.
• Repack the front wheel bearing (or each brake • Verify the rear fluid level. Add fluid as needed.
relining, whichever occurs first). • Inspect the constant velocity joints for leaks.
• Replace the air filter. • Inspect the axle seals for leaks.
• Replace the fuel filter. An Emission 65 000 km (39,000 miles)
Control Service. • Change the engine oil and the filter every
• For vehicles with GVWR above 65,000 km (39,000 miles) or eveiy 3 months,
3 855 kg (8,500 lbs), inspect the following whichever occurs first. An Emission
vehicle components for looseness: Control Service *
- The shields • Lubricate the following vehicle components:
- The underhood insulation - The front suspension
• Adjust or replace shields and the underhood - The steering linkage
insulation components as specified. - The transmission shift linkage
• Inspect the hoses and the ducts for the proper - The parking brake cable guides
maintenance if the engine has a
thermostatically controlled cooling fan. Verify - The rear driveline center splines
that the valve operates properly. - The brake pedal springs
• Rotate the tires. Refer to Tires and Wheels • Do not lubricate the ball joints unless the ball
in Suspension. joint temperature is -1 2 *6 (10*F) or higher.
• Inspect the shields and the • Verify the rear fluid level. Add fluid as needed.
underhood insulation. • Inspect the constant velocity joints for leaks.
55 000 km (33,000 miles) • Inspect the axle seals for leaks.
• Change the engine oil and the filter every 70 000 km (42,000 miles)
55 000 km (33,000 miles) or every 3 months,
• Change the engine oil and the filter every
Control Service *
• Lubricate the following vehicle components: Control Service *
- The front suspension • Lubricate the following vehicle components:
- The steering linkage - The front suspension
- The transmission shift linkage - The steering linkage
- The parking brake cable guides - The transmission shift linkage
- The rear driveline center splines - The parking brake cable guides
- The brake pedal springs - The rear driveline center splines
joint temperature is -12*6 (10* F) or higher.
• Verify the rear fluid level. Add fluid as needed. • Inspect the constant velocity joints for leaks.
• Inspect the constant velocity joints for leaks. • Inspect the axle seals for leaks.
• Rotate the tires. Refer to Tires and Wheels • Change the automatic transmission fluid and
in Suspension. the filter if the vehicle’s GVWR exceeds
75 000 km (45,000 miles) 3 855 kg (8,600 lbs).
• Change the engine oil and the filter every • Change the automatic transmission fluid and
75 000 km (45,000 miles) or every 3 months, the filter.
whichever occurs first. An Emission 85 000 km (51,000 miles)
Control Service * • Change the engine oil and the filter every
• Lubricate the following vehicle components: 85 000 km (51,000 miles) or every 3 months,
- The front suspension whichever occurs first. An Emission
Control Service *
joint temperature is -1 2 *6 (10* F) or higher. - The rear driveline center splines
• Verify the rear fluid level. Add fluid as needed. - The brake pedal springs
• Inspect the constant velocity joints for leaks. • Do not lubricate the ball joints unless the ball
• Regularly inspect the air filter when driving in
dusty conditions. Replace the air filter if • Inspect the constant velocity joints for leaks.
necessary. An Emission Control Service * • Inspect the axle seals for leaks.
• Clean the front wheel bearings (or each brake 90 000 km (54,000 miles)
relining, whichever occurs first). • Change the engine oil and the filter at
• Repack the front wheel bearing (or each brake 90 000 km (54,000 miles) or eveiy 3 months,
Control Service *
• For vehicles with GVWR above
3 855 kg (8,500 lbs), inspect the following • Lubricate the following vehicle components:
vehicle components for looseness: - The front suspension
- The shields - The steering linkage
- The underhood insulation - The transmission shift linkage
• Adjust or replace shields and the underhood - The parking brake cable guides
insulation components as specified. - The rear driveline center splines
• Inspect the hoses and the ducts for the proper - The brake pedal springs
thermostatically controlled cooling fan. Verify • Verify the rear fluid level. Add fluid as needed.
that the valve operates properly. • Inspect the constant velocity joints for leaks.
80 000 km (48,000 miles) • Inspect the axle seals for leaks.
• Change the engine oil and the filter every • Rotate the tires. Refer to Tires and Wheels
80 000 km (48,000 miles) or eveiy 3 months, in Suspension.
whichever occurs first. An Emission 95 000 km (57,000 miles)
Control Service *
• Change the engine oil and the filter at
• Lubricate the following vehicle components: 95 000 km (57,000 miles) or every 3 months,
- The front suspension whichever occurs first. An Emission
- The steering linkage Control Service *
- The transmission shift linkage • Lubricate the following vehicle components:
- The parking brake cable guides - The front suspension
- The rear driveline center splines - The steering linkage
- The brake pedal springs - The transmission shift linkage
• Do not lubricate the ball joints unless the ball - The parking brake cable guides
joint temperature is -12‘ C (10*F) or higher. - The rear driveline center splines
• Verify the rear fluid level. Add fluid as needed. - The brake pedal springs
• Verify the rear fluid level. Add fluid as needed. • Inspect the Control Exhaust Gas Recirculation
• Inspect the constant velocity joints for leaks. (EGR) system.
• Inspect the axle seals for leaks. • Inspect the shields and the
underhood insulation.
100 000 km (60,000 miles)
105 000 km (60,000 miles)
100 000 km (60,000 miles) or every 3 months, • Change the engine oil and the filter every
whichever occurs first. An Emission 105 000 km (63,000 miles) or every 3 months,
Control Service * whichever occurs first. An Emission
Control Service *
joint temperature is -1 2 *6 (10* F) or higher. • Do not lubricate the ball joints unless the ball
joint temperature is -1 2 *6 (10‘ F) or higher.
• Inspect the engine accessory drive belt. An
Emission Control Service * 110 000 km (66,000 miles)
• Replace the air filter. • Change the engine oil and the filter at
• Replace the fuel filter. An Emission whichever occurs first. An Emission
• Inspect the following fuel tank components for • Lubricate the following vehicle components:
leaks or damages:
- The fuel tank
- The cap and lines
- The fuel cap gasket
• Replace the necessary damaged fuel tank
components. An Emission Control Service * - The rear driveline center splines
• Clean the front wheel bearings (or each brake - The brake pedal springs
relining, whichever occurs first). • Do not lubricate the ball joints unless the ball
• Repack the front wheel bearing (or each brake joint temperature is -12‘ C (10* F) or higher.
relining, whichever occurs first). • Verify the rear fluid level. Add fluid as needed.
• For vehicles with GVWR above • Inspect the constant velocity joints for leaks.
3 855 kg (8,500 lbs), inspect the following • Inspect the axle seals for leaks.
vehicle components for looseness:
• Rotate the tires. Refer to Tires and Wheels
- Shields in Suspension.
- Underhood insulation 115 000 km (69,000 miles)
• Adjust or replace shields and the underhood • Change the engine oil and the filter every
insulation components as specified. 115 000 km (69,000 miles) or every 3 months,
• Inspect the hoses and the ducts for the proper whichever occurs first. An Emission
maintenance if the engine has a Control Service *
thermostatically controlled cooling fan. Verify • Lubricate the following vehicle components:
that the valve operates properly. - The front suspension
• Inspect the Evaporative Control System. - The steering linkage
• Verify the following components for proper - The transmission shift linkage
routing and condition maintenance:
- Fuel and vapor lines
- Hoses
• Verify that the purge valve operates properly if
equipped. Replace as necessary. • Do not lubricate the ball joints unless the ball
joint temperature is -12*6 (10* F) or higher.
• Verify the rear fluid level. Add fluid as needed. 130 000 km (78,000 miles)
• Inspect the constant velocity joints for leaks. • Change the engine oil and the filter every
• Inspect the axle seals for leaks. 130 000 km (78,000 miles) or every 3 months,
120 000 km (72,000 miles) whichever occurs first. An Emission
Control Service *
• Change the engine oil and the filter at
120 000 km (72,000 miles) or every 3 months, • Lubricate the following vehicle components:
whichever occurs first. An Emission - The front suspension
Control Service * - The steering linkage
• Lubricate the following vehicle components: - The transmission shift linkage
- The front suspension - The parking brake cable guides
- The steering linkage - The rear driveline center splines
- The transmission shift linkage - The brake pedal springs
- The parking brake cable guides • Do not lubricate the ball joints unless the ball
- The rear driveline center splines joint temperature is -12* C (10* F) or higher.
- The brake pedal springs • Verify the rear fluid level. Add fluid as needed.
• Do not lubricate the ball joints unless the ball • Inspect the constant velocity joints for leaks.
joint temperature is -12* C (10* F) or higher. • Inspect the axle seals for leaks.
• Verify the rear fluid level. Add fluid as needed. • Rotate the tires. Refer to Tires and Wheels
• Inspect the constant velocity joints for leaks. in Suspension.
125 000 km (75,000 miles) • Change the engine oil and the filter every
Control Service *
Control Service * • Lubricate the following vehicle components:
• Lubricate the following vehicle components: - The front suspension
- The front suspension - The steering linkage
- The steering linkage - The transmission shift linkage
- The transmission shift linkage - The parking brake cable guides
- The parking brake cable guides - The rear driveline center splines
- The rear driveline center splines - The brake pedal springs
- The brake pedal springs • Do not lubricate the ball joints unless the ball
joint temperature is -12* C (10* F) or higher. • Verify the rear fluid level. Add fluid as needed.
• Verify the rear fluid level. Add fluid as needed. • Inspect the constant velocity joints for leaks.
• Inspect the constant velocity joints for leaks. • Inspect the axle seals for leaks.
• Clean the front wheel bearings (or each brake • Change the engine oil and the filter every
relining, whichever occurs first). 140 000 km (84,000 miles) or every 3 months,
• Repack the front wheel bearings (or each brake
Control Service *
relining, whichever occurs first).
• For vehicles with GVWR above
3 855 kg (8,500 lbs), inspect the following - The front suspension
vehicle components for looseness: - The steering linkage
- The shields - The transmission shift linkage
- The underhood insulation - The parking brake cable guides
• Adjust or replace shields and the underhood - The rear driveline center splines
insulation components as specified. - The brake pedal springs
• Inspect the hoses and the ducts for the proper • Do not lubricate the ball joints unless the ball
maintenance if the engine has a joint temperature is -12* C (10* F) or higher.
thermostatically controlled cooling fan. Verify
that the valve operates properly. • Verify the rear fluid level. Add fluid as needed.
145 000 km (87,000 miles) 155 000 km (93,000 miles)
145 000 km (87,000 miles) or every 3 months, 155 000 km (93,000 miles) or every 3 months,
joint temperature is -1 2 *6 (10* F) or higher. joint temperature is -12*6 (10*F) or higher.
150 000 km (90,000 miles) 160 000 km (96,000 miles)
150 000 km (90,000 miles) or every 3 months, 160 000 km (96,000 miles) or every 3 months,
joint temperature is -1 2 *6 (10* F) or higher. joint temperature is -1 2 *6 (10* F) or higher.
• Inspect the constant velocity joints for leaks. • inspect the constant velocity joints for leaks.
• Clean the front wheel bearings (or each brake 165 000 km (99,000 miles)
relining, whichever occurs first). • Change the engine oil and the filter every
• Repack the front wheel bearing (or each brake 165 000 km (99,000 miles) or every 3 months,
• For vehicles with GVWR above Control Service *
3 855 kg (8,500 lbs), inspect the following • Lubricate the following vehicle components:
vehicle components for looseness: - The front suspension
- The shields - The steering linkage
- The underhood insulation - The transmission shift linkage
• Adjust or replace shields and the underhood - The parking brake cable guides
insulation components as specified.
• Inspect the hoses and the ducts for the proper
thermostatically controlled cooling fan. Verify • Do not lubricate the ball joints unless the ball
that the valve operates properly. joint temperature is -12*6 (10* F) or higher.
• Replace the air filter. • Verify the rear fluid level. Add fluid as needed.
• Replace the fuel filter. An Emission • Inspect the constant velocity joints for leaks.
Control Service. • Inspect the axle seals for leaks.
in Suspension.
166 000 km (100,000 miles) 8 000 km (5,000 miles)
• Inspect the engine timing. • Change the engine oil and the filter. An
• Replace the spark plugs. An Emission Emission Control Service *
Control Service * Change the engine oil and the filter as soon as
• Replace the spark plug wires. An Emission one of the following conditions occurs:
Control Service * - Three months pass since the last oil change.
• Change the automatic transmission fluid and - The vehicle drives 4 000 km (2,500 miles)
the filter if the vehicle’s GVWR exceeds since the last oil change.
3 900 kg (8,600 lbs). • Lubricate the following components:
• Change the automatic transmission fluid and - The front suspension
the filter if the vehicle’s GVWR exceeds
3 900 kg (8,600 lbs).
• Change the automatic transmission fluid and
the filter. - The parking brake cable guides
• Inspect the Positive Crankcase Ventilation - The rear driveline center splines
(PCV) Valve. - The brake pedal springs
240 000 km (150,000 miles) - The ball joints
• Drain, flush and refill the cooling system every Only lubricate the ball joints if the
240 000 km (150,000 miles) or every temperature of the ball joint is -12* C (10*F)
60 months, whichever occurs first. or higher.
• Refer to Recommended Fluid and Lubricants in • Inspect the rear fluid level.
General Information.
Add fluid if necessary.
• Inspect the hoses. • Inspect the following components for leaking:
• Clean the radiator, condenser, pressure cap
- The constant velocity joints
and the neck. An Emission Control Service *
- The axle seals
• Change the automatic transmission fluid
and filter. 12 000 km (7,500 miles)
• Change the engine oil and the filter. An
Short Trip/City Maintenance Schedule Emission Control Service *
(Diesel) Change the engine oil and the filter as soon as
Perform the services shown in this schedule up to one of the following conditions occurs:
240 000 km (150,000 miles) and after 240 000 km - Three months pass since the last oil change.
(150,000 miles) at the same intervals.
- The vehicle drives 4000 km (2 miles) since
4 000 km (2,500 miles) the last oil change.
• Change the engine oil and the filter. An • Lubricate the following components:
Emission Control Service *
If three months pass before
4 000 km (2,500 miles), then change the oil
after three months. - The transmission shift linkage
• Lubricate the following components: - The parking brake cable guides
- The front suspension - The rear driveline center splines
- The steering linkage - The brake pedal springs
- The transmission shift linkage - The ball joints
- The parking brake cable guides Only lubricate the ball joints if the
temperature of the ball joint is -12 *C (10*F)
or higher.
• Inspect the rear fluid level.
- The ball joints
Only lubricate the ball joints if the
• Inspect the following components for leaking:
temperature of the ball joint is -12 *C (10*F)
or higher. - The constant velocity joints
• Inspect the rear fluid level. - The axle seals
Add fluid if necessary. • Rotate the tires. Refer to Tires and Wheels
in Suspension.
- The axle seals
16 000 km (10,000 miles) • Lubricate the following components:
• Change the engine oil and the filter. An - The front suspension
Emission Control Service * - The steering linkage
Change the engine oil and the filter as soon as - The transmission shift linkage
one of the following conditions occurs: - The parking brake cable guides
- Three months pass since the last oil change. - The rear driveline center splines
- The vehicle drives 4000 km (2,500 miles) - The brake pedal springs
since the last oil change. - The ball joints
• Lubricate the following components: Only lubricate the ball joints if the
- The front suspension temperature of the ball joint is -12 *C (10*F)
- The steering linkage or higher.
- The axle seals
- The ball joints
24 000 km (15,000 miles)
Only lubricate the ball joints if the • Change the engine oil and the filter. An
temperature of the ball joint is -12* C (10* F) Emission Control Service *
or higher.
Change the engine oil and the filter as soon as
• Inspect the rear fluid level. one of the following conditions occurs:
Add fluid if necessary. - Three months pass since the last oil change.
• Inspect the following components for leaking: - The vehicle drives 4 000 km (2,500 miles)
- The constant velocity joints since the last oil change.
- The axle seals • Lubricate the following components:
• Inspect the air intake system installation in - The front suspension
order to ensure that the gaskets are properly - The steering linkage
sealed and that the following components - The transmission shift linkage
remain tight: - The parking brake cable guides
- The hose connections - The rear driveline center splines
- The fasteners - The brake pedal springs
- Other components - The ball joints
• Inspect the air cleaner housing in order to Only lubricate the ball joints if the
ensure the following conditions: temperature of the ball joint is -12* C (10* F)
- The air cleaner housing seats properly. or higher.
- The cover fits tightly. • Inspect the air cleaner filter.
- The wing nuts are tight.
• Tighten the connections and the fasteners or
replace damaged components if necessary. • Inspect the following components for leaking:
20 000 km (12,500 miles) - The constant velocity joints
• Change the engine oil and the filter. An - The axle seals
Emission Control Service * • Clean and repack the front wheel bearings (or
at each brake relining, whichever occurs first)
one of the following conditions occurs: • Rotate the tires. Refer to Tires and Wheels
in Suspension.
- Three months pass since the last oil change.
- The vehicle drives 4 000 km (2,500 miles)
since the last oil change.
28 000 km (17,500 miles) • Inspect the air intake system installation in
• Change the engine oil and the filter. An order to ensure that the gaskets are property
Emission Control Service * sealed and that the following components
remain tight:
one of the following conditions occurs: - The hose connections
- Three months pass since the last oil change. - The fasteners
- The vehicle drives 4 000 km (2,500 miles) - Other components
since the last oil change. • Inspect the air cleaner housing in order to
• Lubricate the following components: ensure the following conditions:
- The front suspension - The air cleaner housing seats properly.
- The steering linkage - The cover fits tightly.
- The transmission shift linkage - The wing nuts are tight.
- The parking brake cable guides • Tighten the connections and the fasteners or
replace damaged components if necessary.
36 000 km (22,500 miles)
- The ball joints Emission Control Service *
Only lubricate the ball joints if the Change the engine oil and the filter as soon as
temperature of the ball joint is -12* C (10* F) one of the following conditions occurs:
or higher.
Add fluid if necessary. since the last oil change.
• Inspect the following components for leaking: • Lubricate the following components:
- The constant velocity joints - The front suspension
- The axle seals - The steering linkage
32 000 km (20,000 miles)
one of the following conditions occurs: - The brake pedal springs
- Three months pass since the last oil change. - The ball joints
- The vehicle drives 4 000 km (2,500 miles) Only lubricate the ball joints if the
since the last oil change. temperature of the ball joint is -12 *C (10*F)
or higher.
• Lubricate the following components:
- The axle seals
in Suspension.
- The ball joints 40 000 km (25,000 miles)
Only lubricate the ball joints if the • Change the engine oil and the filter. An
temperature of the ball joint is -12* C (10* F) Emission Control Service *
or higher.
• Inspect the rear fluid level. one of the following conditions occurs:
• Inspect the following components for leaking: - The vehicle drives 4 000 km (2,500 miles)
- The constant velocity joints since the last oil change.
- The axle seals
• Lubricate the following components: • Lubricate the following components:
- The ball joints - The ball joints
Only lubricate the ball joints if the Only lubricate the ball joints if the
temperature of the ball joint is -12 *C (10 * F) temperature of the ball joint is -12* C (10* F)
or higher. or higher.
• Inspect the rear fluid level. • Inspect the rear fluid level.
Add fluid if necessary. Add fluid if necessary.
• Inspect the following components for leaking: • Inspect the following components for leaking:
- The constant velocity joints - The constant velocity joints
- The axle seals - The axle seals
• Replace the fuel cap. • Replace the air filter. An Emission Control
44 000 km (27,500 miles) Service *
• Change the engine oil and the filter. An • Replace the fuel filter.
Emission Control Service * • Inspect the shields and the underhood
Change the engine oil and the filter as soon as insulation for looseness.
one of the following conditions occurs: Adjust or replace the shields and the
- Three months pass since the last oil change. underhood insulation if necessary.
- The vehicle drives 4 000 km (2,500 miles) • Clean and repack the front wheel bearings (or
since the last oil change. at each brake relining, whichever occurs first).
• Lubricate the following components: • Inspect the air intake system installation in
order to ensure that the gaskets are properly
sealed and that the following components
- The steering linkage remain tight:
- The transmission shift linkage - The hose connections
- The parking brake cable guides - The fasteners
- The rear driveline center splines - Other components
- The brake pedal springs • Inspect the air cleaner housing in order to
- The ball joints ensure the following conditions:
Only lubricate the ball joints if the - The air cleaner housing seats properly.
temperature of the ball joint is -12 *C (10*F) - The cover fits tightly.
or higher.
Add fluid if necessary. replace damaged components if necessary.
• Inspect the following components for leaking: • Rotate the tires. Refer to Tires and Wheels
- The constant velocity joints in Suspension.
- The axle seals 52 000 km (32,500 miles)
48 000 km (30,000 miles) • Change the engine oil and the filter. An
• Change the engine oil and the filter. An Emission Control Service *
Emission Control Service * Change the engine oil and the filter as soon as
Change the engine oil and the filter as soon as one of the following conditions occurs:
one of the following conditions occurs: - Three months pass since the last oil change.
- Three months pass since the last oil change. - The vehicle drives 4 000 km (2,500 miles)
- The vehicle drives 4 000 km (2,500 miles) since the last oil change.
• Lubricate the following components: - The rear driveline center splines
- The front suspension - The brake pedal springs
- The steering linkage - The ball joints
- The transmission shift linkage Only lubricate the ball joints if the
- The parking brake cable guides temperature of the ball joint is -12 *C (10*F)
or higher.
- The ball joints
temperature of the ball joint is -12 *C (10‘ F) - The constant velocity joints
or higher. - The axle seals
• Inspect the rear fluid level. • Rotate the tires. Refer to Tires and Wheels
Add fluid if necessary. in Suspension.
• Inspect the following components for leaking: 64 000 km (40,000 miles)
- The constant velocity joints • Change the engine oil and the filter. An
- The axle seals
56 000 km (35,000 miles) one of the following conditions occurs:
• Change the engine oil and the filter. An - Three months pass since the last oil change.
Change the engine oil and the filter as soon as since the last oil change.
one of the following conditions occurs:
since the last oil change. - The steering linkage
• Lubricate the following components: - The transmission shift linkage
- The front suspension - The parking brake cable guides
- The steering linkage - The rear driveline center splines
- The transmission shift linkage - The brake pedal springs
- The parking brake cable guides - The ball joints
- The rear driveline center splines Only lubricate the ball joints if the
temperature of the ball joint is -12* C (10* F)
or higher.
- The ball joints
temperature of the ball joint is-12*C (10 ’ F)
or higher. • Inspect the following components for leaking:
• Inspect the rear fluid level. - The constant velocity joints
Add fluid if necessary. - The axle seals
• Inspect the following components for leaking: • Inspect the air intake system installation in
sealed and that the following components
- The axle seals remain tight:
60 000 km (37,500 miles) - The hose connections
• Change the engine oil and the filter. An - The fasteners
- Other components
• Inspect the air cleaner housing in order to
ensure the following conditions:
- The air cleaner housing seats properly.
- The cover fits tightly.
- The front suspension • Tighten the connections and the fasteners or
• If the engine has a thermostatically controlled • Inspect the following components for leaking:
cooling fan, inspect the following components - The constant velocity joints
for proper hook-up:
- The axle seals
- All of the hoses
• Inspect the air cleaner filter if the vehicle has
- All of the ducts been driven in dusty conditions.
If twelve months pass before the vehicle Replace the filter if necessary. An Emission
drives 40,000 miles, perform the above Control Service *
inspection procedure every twelve months.
• Clean and repack the front wheel bearings (or
68 000 km (42,500 miles) at each brake relining, whichever occurs first)
• Change the engine oil and the filter. An • Rotate the tires. Refer to Tires and Wheels
Emission Control Service * in Suspension.
Change the engine oil and the filter as soon as 76 000 km (47,500 miles)
- Three months pass since the last oil change. Emission Control Service *
- The vehicle drives 4 000 km (2,500 miles) Change the engine oil and the filter as soon as
since the last oil change. one of the following conditions occurs:
• Lubricate the following components: - Three months pass since the last oil change.
- The front suspension - The vehicle drives 4 000 km (2,500 miles)
- The steering linkage since the last oil change.
- The transmission shift linkage • Lubricate the following components:
- The ball joints - The parking brake cable guides
Only lubricate the ball joints if the - The rear driveline center splines
temperature of the ball joint is -12'C (10*F) - The brake pedal springs
or higher.
- The ball joints
Add fluid if necessary. temperature of the ball joint is -12'C (10‘ F)
• Inspect the following components for leaking: or higher.
- The constant velocity joints • Inspect the rear fluid level.
- The axle seals Add fluid if necessary.
72 000 km (45,000 miles) • Inspect the following components for leaking:
• Change the engine oil and the filter. An - The constant velocity joints
Emission Control Service * - The axle seals
Change the engine oil and the filter as soon as 80 000 km (50,000 miles)
- Three months pass since the last oil change. Emission Control Service *
- The vehicle drives 4 000 km (2,500 miles) Change the engine oil and the filter as soon as
since the last oil change. one of the following conditions occurs:
• Lubricate the following components: - Three months pass since the last oil change.
- The front suspension - The vehicle drives 4 000 km (2,500 miles)
- The steering linkage since the last oil change.
- The transmission shift linkage • Lubricate the following components:
- The ball joints - The parking brake cable guides
Only lubricate the ball joints if the - The rear driveline center splines
temperature of the ball joint is -12 *C (10‘ F) - The brake pedal springs
or higher.
- The ball joints
Add fluid if necessary. temperature of the ball joint is -12 *C (10*F)
or higher.
• Inspect the rear fluid level. - The parking brake cable guides
Add fluid if necessary. - The rear driveline center splines
• Inspect the following components for leaking: - The brake pedal springs
- The constant velocity joints - The ball joints
- The axle seals Only lubricate the ball joints if the
• Change the automatic transmission fluid and temperature of the ball joint is -12 *C (10' F)
the filter if the vehicle’s GVWR exceeds or higher.
3 900 kg (8,600 lbs) or if the vehicle is • Inspect the rear fluid level.
mainly driven under one or more of the Add fluid if necessary.
following conditions:
- In heavy traffic where the outside
temperature regularly reaches 32 * C (90 * F)
or higher. - The axle seals
- In hilly or mountainous terrain. • Rotate the tires. Refer to Tires and Wheels in
Suspension.
- When performing frequent trailer towing.
88 000 km (55,000 miles)
- Uses such as found in the following services:
• Taxi Emission Control Service *
• Police Change the engine oil and the filter as soon as
• Delivery one of the following conditions occurs:
• Inspect the shields and the underhood - Three months pass since the last oil change.
insulation for looseness. - The vehicle drives 4 000 km (2,500 miles)
Adjust or replace the shields and the since the last oil change.
underhood insulation as necessary. • Lubricate the following components:
• Inspect the air intake system installation in - The front suspension
sealed and that the following components - The steering linkage
remain tight: - The transmission shift linkage
- Hose connections - The parking brake cable guides
- Fasteners - The rear driveline center splines
- Other components - The brake pedal springs
• Inspect the air cleaner housing in order to - The ball joints
ensure the following conditions: Only lubricate the ball joints if the
- The air cleaner housing seats properly. temperature of the ball joint is -12 *C (10 * F)
- The cover fits tightly. or higher.
- The wing nuts are tight. • Inspect the rear fluid level.
• Tighten the connections and the fasteners or Add fluid if necessary.
replace damaged components if necessary. • Inspect the following components for leaking:
84 000 km (52,500 miles) - The constant velocity joints
• Change the engine oil and the filter. An - The axle seals
Emission Control Service * 92 000 km (57,500 miles)
Change the engine oil and the filter as soon as • Change the engine oil and the filter. An
one of the following conditions occurs: Emission Control Service *
- Three months pass since the last oil change. Change the engine oil and the filter as soon as
- The vehicle drives 4 000 km (2,500 miles) one of the following conditions occurs:
since the last oil change. - Three months pass since the last oil change.
• Lubricate the following components: - The vehicle drives 4 000 km (2,500 miles)
- The front suspension since the last oil change.
• Lubricate the following components: • Inspect the accessory drive (serpentine) belt for
- The front suspension the following conditions:
- The steering linkage - Cracking
- The transmission shift linkage - Fraying
- The parking brake cable guides - Wear
- The rear driveline center splines - Improper tension
Adjust or replace the belt as necessary.
• Inspect the air intake system installation in
- The ball joints
Only lubricate the ball joints if the sealed and that the following components
temperature of the ball joint is -12 *C (10*F) remain tight:
or higher.
- The hose connections
- The fasteners
- Other components
• Inspect the air cleaner housing in order to
- The constant velocity joints ensure the following conditions:
- The axle seals - The air cleaner housing seats properly.
96 000 km (60,000 miles)
Change the engine oil and the filter as soon as • Tighten the connections and the fasteners or
one of the following conditions occurs: replace damaged components if necessary.
in Suspension.
100 000 km (62,500 miles)
• Lubricate the following components: Emission Control Service *
- The front suspension Change the engine oil and the filter as soon as
- The steering linkage one of the following conditions occurs:
- The transmission shift linkage - Three months pass since the last oil change.
- The parking brake cable guides - The vehicle drives 4 000 km (2,500 miles)
- The rear driveline center splines since the last oil change.
- The brake pedal springs • Lubricate the following components:
- The ball joints - The front suspension
Only lubricate the ball joints if the - The steering linkage
temperature of the ball joint is -12* C (10* F) - The transmission shift linkage
or higher. - The parking brake cable guides
• Inspect the rear fluid level. - The rear driveline center splines
Add fluid if necessary. - The brake pedal springs
• Inspect the following components for leaking: - The ball joints
- The constant velocity joints Only lubricate the ball joints if the
- The axle seals temperature of the ball joint is -12* C (10* F)
• Replace the air filter. An Emission or higher.
Control Service * • Inspect the rear fluid level.
• Clean and repack the front wheel bearings (or Add fluid if necessary.
at each brake relining, whichever occurs first). • Inspect the following components for leaking:
• Inspect the crankcase depression regulator - The constant velocity joints
valve system for hoses exhibiting the
- The axle seals
104 000 km (65,000 miles)
- Wear
- Blockage Emission Control Service *
- Collapse Change the engine oil and the filter as soon as
An Emission Control Service * one of the following conditions occurs:
• Replace the fuel filter. - Three months pass since the last oil change.
• Inspect the crankcase depression regulator - The vehicle drives 4 000 km (2,500 miles)
valve. An Emission Control Service * since the last oil change.
• Lubricate the following components: • Lubricate the following components:
- The ball joints - The ball joints
Only lubricate the ball joints if the Only lubricate the ball joints if the
temperature of the bail joint is -12*C (10*F) temperature of the ball joint is -12* C (10* F)
or higher. or higher.
• Inspect the rear fluid level. • Inspect the rear fluid level.
Add fluid if necessary. Add fluid if necessary.
• Inspect the following components for leaking: • Inspect the following components for leaking:
- The constant velocity joints - The constant velocity joints
- The axle seals - The axle seals
• Change the engine oil and the filter. An order to ensure that the gaskets are properly
Emission Control Service * sealed and that the following components
remain tight:
one of the following conditions occurs: - The hose connections
- Three months pass since the last oil change. - The fasteners
- The vehicle drives 4 000 km (2,500 miles) - Other components
since the last oil change. • Inspect the air cleaner housing in order to
• Lubricate the following components: ensure the following conditions:
- The front suspension - The air cleaner housing seats properly.
- The steering linkage - The cover fits tightly.
- The transmission shift linkage - The wing nuts are tight.
- The parking brake cable guides • Tighten the connections and the fasteners or
- The rear driveline center splines replace damaged components if necessary.
- The brake pedal springs • If the engine has a thermostatically controlled
cooling fan, inspect the following components
- The ball joints for proper hook-up:
Only lubricate the ball joints if the - All of the hoses
or higher. - All of the ducts
• Inspect the rear fluid level. If twelve months pass before the vehicle
drives 64 000 km (40,000 miles) perform the
Add fluid if necessary. above inspection procedure every
• Inspect the following components for leaking: twelve months.
- The constant velocity joints • Verify proper operation of the thermostatically
- The axle seals controlled cooling fan valve.
• Rotate the tires. Refer to Tires and Wheels 116 000 km (72,500 miles)
in Suspension. • Change the engine oil and the filter. An
112 000 km (70,000 miles) Emission Control Service *
• Change the engine oil and the filter. An Change the engine oil and the filter as soon as
Emission Control Service * one of the following conditions occurs:
Change the engine oil and the filter as soon as - Three months pass since the last oil change.
one of the following conditions occurs: - The vehicle drive 4 000 km (2,500 miles)
- Three months pass since the last oil change. since the last oil change.
- The vehicle drive 4 000 km (2,500 miles)
• Lubricate the following components: 124 000 km (77,500 miles)
- The front suspension • Change the engine oil and the filter. An
- The steering linkage Emission Control Service *
- The rear driveline center splines - The vehicle drive 4 000 km (2,500 miles)
- The brake pedal springs since the last oil change.
- The ball joints • Lubricate the following components:
Only lubricate the ball joints if the - The front suspension
temperature of the ball joint is -12 * C (10* F) - The steering linkage
or higher. - The transmission shift linkage
- The constant velocity joints - The ball joints
120 000 km (75,000 miles) temperature of the ball joint is -12*C (10*F)
or higher.
Emission Control Service * • Inspect the rear fluid level.
one of the following conditions occurs: • Inspect the following components for leaking:
- Three months pass since the last oil change. - The constant velocity joints
- The vehicle drive 4 000 km (2,500 miles) - The axle seals
since the last oil change. 128 000 km (80,000 miles)
• Lubricate the following components: • Change the engine oil and the filter. An
- The steering linkage one of the following conditions occurs:
- The transmission shift linkage - Three months pass since the last oil change.
- The parking brake cable guides - The vehicle drive 4 000 km (2,500 miles)
- The rear driveline center splines since the last oil change.
- The brake pedal springs • Lubricate the following components:
- The ball joints - The front suspension
Only lubricate the ball joints if the - The steering linkage
temperature of the ball joint is -12* C (10* F) - The transmission shift linkage
or higher. - The parking brake cable guides
• Inspect the rear fluid level. - The rear driveline center splines
Add fluid if necessary. - The brake pedal springs
• Inspect the following components for leaking: - The ball joints
- The constant velocity joints Only lubricate the ball joints if the
- The axle seals
or higher.
• Inspect the air cleaner filter if the vehicle has • Inspect the rear fluid level.
been driven in dusty conditions.
Replace the filter if necessary. An Emission
Control Service *
• If the vehicle is a 2 wheel drive vehicle, then
clean and repack the front wheel bearings (or - The axle seals
at each brake relining, whichever occurs first.)
in Suspension.
• Inspect the air intake system installation in Change the engine oil and the filter as soon as
order to ensure that the gaskets are properly one of the following conditions occurs:
sealed and that the following components - Three months pass since the last oil change.
remain tight:
- The hose connections since the last oil change.
- The fasteners • Lubricate the following components:
- Other components - The front suspension
• Inspect the air cleaner housing in order to - The steering linkage
ensure the following conditions:
- The air cleaner housing seats properly.
- The ball joints
• If the engine has a thermostatically controlled
cooling fan, inspect the following components
or higher.
for proper hook-up:
- All of the hoses
- All of the ducts
If twelve months pass before the vehicle
drives 64 000 km (40,000 miles), perform the - The constant velocity joints
above inspection procedure every - The axle seals
twelve months. 140 000 km (87,500 miles)
• Verify proper operation of the thermostatically • Change the engine oil and the filter. An
controlled cooling fan valve. Emission Control Service *
132 000 km (82,500 miles) Change the engine oil and the filter as soon as
• Change the engine oil and the filter. An one of the following conditions occurs:
Emission Control Service * - Three months pass since the last oil change.
Change the engine oil and the filter as soon as - The vehicle drive 4 000 km (2,500 miles)
one of the following conditions occurs: since the last oil change.
- Three months pass since the last oil change. • Lubricate the following components:
- The vehicle drive 4 000 km (2,500 miles) - The front suspension
- The ball joints
- The brake pedal springs temperature of the ball joint is -12* C (10* F)
- The ball joints or higher.
Only lubricate the ball joints if the • Inspect the rear fluid level.
temperature of the ball joint is -12* C (10* F) Add fluid if necessary.
or higher.
- The axle seals
144 000 km (90,000 miles)
- The axle seals Emission Control Service *
• Rotate the tires. Refer to Tires and Wheels Change the engine oil and the filter as soon as
in Suspension. one of the following conditions occurs:
136 000 km (85,000 miles) - Three months pass since the last oil change.
• Change the engine oil and the filter. An - The vehicle drive 4 000 km (2,500 miles)
Emission Control Service * since the last oil change.
• Lubricate the following components: 152 000 km (95,000 miles)
- The front suspension • Change the engine oil and the filter. An
- The steering linkage Emission Control Service *
- The transmission shift linkage Change the engine oil and the filter as soon as
- The rear driveline center splines - The vehicle drive 4 000 km (2,500 miles)
- The brake pedal springs since the last oil change.
- The ball joints • Lubricate the following components:
Only lubricate the ball joints if the - The front suspension
temperature of the ball joint is -12* C (10* F) - The steering linkage
or higher. - The transmission shift linkage
- The constant velocity joints - The bail joints
• Replace the air filter. An Emission temperature of the ball joint is -12*C (10*F)
Control Service * or higher.
• Clean and repack the front wheel bearings (or • Inspect the rear fluid level.
at each brake relining, whichever occurs first). Add fluid if necessary.
• Replace the fuel filter. • Inspect the following components for leaking:
• Rotate the tires. Refer to Tires and Wheels - The constant velocity joints
in Suspension. - The axle seals
148 000 km (92,500 miles) 156 000 km (97,500 miles)
• Change the engine oil and the filter. An • Change the engine oil and the filter. An
Emission Control Service * Emission Control Service *
Change the engine oil and the filter as soon as Change the engine oil and the filter as soon as
- The vehicle drive 4 000 km (2,500 miles) since the last oil change.
- The transmission shift linkage - The parking brake cable guides
- The parking brake cable guides - The rear driveline center splines
- The rear driveline center splines - The brake pedal springs
- The brake pedal springs - The ball joints
- The ball joints Only lubricate the ball joints if the
Only lubricate the ball joints if the temperature of the ball joint is -12*C (10*F)
temperature of the ball joint is -12* C (10* F) or higher.
or higher. • Inspect the rear fluid level.
• Inspect the rear fluid level. Add fluid if necessary.
Add fluid if necessary. • Inspect the following components for leaking:
• Inspect the following components for leaking: - The constant velocity joints
- The constant velocity joints - The axle seals
- The axle seals • Rotate the tires. Refer to Tires and Wheels
in Suspension.
160 000 km (100,000 miles) • If the engine has a thermostatically controlled
• Change the engine oil and the filter. An cooling fan, inspect the following components
Emission Control Service * for proper hook-up:
Change the engine oil and the filter as soon as - All of the hoses
one of the following conditions occurs: - All of the ducts
- Three months pass since the last oil change. If twelve months pass before the vehicle
- The vehicle drives 4 000 km (2,500 miles) drives 64 000 km (40,000 miles), perform
since the last oil change. the above inspection procedure every
twelve months.
• Verify proper operation of the thermostatically
- The front suspension controlled cooling fan valve.
- The steering linkage 240 000 km (150,000 miles)
- The transmission shift linkage • Drain, flush and refill the cooling system as
- The parking brake cable guides soon as one of the following conditions occurs:
- The rear driveline center splines - The vehicle reaches
- The brake pedal springs 240 000 km (150,000 miles).
- The ball joints - Sixty months pass since the previous service
Only lubricate the ball joints if the Refer to Recommended Fluid and Lubricants.
temperature of the ball joint is -12* C (10* F) • Inspect the hoses.
or higher. • Clean the following components:
• Inspect the rear fluid level. - The radiator
Add fluid if necessary. - The condenser
• inspect the following components for leaking: - The pressure cap
- The constant velocity joints - The neck
- The axle seals An Emission Control Service *
order to ensure that the gaskets are properly Footnotes
sealed and that the following components The California Air Resources Board has determined
remain tight: that the failure to perform this maintenance item will
- The hose connections not nullify the emission warranty. The California Air
Resources Board has also determined that the
- The fasteners
failure to perform this maintenance item will not limit
- Other components the recall liability prior to the completion of the
• Inspect the air cleaner housing in order to vehicle useful life. GM, however, urges that all
ensure the following conditions: recommended maintenance be recorded.
- The air cleaner housing seats properly. Drive Axle Service:
- The cover fits tightly. • The Locking Differential
- The wing nuts are tight. Drain the fluid and refill the fluid at the first
• Tighten the connections and the fasteners or engine oil change. At subsequent oil changes,
replace damaged components if necessary. inspect the fluid level and add fluid as
necessary. Drain the fluid and refill the fluid
• Inspect the hoses and replace the hoses if the every 25 000 km (15,000 miles) if the vehicle is
hoses exhibit the following conditions: performing either of the following actions:
- Cracking - Driving in dusty areas
- Swelling
- Towing a trailer
- Deterioration
• The Standard Differential
• Tighten all of the hose clamps (except the
Inspect the fluid level and add fluid as
constant tension clamps).
necessary at every oil change. Drain the fluid
• Remove debris and clean the outside of the and refill the fluid every
radiator and air conditioning condenser. 25 000 km (15,000 miles) if the vehicle is
Wash the radiator neck. performing either of the following actions:
• Pressure test the radiator and the cap in order - Driving in dusty areas
to ensure proper operation. - Towing a trailer
• Change the automatic transmission fluid and • Heavy-duty or off-road use may require more
the filter. frequent lubrication.
Long Trip/Highway Maintenance • Inspect the air cleaning housing in order to

Schedule (Diesel) ensure that the air cleaning housing is properly
seated, the cover and wing nuts are
Perform the services shown in this schedule up tightly fitted.
to 240 000 km (150,000 miles) in this schedule
and after 244 000 km (150,000 miles) at the • Inspect the air cleaning housing in order to
same intervals. ensure that the air cleaning housing cover and
wing nuts are tightly fitted.
8 000 km (5,000 miles)
• Tighten the connections and fasteners. Replace
• Change the engine oil and the filter every the necessary damaged components.
whichever occurs first. An Emission • Inspect the hoses and ducts for the proper
Control Service * maintenance if the engine has a
thermostatically controlled cooling fan. Verify
• Lubricate the following vehicle components that the valves operate properly.
when performing a maintenance schedule:
- The front suspension in Suspension.
- The transmission shift linkage • Change engine oil and filter at
- The parking brake cable guides 24 000 km (15,000 miles) or every 3 months,
- The rear driveline center splines whichever occurs first. An Emission
Control Service *
• Lubricate the following vehicle components
• Do not lubricate the ball joints unless their when performing a maintenance schedule:
temperature is -12 *C (10 ’ F) or higher.
• Inspect the rear fluid level. Add fluid
as needed. - The steering linkage
• Inspect the constant velocity joints for leaks. - The transmission shift linkage
• Inspect the axle seals for leaks. - The parking brake cable guides
• Rotate the tires. Refer to Tires and Wheels - The rear driveline center splines
in Suspension. - The brake pedal springs
16 000 km (10,000 miles) • Do not lubricate ball joints unless the ball joint
• Change engine oil and filter every temperature exceeds -12 *C (10*F) or higher.
16 000 km (10,000 miles) or every 3 months, • Inspect the rear fluid level. Add fluid
whichever occurs first. An Emission as needed.
Control Service * • Inspect the constant velocity joints for leaks.
• Lubricate the following vehicle components • Inspect the axle seals for leaks.
• Rotate the tire. Refer to Tires and Wheels
- The front suspension in Suspension.
- The transmission shift linkage • Change engine oil and filter every
- The parking brake cable guides 32 000 km (20,000 miles) or every three
- The rear driveline center splines months, whichever occurs first. An Emission
Control Service *
• Do not lubricate the ball joints unless their
temperature is -12*C (10*F) or higher.
as needed. - The steering linkage
• Inspect the constant velocity joints for leaks. - The transmission shift linkage
• Inspect the axle seals for leaks. - The parking brake cable guides
• Inspect the air intake system installation in - The rear driveline center splines
order to ensure that the gaskets are - The brake pedal springs
properly sealed. • Do not lubricate ball joints unless the ball joint
• Inspect the air intake system installation in temperature exceeds -12 *C (10*F) or higher.
order to ensure that hose connections, • Inspect the rear fluid level. Add fluid as
fasteners and other components are needed.
tightly fitted.
• Inspect the air intake system installation in • Do not lubricate ball joints unless the ball joint
order to ensure that the gaskets are temperature exceeds -12 *C (10*F) or higher.
properly sealed. • Inspect the rear fluid level. Add fluid
• Inspect the air intake system installation in as needed.
order to ensure that hose connections, • Inspect the constant velocity joints for leaks.
fasteners and other components are
tightly fitted.
• Replace the air filters. An Emission
• Inspect the air cleaning housing in order to
Control Service *
ensure that the air cleaning housing is properly
seated, the cover and wing nuts are • Clean the front wheel bearings or each brake
tightly fitted. relining, whichever occurs first.
• Inspect the air cleaning housing in order to • Repack the front wheel bearings or each brake
ensure that the air cleaning housing cover and relining, whichever occurs first.
wing nuts are tightly fitted. • Replace the oil filter.
• Tighten the connections and fasteners. Replace • Inspect the shields and underhood insulation for
the necessary damaged components. looseness. Adjust or replace the shields and
• Inspect the hoses and ducts for the proper underhood insulation as required.
maintenance if the engine has a • Inspect the air intake system installation in
thermostatically controlled cooling fan. Verify order to ensure that the gaskets are
that the valves operate properly. properly sealed.
• Rotate the tire. Refer to Tires and Wheels • Inspect the air intake system installation in
in Suspension. order to ensure that hose connections,
40 000 km (25,000 miles) fasteners and other components are
• Change engine oil and filter every tightly fitted.
40 000 km (25,000 miles) or every 3 months, • Inspect the air cleaning housing in order to
whichever occurs first. An Emission ensure that the air cleaning housing is properly
Control Service * seated, the cover and wing nuts are
• Lubricate the following vehicle components tightly fitted.
when performing a maintenance schedule: • Tighten the connections and fasteners. Replace
- The front suspension the necessary damaged components.
- The steering linkage • Inspect the hoses and ducts for the proper
- The transmission shift linkage thermostatically controlled cooling fan. Verify
- The parking brake cable guides that the valves operate properly.
- The rear driveline center splines • Rotate the tires. Refer to Tires and Wheels
- The brake pedal springs in Suspension.
• Do not lubricate ball joints unless the ball joint 56 000 km (35,000 miles)
temperature exceeds -12 *C (10*F) or higher. • Change engine oil and filter every
• Inspect the rear fluid level. Add fluid 56 000 km (35,000 miles) or every 3 months,
as needed. whichever occurs first. An Emission
Control Service *
• Inspect the axle seals for leaks. when performing a maintenance schedule:
in Suspension.
48 000 km (30,000 miles)
• Change engine oil and filter every
48 000 km (30,000 miles) or every 3 months, - The parking brake cable guides
whichever occurs first. An Emission - The rear driveline center splines
Control Service * - The brake pedal springs
• Lubricate the following vehicle components • Do not lubricate ball joints unless the ball joint
when performing a maintenance schedule: temperature exceeds -12‘ C (10*F) or higher.
- The front suspension • Inspect the rear fluid level. Add fluid
- The steering linkage as needed.
- The transmission shift linkage • Inspect the constant velocity joints for leaks.
- The parking brake cable guides • Inspect the axle seals for leaks.
- The rear driveline center splines . Rotate the tire. Refer to Tires and Wheels
- The brake pedal springs in Suspension.
64 000 km (40,000 miles) • Lubricate the following vehicle components
• Change engine oil and filter every when performing a maintenance schedule:
64 000 km (40,000 miles) or every 3 months, - The front suspension
whichever occurs first. An Emission - The steering linkage
Control Service *
• Do not lubricate ball joints unless the ball joint
temperature exceeds -12 *C (10 *F).
- The rear driveline center splines as needed.
- The brake pedal springs • Inspect the constant velocity joints for leaks.
• Do not lubricate ball joints unless the ball joint • Inspect the axle seals for leaks.
temperature exceeds -12 *C (10 * F) or higher.
• Inspect the rear fluid level. Add fluid filter. 3 900 kg (8,600 lbs).
as needed.
• Inspect the constant velocity joints for leaks. order to ensure that the gaskets are
• Inspect the axle seals for leaks. properly sealed.
• Inspect the air intake system installation in • Inspect the air intake system installation in
order to ensure that hose connections, order to ensure that hose connections,
fasteners and other components tightly fitted. fasteners and other components tightly fitted.
• Inspect the air cleaning housing in order to • Inspect the air cleaning housing in order to
ensure that the air cleaning housing is properly ensure that the air cleaning housing is properly
seated, the cover and wing nuts are seated, the cover and wing nuts are
tightly fitted. tightly fitted.
• Tighten the connections and fasteners. Replace • Tighten the connections and fasteners. Replace
the necessary damaged components. the necessary damaged components.
• Rotate the tire. Refer to Tires and Wheels • Inspect the hoses and ducts for the proper
in Suspension. maintenance if the engine has a
72 000 km (45,000 miles) thermostatically controlled cooling fan. Verify
• Change engine oil and filter every that the valves operate properly.
72 000 km (45,000 miles) or every 3 months, • Rotate the tires. Refer to Tires and Wheels
whichever occurs first. An Emission in Suspension.
Control Service * 88 000 km (55,000 miles)
• Lubricate the following vehicle components • Change engine oil and filter every
when performing a maintenance schedule: 88 000 km (55,000 miles) or every three
- The front suspension months, whichever occurs first. An Emission
Control Service *
temperature exceeds -12 *C (10*F) or higher.
as needed. - The brake pedal springs
• Inspect the constant velocity joints for leaks. • Do not lubricate ball joints unless the ball joint
as needed.
in Suspension.
80 000 km (50,000 miles) • Inspect the constant velocity joints for leaks.
• Change engine oil and filter every • Inspect the axle seals for leaks.
Control Service *
• Change engine oil and filter every order to ensure that hose connections,
96 000 km (60,000 miles) or every 3 months, fasteners and other components tightly fitted.
whichever occurs first. An Emission • Inspect the air cleaning housing in order to
Control Service * ensure that the air cleaning housing is properly
• Lubricate the following vehicle components seated, the cover and wing nuts are
when performing a maintenance schedule: tightly fitted.
- The front suspension • Tighten the connections and fasteners. Replace
the necessary damaged components.
• Inspect the hoses and ducts for the proper
- The transmission shift linkage maintenance if the engine has a
- The parking brake cable guides thermostatically controlled cooling fan. Verify
- The rear driveline center splines that the valves operate properly.
- The brake pedal springs • Rotate the tires. Refer to Tires and Wheels
• Do not lubricate ball joints unless the ball joint in Suspension.
temperature exceeds -12 *C (10*F) or higher. • Inspect the air intake system installation in
• Inspect the rear fluid level. Add fluid order to ensure that the gaskets are
as needed. properly sealed.
• Inspect the constant velocity joints for leaks. • Inspect the air intake system installation in
order to ensure that hose connections,
• Inspect the axle seals for leaks. fasteners and other components tightly fitted.
• Replace the air filter. An Emission • Inspect the air cleaning housing in order to
Control Service. * ensure that the air cleaning housing is properly
• Clean the front wheel bearings or each brake seated, the cover and wing nuts are
relining, or whichever occurs first. tightly fitted.
• Repack the front wheel bearing or each brake • Tighten the connections and fasteners. Replace
relining, or whichever occurs first. the necessary damaged components.
• Inspect the crankcase depression regulator • Inspect the hoses and ducts for the proper
valve system for the following faulty conditions. maintenance if the engine has a
This is also an Emission Control Service. * thermostatically controlled cooling fan. Verify
- Worn hoses that the valves operate properly.
- Plugged hoses • Rotate the tires. Refer to Tires and Wheels
in Suspension.
- Collapsed hoses
104 000 km (65,000 miles)
• Replace the fuel filter.
• Inspect the equipped EGR System except for 104 000 km (65,000 miles) or every three
Code F engine. An Emission Control Service. months, whichever occurs first. An Emission
• Inspect the shields and the underhood Control Service *
insulation for looseness. Adjust or replace the • Lubricate the following vehicle components
shields and the underhood insulation if when performing a maintenance schedule:
damaged or loosed.
filter if the vehicle’s GVWR exceeds - The steering linkage
3900 kg (8,600 lbs). - The transmission shift linkage
• Change the automatic transmission fluid and - The parking brake cable guides
filter if the vehicle is mainly driven under one or - The rear driveline center splines
more of the following conditions.
- In heavy traffic with outdoor temperatures
exceeding 32 * C (90 * F) or higher.
- In hilly and mountainous terrain
- For frequent trailer towing as needed.
- Uses found in the following services • Inspect the constant velocity joints for leaks.
• Taxi • Inspect the axle seals for leaks.
• Police • Rotate the tires. Refer to Tires and Wheels
• Delivery in Suspension.
order to ensure that the gaskets are
properly sealed.
112 000 km (70,000 miles) 128 000 km (80,000 miles)
• Change engine oil and filter every • Change engine oil and filter every
112 000 km (70,000 miles) or every three 128 000 km (80,000 miles) or every three
months, whichever occurs first. An Emission months, or whichever occurs first. An Emission
• Lubricate the following vehicle components • Lubricate the following vehicle components
when performing a maintenance schedule: when performing a maintenance schedule:
• Do not lubricate ball joints unless the ball joint • Do not lubricate ball joints unless the ball joint
temperature exceeds -12*C (10*F) or higher. temperature exceeds -12 *C (10 * F) or higher.
• Inspect the rear fluid level. Add fluid • Inspect the rear fluid level. Add fluid
as needed. as needed.
• Rotate the tires. Refer to Tires and Wheels • Rotate the tire. Refer to Tires and Wheels
in Suspension. in Suspension.
order to ensure that the gaskets are order to ensure that the gaskets are
properly sealed. properly sealed.
order to ensure that hose connections, order to ensure that hose connections,
fasteners and other components tightly fitted. fasteners and other components tightly fitted.
• Inspect the hoses and ducts for the proper • Inspect the hoses and ducts for the proper
maintenance if the engine has a maintenance if the engine has a
thermostatically controlled cooling fan. Verify thermostatically controlled cooling fan. Verify
that the valve operate properly. that the valves operate properly.
• Rotate the tires. Refer to Tires and Wheels • Rotate the tires. Refer to Tires and Wheels
120 000 km (75,000 miles) 136 000 km (85,000 miles)
• Change engine oil and filter every • Change engine oil and filter every
120 000 km (75,000 miles) or every three 136 000 km (85,000 miles) or every 3 months,
months, whichever occurs first. An Emission whichever occurs first. An Emission
• Lubricate the following vehicle components • Lubricate the following vehicle components
when performing a maintenance schedule: when performing a maintenance schedule:
• Do not lubricate ball joints unless the ball joint • Do not lubricate ball joints unless the ball joint
temperature exceeds -12 *C (10*F) or higher. temperature exceeds -12*C (10*F).
• Inspect the rear fluid level. Add fluid • Inspect the rear fluid level. Add fluid as
as needed. needed.
• Rotate the tire. Refer to Tires and Wheels • Rotate the tire. Refer to Tires and Wheels
144 000 km (90,000 miles) • Inspect the rear fluid level. Add fluid
• Change engine oil and filter every as needed.
144,000 km (90,000 miles) or every 3 months, • Inspect the constant velocity joints for leaks.
whichever occurs first. An Emission • Inspect the axle seals for leaks.
Control Service *
• Lubricate the following vehicle components in Suspension.
160 000 km (100,000 miles)
- The front suspension • Change engine oil and filter every
- The steering linkage 160 000 km (100,000 miles) or every 60
- The transmission shift linkage months, whichever occurs first. An Emission
- The rear driveline center splines • Lubricate the following vehicle components
temperature exceeds -12* C (10* F) or higher. - The steering linkage
• Inspect the rear fluid level. Add fluid - The transmission shift linkage
as needed. - The parking brake cable guides
• Inspect the constant velocity joints for leaks. - The rear driveline center splines
• Inspect the axle seals for leaks. - The brake pedal springs
• Replace the air filter. An Emission • Do not lubricate ball joints unless the ball joint
Control Service. temperature exceeds -12 *C (10*F) or higher.
• Clean the front wheel bearings or each brake • Inspect the rear fluid level. Add fluid
relining, or whichever occurs first. as needed.
• Repack the front wheel bearing or each brake • Inspect the constant velocity joints for leaks.
relining, or whichever occurs first. • Inspect the axle seals for leaks.
• Replace the fuel filter. • Drain, flush and refill the cooling system
• Inspect the shields and underhood insulation for with coolant.
looseness. Adjust the shields and underhood • Inspect the hoses if the hoses are cracked,
insulation as required. swollen, or deteriorated. Replace the hoses if
• Inspect the air intake system installation in damaged. Tighten the hose clamps except for
order to ensure that the gaskets are the constant tension clamps. Remove and clean
properly sealed. the debris out the radiator and the air
• Inspect the air intake system installation in conditioning condenser. Clean the radiator neck
order to ensure that hose connections, thoroughly in order to ensure proper operation.
fasteners and other components tightly fitted. Pressure test the radiator and the cap.
• Inspect the hoses and ducts for the proper • Change the automatic transmission fluid
maintenance if the engine has a and filter.
thermostatically controlled cooling fan. Verify • Inspect the shields and underhood insulation for
that the valves operate properly. looseness. Adjust the shields and underhood
• Rotate the tire. Refer to Tires and Wheels insulation as required.
in Suspension. • Inspect the air intake system installation in
152 000 km (95,000 miles) order to ensure that the gaskets are
properly sealed.
152 000 km (95,000 miles) or every three • Inspect the air intake system installation in
months, whichever occurs first. An Emission order to ensure that hose connections,
Control Service * fasteners and other components tightly fitted.
• Lubricate the following vehicle components • Inspect hoses and ducts for the prpper
when performing a maintenance schedule: maintenance if the engine has a
thermostatically controlled cooling fan. Ensure
that the valve operates properly.
- The transmission shift linkage in Suspension.
temperature exceeds -12 *C (10‘ F) or higher.
240 000 km (150,000 miles) 37 500 km (22,500 miles)
• Drain, flush and refill the cooling system every • Change the engine oil and the filter every
240 000 km (150,000 miles ) or every 37 500 km (22,500 miles) or every 3 months,
60 months, whatever exceeds first. Refer to whichever occurs first. An Emission
Recommended Fluid and Lubricants. Inspect Control Service *
the hoses. Clean the radiator, condenser, • Lubricate the following components. Do not
pressure cap and neck. An Emission lubricate the ball joints unless the ball joint
Control Service * temperature is -12 *C (10*F) or higher.
• Change the automatic transmission fluid - The front suspension
and filter.
Long Trip/Highway Maintenance - The transmission shift linkage
Schedule (Gasoline) - The parking brake cable guides
Perform the services shown in this schedule up to - The rear driveline center splines
166 000 km (100,000 miles) and after 166 000 km - The brake pedal springs
(100,000 miles) at the same intervals.
12 500 km (7,500 miles) as needed.
• Change the engine oil and the filter every • Inspect the constant velocity joints and the axle
12 500 km (7,500 miles) or every 12 months, seals for leaks.
Control Service * • Rotate the tires. Refer to Tires and Wheels.
• Lubricate the following components. Do not 50 000 km (30,000 miles)
lubricate the ball joints unless the ball joint • Change the engine oil and the filter every
temperature is -12* C (10* F) or higher. 50 000 km (30,000 miles) or every 12 months,
Control Service *
• Lubricate the following components. Do not
- The transmission shift linkage lubricate the ball joints unless the ball joint
- The parking brake cable guides temperature is -12 *C (10 * F) or higher.
- The rear driveline center splines - The front suspension
- The brake pedal springs - The steering linkage
• Verify the rear fluid level. Add fluid as needed. - The transmission shift linkage
• Verify the constant velocity joints and the axle - The parking brake cable guides
seals for leaks. - The rear driveline center splines
• Rotate the tires. Refer to Tires and Wheels. - The brake pedal springs
25 000 km (15,000 miles) • Inspect the rear fluid level. Add fluid
• Change the engine oil and the filter every as needed.
25 000 km (15,000 miles) or every 12 months, • Inspect the constant velocity joints and the axle
whichever occurs first. An Emission seals for leaks.
Control Service *
• Clean and repack the front wheel bearings (or
• Lubricate the following components. Do not at each brake relining, whichever occurs first).
lubricate the ball joints unless the ball joint
temperature is -12 *C (10 * F) or higher. • Replace the air filter.
- The front suspension • Replace the fuel filter. An Emission
Control Service *
• Inspect the shields and the
- The transmission shift linkage underhood insulation.
- The parking brake cable guides 62 500 km (37,500 miles)
- The rear driveline center splines • Change the engine oil and the filter every
- The brake pedal springs 62 500 km (37,500 miles ) or every 12 months,
• Inspect the rear fluid level. Add fluid whichever occurs first. An Emission
as needed. Control Service *
• Inspect the constant velocity joints and the axle
seals for leaks.
• Inspect the shields and the underhood
insulation (GVWR above 3,855 kg lbs).
• Lubricate the following components. Do not - The parking brake cable guides
lubricate the ball joints unless the ball joint - The rear driveline center splines
temperature is -12 ’ C (10 ’ F) or higher.
- The transmission shift linkage • Inspect the constant velocity joints and axle
- The parking brake cable guides seals for leaks.
- The rear driveline center splines • Rotate the tires. Refer to Tires and Wheels.
- The brake pedal springs 100 000 km (60,000 miles)
• Inspect the rear fluid level. Add fluid • Change the engine oil and filter every
as needed. 100 000 km (60,000 miles) or every 3 months,
• Inspect the constant velocity joints and the axle whichever occurs first. An Emission
seals for leaks. Control Service *
• Rotate the tires. Refer to Tires and Wheels. • Lubricate the following components. Do not
lubricate the ball joints unless the ball joint
75 000 km (45,000 miles) temperature is -12 * C (10 * F) or higher.
• Change the engine oil and the filter every - The front suspension
whichever occurs first. An Emission - The steering linkage
Control Service * - The transmission shift linkage
• Lubricate the following components. Do not - The parking brake cable guides
lubricate the ball joints unless the ball joint - The rear driveline center splines
temperature is -12 *C (10'F) or higher.
- The transmission shift linkage • Inspect the constant velocity joints and axle
- The parking brake cable guides seals for leaks.
- The rear driveline center splines • Clean and repack the front wheel bearings (or
- The brake pedal springs at each brake relining, which ever occurs ffrst).
• Inspect the rear fluid level. Add fluid • Inspect the engine accessory drive belt. An
as needed. Emission Control Service *
• Inspect the constant velocity joints and the axle • Replace the air filter.
seals for leaks. • Replace the fuel filter. An Emission
83 000 km (50,000 miles) Control Service *
• Change the automatic transmission fluid and • Inspect the following components for damage or
the filter if the vehicle’s GVWR is over leaks. Replace the parts as needed. An
3 900 kg (8,600 lbs), or if the vehicle is mainly Emission Control Service *
driven under one or more of these conditions: - Fuel tank
• In heavy traffic where the outside - Fuel cap
temperature regularly reaches 32 * C (90 * F) - Fuel lines
or higher.
- Fuel cap gasket
• In hilly or mountainous terrain
• If the engine has a thermostatically controlled
• When doing frequent trailer towing cooling fan, inspect all of the hoses and all of
• Vehicles performing taxi, police or the ducts for proper hook-up. Ensure that the
delivery services valve works properly.
87 500 km (52,500 miles) • Conduct an Exhaust Gas Recirculation (EGR)
• Change the engine oil and filter every system inspection.
87 500 km (52,500 miles) or every 3 months, • Preform the following steps in order to conduct
whichever occurs first. An Emission an evaporative control system inspection:
Control Service *
1. Inspect all the fuel and vapor lines
• Lubricate the following components. Do not and hoses for proper hook-up, routing
lubricate the bail joints unless the ball joint and condition.
temperature is -12‘ C (10‘ F) or higher.
2. Ensure that the purge valve works
- The front suspension properly (if equipped).
- The steering linkage 3. Replace the vapor lines, hoses, and the
- The transmission shift linkage purge valve as needed.
112 500 km (67,500 miles) 150 000 km (90,000 miles)
• Change the engine oil and the filter (or every • Change the engine oil and filter (or every
3 months, whichever occurs first). An Emission 3 months, whichever occurs first). An Emission
• Lubricate the following components. Do not • Lubricate the following components. Do not
lubricate the ball joints unless the ball joint lubricate the ball joints unless the ball joint
temperature is -12 *C (10 * F) or higher. temperature is -12 *C (10*F) or higher.
as needed. • Inspect the rear fluid level. Add fluid
as needed.
• Inspect the constant velocity joints and axle
seals for leaks. • Inspect the constant velocity joints and axle
• Rotate the tires. Refer to Tires and Wheels. seals for leaks.
125 000 km (75,000 miles) • Clean and repack the front wheel bearings (or
at each brake relining, whichever occurs first).
• Change the engine oil and filter (or every 3
months, whichever occurs first). An Emission • Replace the air filter.
Control Service * • Replace the fuel filter. An Emission
• Lubricate the following components. Do not Control Service *
lubricate the ball joints unless the ball joint 162 500 km (97,500 miles)
temperature is -12 *C (10*F) or higher.
• Change the engine oil and filter (or every
- The front suspension 3 months, whichever occurs first). An Emission
- The steering linkage Control Service *
- The transmission shift linkage • Lubricate the following components. Do not
- The parking brake cable guides lubricate the ball joints unless the ball joint
- The rear driveline center splines temperature is -12* C (10* F) or higher.
- The brake pedal springs - The front suspension
• Inspect the rear fluid level. Add fluid - The steering linkage
as needed. - The transmission shift linkage
• Inspect the constant velocity joints and axle - The parking brake cable guides
seals for leaks.
137 500 km (82,500 miles)
• Change the engine oil and filter (or every 3
months, whichever occurs first). An Emission • Inspect the rear fluid level. Add fluid
Control Service * as needed.
• Lubricate the following components. Do not • Inspect the constant velocity joints and axle
lubricate the ball joints unless the ball joint seals for leaks.
temperature is -12 *C (10*F) or higher. • Rotate the tires. Refer to Tires and Wheels.
- The front suspension 166 000 km (100,000 miles)
- The steering linkage • Inspect the spark plug wires.
- The transmission shift linkage • Replace the spark plug wires. An Emission
- The rear driveline center splines • Change the automatic transmission fluid and
- The brake pedal springs the filter.
• Inspect the rear fluid level. Add fluid • Inspect the positive crankcase ventilation
as needed. (PCV) valve.
• Inspect the constant velocity joints and axle
seals for leaks.
• Rotate the tires. Refer to Tires and Wheels.
240 000 km (150,000 miles) • Instrument panel compartment hinges, latch,
• Drain, flush and refill the cooling system (or and lock cylinder
every 60 months since the last service, • Console cover hinges and latch.
whichever comes first). Refer to Recommended • Seat hardware
Fluid and Lubricants in this section.
More frequent lubrication may be required when
• Inspect the hoses. exposed to a corrosive environment. In order to
• Clean the following components. An Emission locate the proper lubricant, refer to Recommended
Control Service * Fluids and Lubricants.
- The radiator Starter Switch:
- The condenser • Before you start, make sure you have enough
- The pressure cap room around the vehicle in case the vehicle
jumps suddenly.
- The neck
• Firmly apply both the parking brake and the
Owner Checks and Services regular brake. Do not use the accelerator pedal,
and be ready to turn off the engine immediately
The following information covers the checks and
if it starts.
services required to retain the safety, dependability,
and emission control performance of the vehicle. • On automatic transmission vehicles, try to start
the engine in each gear. The starter should
Make sure any necessary repairs are completed on
work only in PARK (P) or NEUTRAL (N). If the
time. Whenever any fluids or lubricants are added to
starter works in any other position, the vehicle
the vehicle, make sure that they are the proper
needs service.
ones. Refer to Recommended Fluids and Lubricants.
On manual transmission vehicles, put the shift lever
At Each Fuel Fill in NEUTRAL (N), push the clutch down halfway and
It is important to perform these underhood check at try to start the engine. The starter should work only
each fuel fill. when the clutch is pushed down all the way to the
Engine Oil Level floor. If the starter works when the clutch is not
Check the engine oil level and add the proper oil pushed all the way down, the vehicle needs service.
if necessary. Steering Column Lock:
In order to select the proper fluids and lubricants, While parked, and with the parking brake set, try to
refer to Recommended Fluids and Lubricants. turn the key to LOCK in each shift lever position.
Engine Coolant Level With an automatic transmission, the key should turn
Check the engine coolant levels and add the proper to LOCK only when the shift lever is in PARK (P).
coolant mixture, if necessary. Refer to
Recommended Fluids and Lubricants. On vehicles with a key release button, try to turn the
key to lock without the button. The key should turn
Windshield Washer Fluid Level to LOCK only with the key button depressed.
Check the windshield washer fluid level in the
windshield washer reservoir and add the proper fluid, Parking Brake and Automatic transmission PARK (P)
if necessary. Refer to Recommended Fluids Mechanism Check.
and Lubricants. Caution: When performing this check, the vehicle
At Least Once a Month could begin to move. You or others could be
Tire Inflation: Check tire inflation. Make sure the tires Injured and property could be damaged. Make
are inflated to the pressures specified on the sure there Is room In front of your vehicle in
Certification/Tire label located on the driver’s door case the vehicle begins to roll. Be ready to apply
lock pillar. Refer to Vehicle Certification Label. the regular brake at once, should the vehicle
Cassette Deck: Clean the playback heads and begin to move.
capstan on the cassette deck. Cleaning should be Follow this procedure to test the parking brake and
done every 50 hours of tape play. Refer to Cleaning automatic transmission PARK mechanism:
Tape Head and Capstan in Audio Systems. 1. Park on a fairly steep hill, with the vehicle
At Least Once a Year facing downhill.
Key Lock Cylinders: Lubricate the lock cylinders with 2. Keep your foot on the hydraulic brake pedal.
the recommended lubricant. Refer to Recommended
Fluids and Lubricants. 3. Set the parking brake.
Body Lubrication: Lubricate all of the following areas: 4. In order to check the parking brake:
• Body door hinges 4.1. Start the engine
• Body hood, safety lever, and prop rod pivot 4.2. Place the transmission in NEUTRAL.
• Fuel door 4.3. Slowly remove foot pressure from the
hydraulic brake pedal.
• Rear compartment hinges
• Rear compartment latches and locks
5. In order to check the PARK (P) mechanism,
follow steps 1-3 above then do the following:
RECDMMENOED M i VISCOSITY GRADE ENGINE OILS
5.1. Shift to PARK (P).
FOR REST FUEL ECONOMY AND COLD STARTUR, SELECT THE LOWEST
5.2. Release all brakes. SAE VISCOSITY SRAO i OIL FOR THE EXPECTED TEMPERATURE RANGE.
Lap and Shoulder Beits Condition and Operation:

Inspect all of the following belt system components:
• Webbing
• Buckles
• Latch plates HOT
WEATHER
• Retractors / 7 n
• Guide loops [H
• Anchors + 100 - - ♦ «
Replace the belt if the webbing has been cut or + 00 - - t Z 7
otherwise damaged. + 00 ■ - + 10
Explanation of Scheduled Services + 40 ■ ■ + «
For time and/or mileage intervals of scheduled +10 ■ ■ - 7
maintenance items, refer to Maintenance Schedule. 0 ■ ■-10
The following text and illustrations describe
J
the details of the required scheduled
maintenance services.
For information on the proper fluids and lubricants to
use, refer to Recommended Fluids and Lubricants. COLO
Engine Oil and Filter Change WEATHER
For the engine oil and filter changing procedure, DO NOT U SE SAE EOW-M OR ANT OTHER
GRADE OIL NOT RECOMMENDED
refer to Engine Oil and Filter Change in
Engine Mechanical.
65536
For information on the correct engine oil quality and
viscosity, refer to the following: Engine Oil Viscosity
Engine Oil Quality The recommended oil viscosity for the C/K Truck is
Oils of the proper quality for the vehicle can be SAE 5W-30.
identified by looking for the STARBURST symbol. Notice: Using oils of any viscosity other than those
The STARBURST symbol indicates that the oil has viscosity’s recommended could result in engine
been certified by the American Petroleum Institute damage. When choosing an oil, consider the range
(API), and is preferred for use in gasoline engines. of temperatures the vehicle will be operated in
before the next oil change. Then, select the
recommended oil viscosity.
Engine oil viscosity (thickness) has an effect on the
fuel economy and the cold-weather operation
(starting and oil flow). Lower viscosity engine oils
can provide better fuel economy and cold-weather
performance. However, higher temperature weather
condition require higher viscosity engine oils for
satisfactory lubrication. When the temperature is
consistently above 0*F (—18*C), SAE 10W-30 can
be used. SAE 20W-50 or oils of other viscosity rating
or quality designations are NOT recommended for
use in any GMC Truck vehicles at any time.
Chassis Lubrication
Notice: Do not lubricate the parking brake cables.
Lubrication destroys the plastic coating on the cable.
Refer to the illustration for the location of the
lubrication points for the chassis. Lubricate
transmission shift linkage. Lubricate the park brake
guides, underbody contact points and linkage.
Lubrication Points (A utom atic/S electable Four-W heel D rive)
179740
Legend
(1) Transmission (7) Engine
(2) Rear Axle Differential (8) Wheel Bearings
(3) Transfer Case (9) Front Axle Differential
(4) Clutch Actuator (10) Front Propeller Shaft
(5) Brake Master Cylinder (11) Steering Linkage
(6) Oil Filter (12) Air Cleaner
Lubrication Points (Rear-Wheel Drive)
179739
Legend
(1) Propeller Shaft-Slip Joint (7) Engine
(2) Rear Axle Differential (8) Steering Linkage
(3) Clutch Actuator (9) Wheel Bearings
(4) Master Cylinder (10) Air Cleaner
(5) Oil Filter (11) Transmission
(6) Steering Grear
Lubricating Joints that have Grease Fittings Apply grease slowly while watching the grease seal.
Refer to the illustration for the location of the Apply grease until grease is seen bleeding from the
grease fittings. seal. If the seal expands but no grease is seen, do
important: Wipe off all dirt from the grease fitting not apply any more grease and allow time for the
before lubricating the joint. Ball joints should not be grease to bleed from the seal.
lubricated unless their temperature is 10*F (-12*C)
or higher. During cold weather, the ball joint should
be allowed to warm up as necessary before being
lubricated. Use a low-pressure grease gun on all
joints to prevent seal damage.
Lubrication Fittings (Driver Side)
Legend
(1) Lubrication Fittings
Lubrication Fittings (Passenger Side)
179742
Legend
(1) Lubrication Fittings
For RWD, lubricate the steering linkage, the
upper and lower ball joint, and the wheel bearing.
Refer to Wheel Bearing Adjustment (2WD) in
Front Suspension.
For S4WD, lubricate the steering linkage, and the
upper and lower ball joint.
Tire and Wheel Inspection and Rotation

Check the tires for abnormal wear for damage.
Rotate the tires to equalize the wear and obtain
maximum tire life. If irregular or premature wear
exists, refer to Abnormal or Excessive Tire Wear
(Center of Tread), Abnormal or Excessive Tire Wear
(General), Abnormal or Excessive Tire Wear (Heel
and Toe Wear), Abnormal or Excessive Tire Wear
(Tire Edges Wear), Abnormal or Excessive Tire Wear
(Uneven), Abnormal or Excessive Tire Wear
(Excessive or Uneven), Abnormal or Excessive
Tire Wear (Scuffed Tires), or Abnormal or
Excessive Tire Wear (Cupped Tires) in Suspension
General Diagnosis.
Accessory Drive Belt Inspection Inspections and Other Services
Inspect the accessory drive belts for the following: Listed below are the vehicle inspections and services
• Cracks that should be made by either the owner or a
• Fraying qualified technician at the frequencies indicated to
• Wear help ensure the following:
• Proper tension • Proper safety of the vehicle.
Replace as needed. (Belts can have many small • The vehicle emission system performance.
cracks in individual ribs without affecting the • Dependability of the vehicle.
performance.) Refer to Drive Belt Diagnosis in Complete any necessary repairs at once. Use the
Engine Mechanical. proper fluids or lubricants whenever adding to the
Automatic Transmission vehicle. For information on fluids and lubricants to
Change both the fluid and the filter according to the use when service is required, refer to Recommended
maintenance schedule intervals. For maintenance Fluids and Lubricants.
schedule information, refer to Maintenance Schedule. For emission system diagnosis information, Refer to
For the fluid and filter changing procedure, refer to Engine Controls.
Transmission Fluid/Filter Changing in
Automatic Transmission. At Least Monthly
Spark Plug Replacement Tire Inflation Check
Replace the spark plugs according to the Check the tire pressure when the tires are COLD.
maintenance schedule intervals with the correct type. Maintain tire pressures indicated on the Tire Placard
For maintenance schedule information, refer to on the driver’s door of the vehicle, or refer to Tire
Maintenance Schedule. Inflation Pressure Specifications.
For information on the correct type of spark plug, Cassette Deck Service
refer to Maintenance Items. Clean the cassette deck. Cleaning should be done
every 50 hours of tape play to prevent permanent
For the spark plug replacement procedure, Refer to damage, or every 30 hours for maximum
Spark Plug Replacement in Engine Electrical. performance. Refer to Body and Accessories.
Spark Plug Wire Inspection
Clean the spark plug wires and inspect for burns, At Least TWice A Year
cracks or other damage. Check the wire boot fit at Restraint System Check
the coils and at the spark plugs. Replace wires as Make sure the safety belt reminder light and all the
needed. Refer to Spark Plug Wire Harness in belts, buckles, latch plates, retractors, anchorages
Engine Electrical. are working properly. Look for any other loose or
Air Cleaner Filter Replacement damaged safety belt system parts. If anything is
Replace the air cleaner filter according to the seen that might keep a seat belt system from doing
maintenance schedule intervals with the correct type. it’s job, have it repaired. Have any torn or frayed
For maintenance schedule information, refer to seat belts replaced. For seat belt diagnosis
Maintenance Schedule. information, Refer to Restraints.
For information on the correct type of air cleaner Also look for any opened or broken supplemental
filter, refer to Maintenance Items. inflatable restraint (SIR) covers. For SIR diagnosis
information, Refer to Restraints.
For the air cleaner filter replacement procedure, refer
to Air Cleaner Replacement in Engine Controls. The SIR system does not need regular maintenance.
Fuel Tanks, Cap and Lines Inspection Throttle System Inspection
Inspect the following components for damage Throttle system (includes accelerator and cruise
or leaks: control) should operate freely without hesitation
• The fuel tanks between full closed and wide open throttle.
• The cap Important: The accelerator and cruise control cables
should not be lubricated under any condition. Throttle
• The lines
system components causing hesitation or sticking
• The fuel rails should be replaced.
• The injection assemblies
Inspect the fuel cap gasket for an even filler neck
imprint and any damage. Replace parts as needed.
Periodic replacement of the fuel filter is not required.
For fuel system diagnosis information, refer to Fuel
System Diagnosis in Engine Controls.
Inspect the following: Starter Switch Check
• Missing parts such as retainers or clips. Caution: When performing this check, the vehicle
• Interference of the linkage or the cable conduit could move suddenly. Personal injury or property
to critical components such as fuel lines, brake damage may result. Make sure there is enough
lines, harness leads, etc. room around the vehicle, in case the vehicle
• Proximity of the cable to the exhaust system does move. Do not use the accelerator pedal,
and other heat sources: check for melting and be ready to turn OFF the engine immediately
and/or discoloration. if it starts.
• Cable kinking. Avoid sharp bends of cables. On an automatic transmission vehicle, try to start the
• Clearance of the throttle system moving engine in each gear. The starter should crank only in
parts throughout their travel from other PARK or NEUTRAL. If the starter operates in any
stationary components. other position, the vehicle needs service.
• Damage of the components due to cable On a manual transmission vehicle, place the shift
kinking, severe kinking, severe abrasion, lever in NEUTRAL, push the clutch pedal down
misalignment, etc. If any of the above halfway and try to start the engine. The starter
conditions exists, notify your dealer for a should operate only when the clutch pedal is fully
recommended rerouting, adjustment, depressed all the way to the floor. If the starter
or replacement. operates when the clutch pedal is not pushed all the
way down to the floor, the vehicle needs service.
Automatic Transmission Check
Check the automatic transmission fluid level. Add the Brake Transmission Shift Interlock (BTSI) Check
proper transmission fluid if needed. A fluid loss may Caution: When performing this check, the vehicle
indicate a problem. Check the system and repair if could move suddenly. Personal injury or property
needed. For information on the correct fluid to use, damage may result. Make sure there is enough
refer to Recommended Fluids and Lubricants. room around the vehicle, in case the vehicle
For the automatic transmission fluid level checking does move. Be ready to apply the regular brake
procedure, Refer to Transmission/Transaxle. Immediately should the vehicle begin to move.
Weatherstrip Lubrication With the engine OFF, turn the ignition to RUN, but
Clean the weatherstrip surface, and then apply a thin do not start the engine. Without applying the regular
film of silicone grease, GM P/N 12345579 or brakes, try to move the transmission shift lever out
equivalent, using a clean, dry cloth. of PARK with normal effort. If the shift lever moves
Wiper Blade Check out of PARK, the brake transmission shift interlock
Inspect wiper blades for wear or cracking. Replace (BTSI) needs service. For wiring schematic
blade inserts that appear worn or damaged, or that information, Refer to Steering.
streak or miss areas of the windshield. Refer to For the BTSI solenoid replacement procedure, refer
Body and Accessories. to Transmission/Transaxle.
Steering Column Park Lock Check
At Least Once A Year While parked and with the parking brake set,
Key Lock Cylinders try to turn the ignition key to LOCK in each shift
Lubricate the key lock cylinders with the proper lever position.
lubricant. For information on the proper lubricant to
On an automatic transmission vehicle, the key
use, refer to Recommended Fluids and Lubricants.
should turn to LOCK only when the shift lever is
Body Lubrication in PARK.
Lubricate all body door hinges and latches, including
On a manual transmission vehicle, the key
the following: should turn to LOCK only when the shift lever
• The hood is in REVERSE.
• The rear compartment lid On all vehicles, the key should come out only in the
• The fuel door LOCK position. For wiring schematic information,
• The headlamp pivot points Refer to Steering.
• The console door
• The l/P passenger compartment
For information on the proper lubricants to use, refer
to Recommended Fluids and Lubricants.
More frequent lubrication may be required when
exposed to a corrosive environment.
Parking Brake and Automatic Transmission PARK Exhaust System Inspection
Mechanism Check Inspect the complete system. Inspect the body near
the exhaust system. Look for broken, damaged,
Caution: When perform ing this check, the vehicle
missing or out-of-position parts as well as open
could begin to move. Personal in ju ry o r property
damage may re s u lt Make sure there is enough seams, holes, loose connections or other conditions
which could cause a heat build-up in the floor pan or
room in fron t o f the vehicle, in case the vehicle
could let exhaust fumes into the vehicle. For
begins to roll. Be ready to apply the regular
brake im m ediately should the vehicle begin exhaust system inspection diagnosis, refer to
Engine Exhaust.
to move.
Radiator and Heater Hose Inspection
To check the parking brake’s holding ability: with the Inspect the hoses and replace if they are cracked,
engine running and transmission in NEUTRAL, slowly swollen or deteriorated.
remove foot pressure from the regular brake pedal.
Do this until the vehicle is held by the parking Inspect all pipes, fittings and clamps; replace
brake only. as needed.
To check the automatic transmission PARK Throttle Linkage Inspection
mechanism’s holding ability: with the engine running, Inspect the following:
shift the transmission to PARK, then release all • Missing parts such as retainers or clips
brakes. For diagnosis information of a malfunctioning • Interference of the linkage or cable conduit to
PARK mechanism, refer to Transmission/Transaxle. critical components such as fuel lines, brake
Underbody Flushing lines, harness leads, etc.
At least every spring, use plain water to flush any • Proximity of the cable to the exhaust system
corrosive materials from the underbody. Take care to and other head sources: check for melting
thoroughly clean any areas where mud and other and/or discoloration
debris can collect.
• Cable for kinks and sharp bends
Periodic Maintenance Inspection • Clearance of the throttle system moving
(General Maintenance) parts throughout their travel from other
stationary components
Listed below are inspections and services which • Damage of the components due to cable
should be performed at least twice a year (for kinking, severe kinking, severe abrasion,
instance, each spring and fall). A dealer’s service misalignment, etc.
department or qualified service center should perform Replace high effort or excessively worn cables.
these inspections. All repairs should be completed
Drive Axle Inspection
at once.
Check the frontfrear axle fluid level, add the proper
Steering, Suspension and Front Drive Axle Boot fluid as needed. Refer to Recommended Fluids
and Seal Inspection and Lubricants
Inspect the front and the rear suspension for
Check the constant velocity (CV) joints and axle
the following:
seals for leakage.
• Damaged parts
Transfer Case Inspection (Automatic Four
• Loose or missing parts Wheel Drive)
• Signs of wear or lack of lubrication Check every 12 months or at oil interval changes,
Inspect the power steering lines and the hoses for add the proper fluid as needed. Refer to
the following: Recommended Fluids and Lubricants
• Proper hookup Check the transfer case vent hose for kinks and
proper installation.
• Binding
Brake System Inspection
• Leaks
Inspect the complete system.
• Cracks
Notice: A low brake fluid level can indicate worn
• Chafing, etc.
disc brake pads which may need to be serviced.
Inspect the drive axle boot seals for the following: Also, if the brake system warning light stays on or
• Damage comes on, something may be wrong with the brake
• Tears system. If the anti-lock brake system warning light
stays on or comes on, something may be wrong with
• Leakage
the anti-lock brake system.
Replace damaged, torn or leaking seals.
Inspect the brake lines and the hoses for • Check the radiator hoses for cracking or for a
the following: spongy appearance. Replace deteriorated hoses
• Proper hookup or bursting could occur, resulting in coolant loss
and extensive damage from overheating.
• Binding
• Check the radiator core for leaks and for
• Leaks
accumulation of dirt that could obstruct the air
• Cracks passages and reduce heat transfer.
• Chafing, etc. • Check the coolant recovery reservoir for leaks.
Inspect the disc brake pads for wear. Inspect the • Inspect the radiator rubber mountings and
rotors for surface condition. Inspect the drum brake bumpers for deterioration. Replace these as
linings for wear and cracks. Inspect other brake necessary. Check the mounting bolts, the
parts, including the calipers, the wheel cylinders, supports, and the braces. Also, check for
the parking brake, etc. Check the parking damage to the radiator core, the side flanges,
brake adjustment. and the supporting components.
The brakes may need to be inspected more often if • Check for clearance between the fan blade, the
driving habits or conditions result in frequent braking. core, and the shroud. Check the fan attaching
bolts for tightness. Make sure no bolts are
Periodic Maintenance Inspection
missing. Replace the fan if any blade is bent.
(Cooling System Maint Recommend) The blade and the shroud should be equal
Notice: Do not spray cold water on a hot radiator. distance around the entire perimeter of the
shroud. Adjust the distance as necessary after
Notice: Do not use pressure greater than 138 kPa you make any adjustment to the fan or the fan
(20 psi) to test the radiator. Damage to the radiator mounting bracket and hub.
will result if a higher pressure is used.
• Inspect the filler cap seal. Replace the cap if
• Check the outside of the radiator for bent fins the following seal conditions apply:
or signs of leakage. Do not temporarily seal the
• Cracking
cooling system with a sealer type antifreeze or
coolant additive. • Separation
• Remove any stones from between the fins. • Deterioration
• Clean loose debris and road film from the • In order to help maintain efficient heat
radiator core with a quality grease solvent and dissipation, do an occasional external flush of
compressed air. For a more efficient cleaning, the radiator with water. This removes the
direct the stream of solvent at the front of the majority of dirt accumulation and foreign matter
core. Remove the radiator grille, the fan guard, from between the core fins. Using moderate
and the fan shroud in order to ensure a pressure, direct water from behind the core in
thorough cleaning. order to force out debris. Direct the water
stream in line with the fins in order to reduce
• Remove the radiator cap and look for plugging
the possibility of bending the fins.
and scale on the inside of the tank. Replace a
badly plugged radiator. Test the cooling system • A radiator with a dirty, obstructed, or leaking
and the radiator. core causes the engine to overheat. Radiator
scale deposits result from using water that is
• Check the coolant level. If the level is low, add
hard and has a high mineral content in the
the recommended coolant as required.
cooling system. Heat affects the minerals in the
• Check the condition of the' radiator hose water causing the formation of scale, or hard
clamps. Tighten the clamps if any leakage is coating, on the metal surfaces within the
seen. Replace the clamps if you see the radiator, reducing the transfer of heat. Some
following conditions: hard water produces a silt-like deposit that
• Cracked clamps restricts the flow of water. Replace a radiator
• Stripped clamps that is plugged, or has a heavy scale on
the core.
• Corroded clamps
General Information___________________________ Vibration Diagnosis and Correction 0-85
Vibration Diagnosis and Correction

Specifications
Specifications
A pplication M illim eters Inches
Aluminum Wheel
Lateral 0.762 0.030
Radial 0.762 0.030
Steel Wheel
Lateral 1.143 0.045
Radial 1.015 0.040
Tire and Wheel Assembly (Radial and Lateral)
Off-Vehicle 1.27 0.05
On-Vehicle 1.52 0.06
Wheel Stud 0.25 0.01
Wheel Hub 0.132 0.0052
One Piece Propeller Shaft Runout Propeller Shaft Balancing Weight Amounts
Application M etric English Correction, Total W eight Clam p Spread, Degrees
Front 1.016 mm 0.040 in 0.0 180
Center 1.27 mm 0.050 in 0.1 174
Rear 1.40 mm 0.055 in 0.2 169
0.3 163
Itao-Piece Propeller Shaft Runout 0.4 157
A pplication M etric English 0.5 151
Front 0.762 mm 0.030 in 0.6 145
Center 0.762 mm 0.030 in 0.7 139
Rear 0.889 mm 0.035 in 0.8 133
0.9 127
Pinion Runout
1.0 120
Application M etric English
1.1 113
Pinion Runout 0.076 mm 0.003 in
1.2 106
1.3 99
1.4 91
1.5 83
1.6 74
1.7 64
1.8 52
1.9 36
2.0 0
0-86 Vibration Diagnosis and Correction General Information
Diagnostic Information and The following questions should be asked when

attempting to identify a vibration complaint:
Procedures
• At what speed is the vibration the worst?
Vibration Diagnosis • Can the vibration be felt? If so, where?
The techniques and procedures for correcting the • Can the vibration be heard?
following types of vibrations are including in the road • Does the engine or the vehicle load affect the
testing diagnosis: vibration?
• Tire and wheel shake • Does the vibration occur in more than one gear
• Steering/suspension shimmy and shake range?
• Launch shudder • When did the vibration first appear?
• Exhaust moan The answers to these questions will help in
• Engine firing frequency duplicating and diagnosing the vibration.
If the vibration that has been duplicated is suspected
A Process of Elimination as being normal, compare the vibration with a
A few basic concepts must be understood before vehicle that is equipped, in the same way. The same
attempting to diagnose a vibration. As in any equipment should include the following:
diagnostic process, information must be gathered • Body style
and deciphered, and a correction made based on • Engine option
the results. Road testing and inspecting the vehicle
in a manner which systematically eliminates different • Engine driven accessories
components, in turn supplements the information • Transmission type
received from the customer concerning the • Tire size
complaint. Concentrating efforts on the areas that • Suspension performance type
have not been eliminated will make repairs faster
and more effective. • Axle ratio
Important: Once an attempt has been made to
Duplicate the Condition repair what may be a normal condition, the customer
All vehicles produce vibrations. Some vibrations are will likely be convinced that the vehicle has a
normal, while others are not. Some vibrations can be problem. Customer satisfaction becomes extremely
repaired, some cannot. The customer’s complaint difficult after this point.
must be duplicated or experienced. The vibration and
If necessary, make the comparison with the customer
the cause of the vibration must be evaluated under
present and explain the situation.
changing conditions. Otherwise, there is no way to
know for sure that you are fixing what the customer Purpose of Road Testing
would like fixed. The purpose of road testing is to duplicate the
The symptoms and characteristics of a noise or vibration complaint and to find any operating
vibration are also important information. Ask yourself conditions that change or eliminate the vibration.
the following questions before you begin: Most importantly, road testing will determine whether
• What does the vibration feel like? the vibration is related to the engine speed or the
• Does the vibration make noise? If so, what road speed.
does the vibration sound like? In order to complete a quick and accurate road test,
install an engine tachometer (such as a scan tool)
What Does the Vibration Feel Like? and the EVA in the vehicle. Place the EVA vibration
Different types of noise and vibration have particular sensor in a location where the customer’s concern
characteristics. These characteristics will help can be felt.
determine the cause of the condition, and the best Which Component Group is Causing
way to correct the condition. This is the reason for
the Vibration
duplicating the vibration.
After a vibration has been categorized as being
Identifying the Complaint engine or vehicle-speed related, the vibration can be
The first step in diagnosing a vibration complaint is broken down further to fit into one of the following
identifying the exact vibration that the customer is three groups of rotating components:
complaining about. • The engine, the clutch disc (manual
Sometimes the vibration can be duplicated at a given transmission), the propeller shaft (within the
speed. Other vibrations may not be as evident and driveline support assembly), the transmission
may require questioning the customer carefully. A flexplate (automatic transmission) and the
road test may need to be performed with the transmission torque converter
customer in the vehicle in order to point out the • The transmission output shaft and the rear axle
specific vibration complaint. differential pinion (mounted in the rear of
the differential)
• The tires, wheels, hubs, and rotors
General Information Vibration Diagnosis and Correction 0-87
These three groups represent the major areas that Road Test
can produce vibration complaints. The components in
each group are related to each other because they Tire and Wheel Inspection
are either bolted or splined together. This means that
each group of components rotates at the exact
same speed.
These categories can be broken down further in
order to identify the exact component responsible for
the disturbance. The emphasis is on testing (and
more testing) in order to pinpoint the source and to
eliminate unnecessary parts replacement.
Types of Road Tests
The following are the most often used and
informative road test procedures:
• Tire and Wheel Inspection
• Slow Acceleration Test
• Neutral Coast-Down Test
• Downshift Test
• Neutral Run-up Test
• Brake Torque Test
• Steering Input Test 70080
• Standing Start Acceleration Test The tires on all new GM models have a tire
(Launch Shudder) performance criteria (TPC) rating number molded on
Caution: These tests will help to pinpoint the the sidewall. The TPC rating will appear as a
vibration. Perform all of the tests on a smooth, four-digit number preceded by TPC SPEC on the tire
level road. Refer to Road Test Caution In wall near the tire size. A replacement tire should
General Information. have the same TPC rating.
Legend
(1) Hard Cornering, Under Inflation
(2) Excessive Toe on Non-Drive Axle
(3) Heavy Acceleration on Drive Axle,
Excessive Toe on Drive Axle, Over Inflation
This test should be performed for ALL vibration If the vibration still occurs in NEUTRAL, then the
complaints unless the disturbance occurs only with vibration is definitely vehicle-speed sensitive. At this
the vehicle at a standstill. point, the engine, the clutch disc (manual
transmission), the propeller shaft (located inside the
Inspect the tire and wheel assemblies for the
driveline support assembly), the transmission flex
following conditions: plate (automatic transmission) and the torque
• Unusual wear such as cupping, flat spots, and converter have been eliminated as a cause.
heel-and-toe wear Depending on the symptoms or frequency, the repair
(These conditions can cause tire growl, howl, will concentrate on the tire and wheel assemblies,
the transmission output shaft, the rear axle
slapping noises, and vibrations throughout
differential pinion, or the rear drive axle shafts.
the vehicle.)
• Proper inflation Downshift Test
• Bulges in the sidewalls Caution: Observe the necessary safety
(Not to be confused with normal ply splices, precautions. Refer to Road Test Caution in
Cautions and Notices.
commonly seen as indentations in the sidewall.)
• Bent rim flanges 1. On a smooth, level road, accelerate to the
speed at which the complaint vibration occurs.
Inspecting these characteristics of the tire and wheel
assemblies may lead to the cause of the vibration. Note the engine RPM.
At the very least, the inspection will provide 2. Decelerate and safely downshift to the next
assurance that the vehicle is safe for road testing. lower gear (from OVERDRIVE to DRIVE, or
from DRIVE to SECOND, etc.)
S low A cceleration Test 3. Operate the vehicle at the previous
engine RPM.
This test will identify the engine-speed or
vehicle-speed related conditions. Additional tests may If the vibration returns at the same engine RPM, the
be necessary in order to determine in which category engine, the clutch disc (manual transmission), the
propeller shaft (located inside the driveline support
the vibration belongs.
assembly), the transmission flex plate (automatic
Caution: Observe the necessary safety transmission), or the torque converter are the most
precautions. Refer to Road Test Caution in probable causes. You may repeat this test is still
Cautions and Notices. smaller gears, and in NEUTRAL, in order to confirm
the results.
1. On a smooth, level road, slowly accelerate up
In some cases, a vibration may be sensitive to
to highway speed. torque or engine load, as well as being related to a
2. Look for disturbances that match the specific engine (RPM) or vehicle (km/h / mph) speed.
customer’s description. These vibrations can be most difficult to diagnose,
3. Note the following readings where the and require additional testing. Still, following a
systematic approach usually leads to pinpointing
disturbance occurs:
the problem.
• The vehicle speed, km/h (mph)
• The engine speed (RPM) Neutral Run-Up Test
This test is designed to identify engine-speed related
• The frequency (if possible)
vibrations. Use this test when the customer
Following this test, perform the Neutral Coast-Down complains of vibration at idle, or as a follow-up to
Test and the Downshift Test. the downshift test. This test more than likely doesn’t
apply when the complaint is vehicle-speed related
N eutral Coast-Dow n Test only (appearing at the same vehicle speed
Caution: Observe the necessary safety regardless of the engine speed).
precautions. Refer to Road Test Caution in Caution: Observe the necessary safety
Cautions and Notices. precautions. Refer to Road Test Caution in
1. On a smooth level road, accelerate to a speed
slightly higher than the speed at which the 1. Slowly increase the engine speed while looking
vibration occurs. for disturbances that match the customer’s
complaint.
2. Shift the vehicle into NEUTRAL and coast down
2. Note at which engine speed (rpm) and
through the vibration range.
frequency (if possible) that the vibration occurs.
Note if the vibration is present in NEUTRAL.
Brake Torque Test Standing S tart A cceleration
This test is designed to identify engine-related (Launch Shudder) Test
vibrations that were not uncovered with the Neutral The purpose of this test is to duplicate a vibration
Run-Up Test. This test also works for vibrations that called launch shudder. In some cases, a powertrain
are sensitive to the engine load or to the torque. mount or an exhaust ground-out may also be
This test will more than likely not apply to suspected, depending on the symptoms.
vehicle-speed related only vibrations.
Caution: Observe the necessary safety
Caution: Observe the necessary safety precautions. Refer to Road Test Caution in
precautions. Refer to Road Test Caution Cautions and Notices.
in Cautions and Notices.
1. With the vehicle at a complete stop and in
1. Apply the parking brake. gear, remove your foot from the brake pedal.
2. Block the front wheels. 2. Accelerate to 48-64 km/h (30-40 mph) while
3. Step firmly on the brake pedal. looking for vibrations that match the customer’s
description.
4. Place the vehicle in Drive.
Other possible causes of launch shudder include the
5. Slowly increase the engine speed while looking
for vibrations that match the customer’s
description. • Incorrect trim height. Refer to Trim Height in
Suspension General Diagnosis.
6. Note the engine speed (rpm) and frequency (if
possible) at which the disturbance occurs. • A worn or damaged drive axle CV joint.
7. Repeat steps 4, 6, and 7 in Reverse, if • A ground-out engine/transmission mount.
necessary. • Faulty exhaust hangers and mounts.
A dditional Tests Classifying the Vibration
You can perform one or more of the following tests The next step after road testing the vehicle is to
for unique vibration complaints such as those that identify the frequency of the duplicated and abnormal
are torque/load sensitive, in addition to vehicle-speed vibration. Use the EVA in order to measure the
or engine-speed sensitive: frequency. If the EVA is not available, the frequency
• Steering Input Test can be categorized into groups according to how the
vibration feels or sounds. The majority of vibrations
• Standing Start Acceleration Test
will fit into one of the following categories.
Steering Input Test • Vibrations that can be felt:
This test is intended to determine how much the - Shake
wheel bearings and other suspension components - Roughness
contribute to the vibration, especially those relating to
noises such as growl, grinding, and roaring. - Buzz
- Tingling
Caution: Observe the necessary safety
precautions. Refer to Road Test Caution In • Vibrations that make noise:
Cautions and Notices. - Boom
1. Drive through slow sweeping turns with the - Moan and groan
vehicle at the vibration speed (mph) in one - Howl
direction, then in the other. - Whine
2. If the vibration gets worse or goes away,
inspect the following components as possible
causes of the vibration:
• The wheel bearings
• The hubs
• The tire tread
Vibrations That Can Be Felt NEEDLES sensation. Customers may say the
Shake vibration puts their hands or feet TO SLEEP.
Vibrations That Make Noise
Boom
Boom is a low frequency interior noise of 20-60 Hz.
Sometimes the customer complains of a pressure in
their ears. Examples of similar noises include a
bowling ball rolling down an alley, deep thunder, or a
bass drum.
A customer may use the following words to
describe boom:
• Droning
• Growling
• Moaning
• Roaring
• Rumbling
• Humming
Boom may not be accompanied by a perceptible
vibration (roughness).
Moan or Drone
Moan or drone is a sustained tone at a low
The shake is a low frequency vibration, typically frequency of 60-120 Hz, somewhat higher
5-20 Hz. The shake is sometimes seen in the than boom.
steering wheel, the seat, or the console. The best
Examples of similar noises include a bumble bee, or
description is the feeling from an out-of-round or
blowing air across the top of a soda bottle.
unbalanced tire. Customers may refer to shake in
Examples of words to describe moan or drone are
one of the following terms:
humming, buzzing, resonance. Moan or drone may
• Shimmy be accompanied by a perceptible buzzing vibration.
• Wobble Inspect the following systems:
• Shudder • The powertrain mounts
• Waddle • The exhaust system.
• Hop Howl
In most cases, damage to or wear of the following Howl is a noise at mid-range frequency of
components is to blame for the shake: 120-300 Hz. This sounds like the wind howling.
• The tires Whine
Whine is a prolonged, high-pitched sound in the
• The wheels
300-500 Hz range, and is usually related to the
• The brake rotors (vehicle-speed sensitive) meshing gears or gear noise. Similar sounds include
• The steering tie rod ends mosquitoes, turbine engines, and vacuum cleaners.
• The suspension ball joints Matching Frequency to Component Speed
• The engine (engine-speed sensitive) At this point in the diagnosis, the vibration has been
Roughness duplicated, designated as abnormal, identified as being
Roughness is a vibration with a slightly higher related to engine speed or vehicle speed, and
frequency than the shake, usually 20-50 Hz. assigned a frequency from the EVA or categorized into
Roughness is similar to the feeling you get from a symptom group based on how it feels or sounds.
holding a jigsaw. Automotive vibrations are usually related to the
Buzz rotating speed of a component. The speed of these
Buzz is slightly higher in frequency: 50-100 Hz. A components will be calculated using either an engine
buzz is similar to the feel of an electric razor. You speed or vehicle speed method. The engine rpm
may feel it in your hands through the steering wheel, readings taken during the road test will be used in
in the feet through the floor, or in the seat. Inspect diagnosing vibrations that are engine speed
the following components for a possible cause: sensitive. If the vibration is vehicle speed sensitive,
• The exhaust system the rotational speed of the tires needs to be
determined. As long as the vehicle is operated at a
• The A/C compressor
constant speed, the tires will operate at a constant
• The engine speed. These speed is measured in rotations or
Tingling cycles per second. The reading is then compared to
This is the highest frequency that can still be felt. the frequency of the vibration, which is also
Tingling may sometimes produce a PINS AND measured in cycles per second.
Calculating Tire Rotation
T IR E /W H E E L R O T A T IO N W O R K S H E E T
Vehicle Information
Complaint Speed:__________________________________mph Year: Model:
Symptom: __________________________________ VIN:
Frequency: __________________________________ Engine: Trane:
Engine Speed: __________________________________rpm Tire Size: Axle Ratio:
Gear: __________________________________ TPC Spec:
Tire/W heel Speed
V ib ra tio n
mph -r 8 (km/h) 5 (mph) Increments of 8 km/h /5m ph
Ocoureat:
8 km/h --------------- tire RPS Tire/Wheel Speed,

/5m ph x at 8 km/h RPS (Hz)
increments — / 5 mph 1st order
(from table)
1st order x2 2nd order
1st order x3 3rd order
*fV 6 -m o lu lio n « par tM o n A «quK M to o yo ltt p«r M oord (HQ.
95609
Determine the rotational speed of the tires in 3. Determine the vehicle tire size.
revolutions per second, or Hertz (Hz), based on the 4. Locate on the table below, the Hertz value at
vehicle speed at which the vibration occurs. In 8 km/h (5 mph) for that tire size.
order to determine the rotational speed, follow
this procedure: 5. Multiply the Hertz value by the number of
8 km/h (5 mph) increments.
1. Determine the complaint speed — the vehicle
speed at which the vibration occurs. 6. The result is the rotational speed of the tires in
Hertz at the complaint speed. If this figure
2. Determine the number of 8 km/h matches the vibration frequency, a first-order
(5 mph) increments: vibration is present in the tire and
• Divide the complaint speed by 8 when wheel assembly.
using km/h.
• Divide the complaint speed by 5 when
using mph.
Tire/Speed Table Tire and Wheel Vibration

Revs/Sec Tire and wheel assembly vibrations are the next level
of testing for low-frequency vibrations that are
Tire Size Tread at 5 MPH
vehicle speed sensitive. The tires, wheels, brake
P205/75R15 OOR 1.06 rotors and wheel hubs should be systematically
P215/75R15 ALS 1.05 tested, according to the symptoms.
P235/65R15 AL2 1.07 First-Order Tire and Wheel Assembly
ALS 1.00 Vibration
P235/70R15
OOR 0.99 The following are symptoms of first-order vibrations
caused by tire and wheel assemblies:
P235/75R15 ALS 1.00
• The vibration is always vehicle-speed related.
31X10.5R15/B OOR 0.95
If the vibration is affected by the speed of the
ALS 0.99 engine, or is eliminated by placing the
LT225/75R16
OOR 0.98 transmission in NEUTRAL, then the vibration is
ALS 0.95 not related to the tire and wheel assemblies.
LT245/75R16 • The vibration will feel like a SHAKE, usually in
OOR 0.94
the steering wheel or the seat:
LT265/75R16 OOR 0.90
- Tire and wheel vibrations that are felt in the
HWY 0.95 steering wheel are most likely related to the
LT215/85R16
OOR 0.94 front tire and wheel assemblies.
HWY 0.91 - Tire and wheel vibrations that are felt in the
LT235/85R16 seat or the floor are most likely related to the
OOR 0.90
rear tire and wheel assemblies.
HWY 0.90
7.50R16 This may not always hold true, but is a
OOR 0.90 general rule that may serve to initially
8.75R 16.5 HWY 0.98 isolate a problem to the front or the rear of
the vehicle.
225/70R 19.5 HWY 0.89
• The customer may complain of a WADDLE at
AL2 Touring
low speeds of 8 to 56 km/h (5 to 35 mph).
ALS All Season • The frequency on the EVA will correspond to
HWY Highway the first-order of tire rotation. This frequency will
OOR On/Off Road
usually be in the 10 to 20 Hz range, depending
on the speed of the complaint and the size of
the tire. The smaller the tire, the faster it will
Sometimes, the tire/wheel vibration may be of a
rotate at any given speed.
higher-order. In order to compute possible
higher-order vibrations, multiply the rotational speed • The range of the human ear begins at 20 Hz.
of the tires in Hertz at the complaint speed by the For this reason, first-order tire vibrations are
order number. If any of these matches the vibration rarely produce noise. The exception to this
frequency, then a vibration of that particular order is would be if the tires display an irregular tread
present in one of the tire and wheel assemblies. pattern or flat spots, causing a GROWLING or
SLAPPING noise.
Steering and Suspension Assembly Vibrations
Steering and suspension assembly vibrations are the
Tire and Wheel Runout Measurement
first level of testing for low-frequency vibrations that Measure wheel runout with an accurate dial indicator.
are vehicle-speed sensitive. The symptoms if a Measure with the wheel installed or with the wheel
steering/suspension first-order vibration are shimmy off of the vehicle. Use an accurate mounting surface
or shake, usually felt in the steering wheel or in the such as a wheel balancer. You can measure with or
seat. Inspect the following components for wear without the tire mounted on the wheel.
or damage: Measure radial runout and lateral runout on the
• The steering tie rod ends. inboard and outboard rim flanges. With the dial
• The suspension ball joints. indicator in position, rotate the wheel slowly one
revolution. Record the total indicator reading. If any
measurement exceeds the specifications, and if there
is a vibration that wheel balancing does not correct,
replace the wheel. Disregard any indicator readings
that are due to welds, paint runs, or scratches.
Radial Runout Lateral Runout
1
078
Legend
Legend
(1) Dial Indicator
(1) Dial Indicator
(2) High Spot
(2) Tire High Spot
(3) Low Spot*•
(3) Wheel High Spot
Unlike a perfect circle, the tire shape of radial runout (4) Wheel Low Spot
is oval. Measure radial tire runout from the center (5) Tire Low Spot
tire tread rib. You can measure other tread ribs. The
gauge reads the total runout. The high spot is the Lateral runout is a sideways variation of the wheel.
location of the maximum runout. If either flange is This runout causes a twist or a wobble. Measure
beyond specifications, replace the rim. lateral runout on a side surface. On the tire and
• Aluminum Wheels - 0.762 mm (0.030 in) wheel assembly, measure the side wall of the tire as
• Steel Wheels - 1.015 mm (0.040 in) close to the tread shoulder design edge as possible.
The gage reads the total runout. The high spot is
the location of the maximum runout. If either flange
is beyond guidelines, replace the rim.
• Aluminum Wheels - 0.762 mm (0.030 in)
• Steel Wheels - 1.143 mm (0.045 in)
Measurement Procedures Driveline Vibration Analysis with EVA
Do the following tire and wheel runout measurement:
1. Inflate the tires to specifications.
2. Warm up the tires before taking measurements.
This eliminates flat spotting. You do not need to
warm up newly installed tires.
3. Raise the vehicle on a lift.
If measurement is taken with the wheel off of
the vehicle, mount each tire and wheel
assembly on a dynamic balance machine.
4. Mark the tire and wheel assemblies for
exact replacement.
4.1. Mark a wheel hub bolt. Mark the hub
bolt’s exact position on the wheel.
4.2. Mark each tire and wheel assembly
for replacement on the exact
hub/rotor assembly.
5. Take a radial measurement or a lateral
runout measurement.
5.1. Place the dial indicator in position.
5.2. Rotate the tire and wheel assembly. Or The following components are possible sources of
rotate the wheel in order to find the driveline vibration:
wheel’s low spot. Adjust the dial indicator • The transmission output shaft
to read zero.
• The propeller shaft/s (driveshaft/s)
5.3. Rotate the tire and wheel assembly again
in order to verify the low spot location. • The union flange
The dial indicator must return to zero. • The pinion gear
Disregard any dial activity due to welds, The above components are either bolted or splined
paint runs, or scratches on the wheel. together. Therefore, all of the components rotate at
5.4. Rotate the tire and wheel assembly, or the same speed, vibrate at the same frequency and
rotate the wheel. Note the amount of have the same symptoms.
variance (runout) from zero. Locate the Driveline vibrations may relate either to the first or to
high spot. Mark the high spot. the second order of driveline rotation. Driveline
6. If there is a large difference in runout vibrations are always related to the speed of the
measurements from on-vehicle to off-vehicle, vehicle. The vibration is often related to torque. If the
excessive runout of the bolt circle or the hub vibration is worse or only noticeable when
may be causing the problem. accelerating, decelerating, or crowding the throttle,
7. If the measured runouts are not within then the vibration is related to the torque. The
specifications, vector the tire and wheel vibration will always occur at the same speed. If a
assembly in order to correct the problem. vibration is both torque and speed sensitive, the
driveline is the probable cause. Tire/wheel vibrations
are speed sensitive, but not torque sensitive.
First-Order Driveline Vibration Symptoms
The following symptoms may indicate first-order
driveline vibration:
• The vibration is related to vehicle speed.
• The vibration is torque sensitive.
• A '"boom"' or "moan" noise is present.
• The vibration occurs commonly above 72 km/h
(45 mph), but possibly as low as 48 km/h
(30 mph).
• The "roughness" or "buzz" vibration is felt in
the seat, floor or steering wheel.
• The corresponding frequency on the EVA
equals first-order driveline rotation (25-60 Hz),
depending on the speed of the vehicle and the
ratio of the axle. Refer to the worksheet in
order to obtain the rotation speed of the
propeller shaft.
Driveline Vibration Analysis 176032
Once you identify a vibration that is related to the Hold the EVA sensor against the pinion nose and
driveline, continue testing in this service area. The the transmission tailshaft assembly in order to
following components are possible sources of determine which end of the propeller shaft has the
first-order driveline vibration: most vibration. The end that has the most vibration
• The propeller shafts will have a higher amplitude on the EVA.
• The transmission output shaft If the vehicle has a two-piece propeller shaft, inspect
• The pinion flange the center support bearing.
• The pinion gear If the transmission tailshaft vibrates, inspect the
transmission crossmember under the transmission
Locate the Source of Driveline Vibration with mount. If the mount is secured properly, there should
the EVA be no vibration at the crossmember.
Caution: Never run the vehicle faster than
112 km/h (70 mph) when performing propeller
Runout and Balance Testing with the EVA
shaft vibration or checking for balance. Stay
clear o f rotating components and balance
weights to avoid personal Injury. Do not run the
vehicle on the hoist for extended periods o f time
to avoid engine or transmission overheating. Do
not step on the brake pedal with the brake
drums removed.
In order to pinpoint the source of vibration,
reproduce the vibration with the vehicle in the
service stall. Then determine which component is
vibrating the most using the EVA and the
following procedure:
1. Raise the vehicle to curb height. Support the
vehicle on a hoist or on safety stands. Do not
allow the axle to hang. Refer to Vehicle Lifting
and Jacking in General Information.
2. Remove the rear tire/wheel assemblies. Refer
to Wheel Removal in Tires and Wheels.
3. Remove the brake drums.
4. Ensure that the propeller shaft is free
of undercoating. Ensure that the runout of the various driveline
components are within specifications. If the runouts
5. Inspect the propeller shaft and U-joints for
are within specifications, strobe balance the driveline,
dents or damage.
The EVA is able to simplify the balancing process.
6. Start the engine. Use the following procedure:
7. Place the transmission in gear. 1. Use the EVA in order to determine which end
8. Run the vehicle at the speed which the of the propeller shaft has the most vibration.
vibration occurs.
2. Mark the end of the propeller shaft (1) that has 15. Turn the engine off.
the most vibration at four points (2), 90 degrees 16. Install a weight directly on the light spot.
apart. Number the marks 1 through 4.
17. Start the engine.
3. Mount the EVA sensor onto the bottom of the
18. Run the vehicle at peak vibration speed.
following components:
19. Strobe the propeller shaft again.
• The differential housing
The propeller shaft is balanced if the strobe image is
• The center bearing support (for two-part erratic and the amplitude is near two.
propeller shafts)
The propeller shaft is not balanced if one of the
• The transmission tailshaft assembly following conditions exist:
4. Position the sensor as close to the propeller • The weight and the original light spot are at
shaft as possible. Ensure that the UP side of the 6 o’clock position — This condition means
the sensor faces up. Ensure that the sensor that there is not enough weight on the
is horizontal. propeller shaft.
Notice: Do not use cruise control to maintain In order to correct the balance, add a second
vehicle speed. weight next to the first weight. Inspect the
5. Start the engine. balance again using the strobe light.
6. Turn off all engine accessories.
7. Place the transmission in gear.
8. Run the vehicle at the speed which causes the
most vibration in the propeller shaft.
9. Hook the timing light clip to the trigger wire.
10. Plug the vibration sensor into Input A of
the EVA. Input B does not have strobe
light capability.
11. Verify that the predominant frequency on the
EVA display matches the frequency of the
original vibration. Use the strobe light only if the
rotation speed of the propeller shaft is the
predominant frequency.
12. The EVA displays a series of questions in order
to select the correct filter. Press YES in order
to select the desired filter. Ensure that the
frequency is in the middle of the filter range.
Use the full range only as a last resort.
13. The EVA displays the test frequency, the
amplitude and the filter range. The driveline is
If the weights are now between 90 and
balanced when the amplitude is near two. In
180 degrees off (between the 9 and the
some cases a slightly higher amplitude will
3 o’clock positions) there is too much weight. In
provide adequate balance.
order to correct the balance, split the two
14. Point the timing light at the propeller shaft. The weights equally on either side of the original
strobe effect will appear to freeze the propeller light spot. Splitting the weight will produce a
shaft. Note which of the numbered marks is at total weight between one and two weights.
the bottom of the propeller shaft (the 6 o’clock
Inspect the balance again using the strobe light.
position). This position is the light spot.
Adjust the weights as necessary.
• The weight and original light spot are 90 to 4. Touch the pinion nose, or hold the EVA
180 degrees off (between the 9 and the vibration sensor up to the pinion nose.
3 o’clock positions) — This condition means 5. Use another technician in order to accelerate
that one weight is too much. and decelerate the vehicle through the speed
In order to correct the balance, split the two range at which the vibration was noticed during
weights equally on either side of the original the road test.
light spot, in order to produce a total weight Example
less than one (between 120 and
180 degrees apart). • If the vibration was originally noticed at
88 km/h (55 mph), accelerate from 72 km/h
Inspect the balance again using the strobe light. (45 mph) to 107 km/h (65 mph). Then
Adjust the weights as necessary. decelerate from 107 km/h (65 mph) back to
• The weight and the original light spot are within 72 km/h (45 mph).
180 degrees of the 6 o’clock position. • Repeat the above step and note whether or
Move weight towards the 6 o’clock position. not the pinion nose vibrates under load
Inspect the balance again using the strobe light. during acceleration and/or deceleration.
Adjust the weight as necessary. Refer to the If the vibration does not occur during the above
previous two conditions. procedure, install the brake drums and the tire/wheel
If the shaft will not balance using two weights, then assemblies. The brake drums and tire/wheel
place a third weight on the light spot. Split the first assemblies will add additional load on the system.
two weights in order to produce a total weight Then repeat the above test.
between two and three weights. Ensure that both axle shafts rotate at the same
If three weights fail to balance the driveline, replace speed. The differential may mask a vibration when
the propeller shaft. one tire is spinning faster than the other tire. Adjust
When the propeller shaft balances, road test the the brakes in order to correct unequal tire
vehicle in order to verify that the vibration rotation speed.
is eliminated. If you are unable to reproduce the vibration in the
stall, apply the brake lightly in order to load the
First-Order Driveline Vibration Analysis system further. Maintain the vehicle speed at which
(Torque Sensitive) the vibration was noticed. Do not overheat
If the vehicle has a vibration that is equal to the brakes.
first-order driveline rotation, and the vibration is not If the pinion nose vibrates under acceleration and/or
present when testing the vehicle in the stall, then deceleration, and the other driveline components are
internal rear axle components are the probable eliminated as the cause of the vibration, then one of
cause of the vibration. the following conditions may cause the vibration:
Internal rear axle components are also the probable • A high spot on the pinion gear
cause of the vibration if you were able to correct the
• A bent pinion stem
vibration in the stall, but the vibration returned during
the road test. Internal rear axle vibrations may be • A cocked pinion bearing
aggravated by the load of the vehicle working • An improper axle housing bore
against the ring and pinion gear seat. Anything that effects the pinion gear and how the
Since the propeller shaft and the pinion gear are pinion gear contacts the rotating ring gear may
bolted together through the pinion flange, the contribute to a first-order, torque-sensitive driveline
propeller shaft and the pinion gear operate at the vibration. The only way to correct the condition is to
same speed. Vibration in the pinion gear will replace the faulty components. In most cases, the
therefore have the same frequency and symptoms ring and pinion gear set and the related bearings
as the propeller shaft. must be replaced. In some case, however, the axle
In order to isolate the vibration to the pinion gear, housing must be replaced. Complete a close-up
use the following procedure: visual inspection for damage or unusual wear in
order to measure or identify the specific
1. Raise the vehicle to curb height. Support the faulty component.
vehicle on a hoist or on safety stands.
Refer to Vehicle Lifting and Jacking in It is possible to isolate an internal axle vibration.
General Information. Install a "known good" axle assembly from a stock
unit. Verify that the "known good" axle assembly
2. Remove the tire/wheel assemblies. Refer to does not have a vibration problem.
Wheel Removal in Tires and Wheels.
Once you correct the internal axle problem, road test
3. Remove the brake drums. Refer to Brake Drum the vehicle. Inspect the vehicle for vibration. Balance
in Drum Brakes.
the driveline as necessary in order to eliminate any
remaining vibration.
0-98 Vibration Diagnosis and Correction ______________ General Information
Second-Order Driveline Vibration Theory Canceled Out Driveline Angles
162180
A faulty universal joint (U-joint) may cause a Legend

vibration that occurs twice for each rotation of the (1) Front Working Angle
propeller shaft. This type of vibration is called a (2) Rear Working Angle
second-order vibration.
Second-order driveline vibrations are independent of Engineers design drivelines in order to compensate
runout or balance of a driveline component. for the accelerations and decelerations in order to
The following description of basic U-joint theory will produce a smooth, constant flow of power, as
help you to understand where second-order driveline listed below:
vibrations originate and why they occur. • The transmission drives the front yoke of the
• As the propeller shaft rotates, the U-joints propeller shaft at a smooth and constant speed.
speed up and slow down twice for each rotation • The first U-joint causes the power to fluctuate
of the propeller shaft. twice for each revolution of the propeller s h a ft.
• The acceleration and deceleration of the • The second U-joint, oriented 90 degrees from
U-joints is not visible. If there is vibration in the the first U-joint, causes the power to fluctuate
U-joints, the acceleration and deceleration will opposite that of the first U-joint.
be audible and tactile. • As the first joint slows down, the second joint
• Compare the U-joint in a vehicle to a speeds up.
universal-type socket. When a universal-type This design causes one U-joint to cancel out the
socket is used to tighten a bolt, the socket will effect of the other U-joint. The cancelled effects
"'bind and release"' as the socket turns toward result in a smooth, constant power flow from the
90 degrees. The "bind and release" occurs output yoke of the propeller shaft.
twice for each revolution of the socket. Second-order driveline vibrations occur when the
• The U-joint in a vehicle works in the same way cancellation become unequal between the front and
as the universal-type socket. The "bind and rear U-joints.
release" effect is directly proportional to the
angle that the U-joint operates: the greater the Second-Order Driveline Vibration Symptoms
angle, the greater the effect.
Second-Order driveline vibration has the following
. Because the transmission output speed is signs and symptoms:
constant, the binding and releasing of the
U-joints is better described as an acceleration • The vibration is always related to
and deceleration which occurs twice for each vehicle speed.
revolution of the propeller shaft. • The vibration is usually torque-sensitive.
• If the propeller shaft is running slowly, the • The vibration is worse under a torque load.
accelerating and decelerating effect is visible. Launch shudder is the most common complaint of a
The acceleration and deceleration may create a second-order driveline vibration.
vibration due to the fluctuations in force that
are generated at high speeds.
Launch shudder occurs during acceleration from vibration is probably engine-speed related. Any
0-40 km/h (0-25 mph). Launch shudder appears as a disturbance or vibration that is present during the
low frequency shake, wobble, or shudder. The driver following road tests would be considered
may feel the vibrations in the seat or steering wheel engine-speed related:
at low speeds [0-24 km/h (0-15 mph)]. The vibrations • The Neutral run-up test
will increase in frequency as the vehicle speed
increases. Launch shudder feels more like driveline • The downshift test
roughness at higher speeds [24-40 km/h • The brake torque test
(15-25 mph)]. At speeds greater than 40 km/h Any vibration that is present during the Neutral
(25 mph) the vibration usually disappears. coast-down test is not engine-speed related. The
Launch shudder vibration is equal to a second-order engine-related vibrations covered in this diagnosis
vibration of the driveline. The EVA will not perceive are engine-speed sensitive only.
frequency information due to the transitory nature of
First-Order Engine Imbalance
launch shudder.
Notice: Do not accelerate against the brakes for
Engine Related Vibration longer than 10 seconds. Do not overheat the engine
or the transmission. Depending on the vehicle
Engine vibration is usually due to one or more of the design, the engine will only accelerate to a certain
following conditions: point under these conditions. Also, care should be
• First-order engine imbalance taken during diagnosis as some disturbances may be
• Inherent engine firing sequence created during brake torque that normally do
not exist.
• Inherent shaking engine forces
• Engine-driven accessories Notice: Proper flywheel installation requires carefully
WALKING the flywheel onto the crankshaft and
Because these vibrations are engine-speed related, stagger-tightening the bolts. Proper torque converter
they are also normally torque sensitive. These to flywheel installation then requires gradually
vibrations may appear and disappear at different WALKING the torque converter to be flush with the
vehicle or road speeds, but will always appear at the flywheel, prior to installing the bolts. Do not draw the
same engine speed. torque converter to the flywheel with the bolts. If
For example, if a customer states that a vibration is these precautions are not followed, warping or
present at 40 km/h (25 mph), 64 km/h (40 mph), and bending of the flywheel and/or damage to the
again at 104 km/h (65 mph), and that the symptoms transmission torque converter may result.
of the vibration are similar at all of these speeds, the
Components Contributing to First-Order Engine Imbalance
95610
Engine imbalance is a condition that exists when a 6. Tie up the converter, away from the flywheel.
component that rotates at crankshaft speed is either 7. Perform the Neutral run-up test again. Refer to
unbalanced or has excessive runout. In rare cases, Road Test.
the crankshaft may be unbalanced. In any case,
• If the flexplate shows any wobble or lateral
balancing the component or correcting the runout
runout, replace the flexplate. Refer to Engine
may bring the disturbance to an acceptable level.
Flywheel Replacement (Automatic
Symptoms Transmission) in Engine Mechanical.
• Vehicle shake at low speeds of 500-1200 rpm, • Reindex the torque converter in three
or 8-20 Hz different positions. If the disturbance still
exists, replace the torque converter.
• Roughness and BOOM at higher speeds of
1200-3000 rpm, or 20-50 Hz 8. If the vibration still exists, inspect the propeller
shaft runout.
• Vibration usually detected during the Neutral
run-up test 9. If the vibration still exists, inspect the
harmonic balancer.
Isolating the Components 10. If the vibration still exists, the problem is related
1. Perform the Neutral run-up test, noting the rpm to residual engine imbalance. Refer to the
at which the vibration is the worst, and the procedure below.
severity. Refer to Road Test.
2. Inspect all powertrain mounts. Repair or replace
Correcting Residual Engine Imbalance
as needed. 1. Install washers on the harmonic balancer
pulley bolts.
3. Inspect for any bindings or ground-outs in the
exhaust system. 2. Replace bolts with longer bolts of equal
hardness as needed.
Important: The following steps apply to
A/T-equipped vehicles only. 3. (M/T only): Inspect the flywheel and the
pressure plate for the following conditions:
4. Matchmark the torque converter and
the flywheel. • Correct factory indexing. (The white paint
spot on the flywheel and the pressure plate
5. Disconnect the torque converter from the should line up.)
propeller shaft, pushing the converter back from
the flywheel. • Warping
• Balance
Excessive Inherent Engine Firing Frequency Engine Vibration Diagnosis with the EVA
Engine Speeds and Frequencies

Firing INPUT A INPUTS
Type of First O rder Frequency
Vibration rpm Hz V8 Fourth O rder
500 8.3 33.2 |KCMT£M:<£<5R!E
Shake 750
1000
12.5
16.6
50.0
66.4
1500 25.0 100.0
Roughness 2000
2500
33.3
41.6
133.2
166.4
3000 50.0 200.0
Buzz 3500 110.6 233.2
4000 132.4 266.4
Firing frequency is a term used to describe the

pulses created as the engine fires each cylinder. All 95611
engines have a firing frequency — but the object is 1. Place the EVA vibration sensor on the seat
to keep these disturbances from entering the track rail with the UP label facing upward.
passenger compartment. Initially, inspect for the
2. Plug the EVA into a 12-volt power supply.
3. Prepare the EVA for data recording:
• The engine and the exhaust system are
mounted in a relaxed position. 3.1. Press RECORD.
• All of the mounts and hangers should be in 3.2. Select a snapshot tag number.
good condition and correct for the application. 3.3. Press ENTER in order to begin
• No components, hoses, or lines are grounding recording.
to the frame or to the body. 4. Slowly accelerate until the vibration occurs.
The frequency of these disturbances will depend on 5. Note the vehicle and engine rpm where the
the number of cylinders. The engine order will disturbance occurs.
always be equal to one-half the number of cylinders. 6. Press ENTER on the EVA in order to record
This is because a four-stroke engine requires two
the vibration data.
complete revolutions of the crankshaft in order to fire
all of the cylinders. 7. Perform the road test diagnoses in order to
determine engine-speed or vehicle-speed
For example, a V8 engine will fire cylinders 1, 3, 5,
sensitivity. Refer to Road Test
and 7 on the first revolution. Cylinders 2, 4, 6, and 8
will fire on the second revolution. This results in four Engine Firing Frequency Symptoms
firing pulses per revolution of the crankshaft, or
• The vibration may be torque sensitive.
fourth order.
• The vibration is engine-speed related.
• The vibration is heard as a boom or a moan.
• The vibration is felt ass shake, roughness, or
buzz (depending on the number of cylinders).
• The vibration excites the resonance of a system
or a component, causing the system or the
component to have a narrow rpm range.
The key to correcting these types of complaints is to
isolate the vibration from the passenger compartment
or the body.
Diagnosis and Repair of Engine Firing Inherent Engine Shaking Forces
Frequency-R elated Vibrations
1. Raise and suitably support the vehicle. Refer to Engine O rder Vibration Table
Vehicle Lifting and Jacking in General Engine O rder V8 90*
Information.
1/2 Order Torque Sensitive Single Cylinder Misfire
Caution: Take the necessary safety
1st Order Imbalance Abnormal
precautions. Refer to Work Stall Test
Caution in Cautions and Notices. 1.5 Order Torque Sensitive —
3. Attempt to duplicate the vibration. 2nd Order Abnormal

4. While the vibration is present, find the area(s) 2nd Order Torque Sensitive Bank-to-Bank EGR/Fuel Var.
of the vehicle excited by the vibration.
3rd Order Torque Sensitive —
5. Inspect for witness marks due to a
4th Order Torque Sensitive Normal
rubbing component.
6. Isolate the component and re-evaluate
the vibration.
7. Inspect for proper torque on the excited
component(s). Tighten as needed.
8. If the vibration still exists, proceed to the
procedure below.
Engine Firing Frequency-R elated Vibration
Causing Com ponents
1. Inspect for collapsed engine mounts.
Replace as needed. Refer to Engine Mount
Replacement (Front K Model) in
Engine Mechanical.
2. Inspect the exhaust hangers.
• Exhaust systems can expand one to two
inches when hot.
• Remove the hangers one at a time.
• Adjust or replace as needed.
3. Lubricate the manifold flexible coupling. 163028
4. Inspect the A/C and P/S lines. Just like firing frequency, some engine disturbances
• Isolate the hoses from the body. are the result of normal operation. Some engines
• Install the retainers. can have additional inherent vibration due to the
cylinder arrangement, the design, and the
5. Inspect the drive belts for whipping. firing order.
6. Inspect the accessory unit fasteners for damage Before attempting to repair a disturbance, compare
or looseness. the disturbance to another known good vehicle.
7. Inspect the body panels for missing or Although some vibrations could be normal, they may
loose welds. not be pleasant to the customer.
8. Remove any aftermarket equipment that The key to resolve an inherent engine disturbance is
may complete a transfer path into the to isolate the vibration from the passenger
passenger compartment. compartment. Follow the same procedures as
9. Inspect the exhaust system and powertrain outlined for the engine firing frequency-
mounts. Re-bed the engine and align the related vibrations.
exhaust system as follows if needed:
• Loosen the mounts and hangers.
• Tighten all fasteners with the powertrain in
the relaxed position.
Some residual vibrations may be normal. Compare
the vibrations with a similar vehicle to get a feel for
what is commercially acceptable, preferably with the
customer present. Also, refer to bulletins for
updates on the use of mass damper weights
for specific applications.
Engine-Driven Accessories Diagnosis
1. Compare the vibrations to a known good
vehicle in order to ensure they are abnormal.
2. Remove the drive belts.
3. If the vibration stops, perform the
following steps:
3.1. Install the drive belts.
Important: The drive belts drive all of
the engine accessories. Therefore, one
component may affect another.
3.2. Operate each accessory one at a time in
order to see which has the most effect
on the vibration.
4. Inspect for accessory load affecting the engine
firing frequency.
5. Inspect the pulleys for misalignment or bends.
Repair or replace as needed.
6. Inspect the A/C system for overcharging.
Evacuate and Recharge as needed. Refer to
Evacuation and A.C Charging in HVAC Systems
Engine driven accessories that exhibit vibration pose with A/C - Manual.
some special challenges. For example, the drive 7. Inspect the engine oil level. Add or drain
belts can no longer be removed one at a time in as needed.
order to isolate the condition. If removing the belt
eliminates the vibration, reinstall the belt and operate
each accessory one at a time in order to see which
has the most effect on the vibration. However, one
component may affect another because the drive belt
drives all of the accessories.
Inspect that the accessory load is not exciting the
engine firing frequency.
Repair Instructions Methods of Measuring Tire/Wheel Assembly

Runout
General Service Precautions The tire and wheel assembly runout will directly
Caution: One or more o f the following guidelines affect the amount of the imbalance and the radial
may apply when performing specific required force variation. Therefore, correct the runout first
tests In the work stall: before further diagnosis. The less runout, the less
1. When a test requires spinning the drive imbalance and radial force variation. Radial and
wheels with the vehicle Jacked up: lateral runout can be corrected at the same time.
There are two methods for correcting the tire and
• On vehicles equipped with a limited-slip
wheel assembly runout:
differential, do not attem pt to spin one
drive wheel with the other wheel on the • The on-vehicle method, with the tire and wheel
ground. The vehicle may drive through assembly mounted on the hub. The wheel
this wheel and cause the vehicle to move bearing must be in good condition.
unexpectedly, or drive off the safety • The off-vehicle method, with the tire and wheel
stands. This may result In personal Injury assembly mounted on a spin-type tire balancer.
or damage. Perform the following initial on-vehicle inspections
• Do not exceed 56 km/h (35 mph) when prior to the off-vehicle runout checks:
spinning one drive wheel with the other 1. Inspect the tires for any uneven bead seatings.
drive wheel stopped. This lim it Is The distance from the edge of the ring to the
necessary because the speedometer concentric rim locating ring should be equal
Indicates only one-half the actual wheel around the entire circumference.
speed under these conditions. If all drive
wheels are spinning a t the same speed, 2. Properly mount the tires if the beads are not
do not exceed 112 km/h (70 mph). seated properly in order to avoid excessive
Personal Injury may result from excessive runout and imbalance.
speed wheel spinning. A ll persons should
stay clear o f rotating components and
balance weight areas to avoid possible
personal Injury.
• When running an engine In the repair
stall for an extended period o f time,
use care not to overheat the engine
and transmission.
2. When a test requires Jacking up the vehicle
and running with the wheels and brake
drum removed:
• Do not apply the brake with the brake
drums removed.
• Do not place the transmission In Park
with the propeller shaft still spinning.
• Turn off the ignition to stop the
powertrain components from spinning.
Correcting Tire and Wheel Vibration
A first order tire and wheel vibration is usually the 95617
result of one of the following five conditions: The off-vehicle method is the easiest way of
• Excessive radial runout measuring the tire and wheel runout. Properly
• Excessive lateral runout mounting the dial indicator in the correct location in
relation to the tire (1) is easier. The dial indicator is
• Excessive imbalance
less likely to be subjected to water, snow, dirt, or
• Excessive radial force variation other elements. After measuring the correct runout
• Excessive lateral force variation off-vehicle, inspect the runout with the tire and wheel
These conditions must be eliminated one at a time assembly mounted on the vehicle. The runout
in order to attain a set of tires that are free from measurement may vary greatly between these two
vibration causing elements. Substitute a set of tires methods. If so, the runout is due to one of the
from another vehicle only as a last resort, and only following conditions:
after the tires have been tested on a similar vehicle • Stud circle runout
under the same conditions. Correcting the existing • Hub flange runout
tire and wheel assemblies is the most accurate and
least time consuming approach. This is due to • A mounting problem between the wheel and
vehicie-to-vehicie sensitivities and the differences the vehicle
between the hubs of any two vehicles.
Measuring Tire/Wheel Assembly Runout
If the vehicle has been sitting in one place for an
extended period of time, the tires may develop flat
spots at the point where the tires were resting on
the ground. These flat spots will affect the runout
readings. In order to eliminate these flat spots, drive
the vehicle long enough to warm up the tires. The
flat spots must be eliminated prior to taking any
runout measurements.
Measurement Procedure
1. Raise and suitably support the vehicle. Refer to
Vehicle Lifting and Jacking in General
Information.
2. Obtain an initial indication of how much
runout exists:
2.1. Spin the each tire and wheel assembly
on the vehicle by hand (or at a slow
speed using the engine to run the
drive wheels).
2.2. Visually inspect the amount of runout
from the front or rear of the tire.
3. Matchmark the each of the tire and wheel
assemblies in relation to the wheel studs and to
their position on the vehicle (LF, LR, RF, RR)
for future reference.
4. Remove the tire and wheel assemblies one at a
time and mount on a spin-type wheel balancer.
Refer to Wheel Removal (Single Wheels) in
Tires and Wheels.
Locate the tire and wheel assembly on the
balancer with a cone through the back side of an all-season or aggressive tread pattern with
the center pilot hole. tape (1), in order to accurately measure the
radial runout.
6. Measure the tire and wheel assembly
radial runout.
6.1. Slowly rotate the tire and wheel
assembly one complete revolution and
ZERO the dial indicator on the low spot.
6.2. Rotate the assembly one more complete
revolution and note the total amount of
runout indicated.
Maximum Radial Runout
• Measured off-vehicle: 1.27 mm
(0.050 in)
• Measured on-vehicle: 1.52 mm
(0.060 in)
9. Install the tire and wheel assembly to the
vehicle. Refer to Wheel Removal (Single
Wheels) in Tires and Wheels.
10. Repeat the procedure until all the wheel
runouts have been measured.
11. Lower the vehicle.
Measuring Wheel Runout
If tire and wheel assembly runout cannot be brought
within tolerance, measure the wheel runout.
If any runout measurement of a wheel exceeds
specifications, the wheel should be replaced.
(ALWAYS measure the runout of a new wheel.)
If the runout of the wheel is within tolerance, and the
tire and wheel assembly runout cannot be reduced
to an acceptable level, the tire should be replaced.
(ALWAYS measure the tire and wheel assembly
runout after replacing the tire.)
Measurement Procedure
1. Raise and suitably support the vehicle. Refer to
Vehicle Lifting and Jacking Vehicle Lifting and
Jacking in General Information.
2. Matchmark the each of the tire and wheel
assemblies in relation to the wheel studs and to
their position on the vehicle (LF, LR, RF, RR)
for future reference.
3. Remove the tire and wheel assemblies one at a
time and mount on a spin-type wheel balancer.
176958 Refer to Wheel Removal (Single Wheels) Wheel
7. Measure the tire and wheel assembly Removal in Tires and Wheels.
lateral runout. Locate the tire and wheel assembly on the
balancer with a cone through the back side of
Lateral runout should be measured on a
the center pilot hole.
smooth area of the sidewall as close to the
tread as possible. Ignore any jumps or dips due
to sidewall splices and attain an average
amount of runout.
runout indicated.
Maximum Lateral Runout
• Measured off-vehicle: 1.27 mm
(0.050 in)
• Measured on-vehicle: 1.52 mm
(0.060 in)
8. Make the necessary repairs to the tire and
wheel assembly.
176966
4. Measure the wheel radial runout on the outside
of the wheel (with the tire mounted), if the
wheel design allows.
Wheel runout should be measured on both the
inboard and outboard rim flanges. Ignore any
jumps or dips due to paint drips, chips,
or welds.
runout indicated.
Aluminum Wheel Maximum
Radial Runout
0.762 mm (0.030 in)
176960
7. Measure the wheel radial runout on the inside

of the wheel.
inboard and outboard rim flanges, ignore any
or welds.
7.1. Slowly rotate the wheel one complete
revolution and ZERO the dial indicator on
the low spot.
7.2. Rotate the wheel one more complete
runout indicated.
Radial Runout
0.762 mm (0.030 in)
5. Measure the wheel lateral runout on the outside

of the wheel (with the tire mounted), if the
wheel design allows.
or welds.
runout indicated.
Aluminum Wheel Maximum Lateral
Runout
0.762 mm (0.030 in)
6. If the wheel design does not allow runout
measurements to be made with the tire 176964
mounted, dismount the tire from the wheel.
Refer to Tire Mounting and Dismounting in
Tires and Wheels.
8. Measure the wheel lateral runout on the inside
of the wheel.
or welds.
8.1. Slowly rotate the wheel one complete
revolution and ZERO the dial indicator on
the low spot.
8.2. Rotate the wheel one more complete
runout indicated.
Lateral Runout
0.762 mm (0.030 in)
9. Make the necessary repairs to the tire and
wheel assembly.
10. Install the tire and wheel assembly to the
vehicle. Refer to Wheel Removal (Single
Wheels) in Tires and Wheels.
11. Repeat the procedure until all the wheel
runouts have been measured.
12. Lower the vehicle.
Balancing Tires and Wheels
Caution: Failure to adhere to the following
precautions before tire balancing can result In
personal Injury or damage to components:
95621
1. Clean away any dirt or deposits from the
Inside o f the wheels. Tire and wheel balancers can drift out of calibration
2. Remove any stones from the tread. without warning, or can become inaccurate as a
result of abuse. The balancer calibration should be
3. Wear eye protection. inspected every two weeks, and whenever the
4. Use coated weights on aluminum wheels. readings are questionable.
Important: The tires can be balanced either Tire Balancer Calibration Test
on-vehicle or off-vehicle, but the off-vehicle balancing
procedures are recommended. Off-vehicle methods 1. Spin the balancer without a wheel or any of the
are better because tire rotation will not affect the adapters on the shaft.
balancing. The off-vehicle balancers are also more 2. Inspect the balancer readings.
accurate than the on-vehicle balancers. Off-vehicle Specification
balancers can perform dynamic,balancing as well as
static balancing. 0.00-0.25 oz
3. Balance a tire and wheel assembly that is
within radial and lateral tolerances to ZERO.
4. Add a 3 ounce test weight to the wheel at
any location.
5. Spin the tire and wheel assembly again, noting
the readings.
• In the static and dynamic modes, the
balancer should call for 3 ounces of weight,
180 degrees opposite the test weight.
• In the dynamic mode only, the weight should
be called for on the flange of the wheel
opposite the last weight.
6. With the assembly unbalanced to 3 ounces,
cycle the balancer 5 times.
7. Take the balancer readings:
Specification
Variation: 0.25 oz or less
8. Index the tire and wheel assembly at four Most off-vehicle balancers are capable of checking
separate locations on the balancer shaft, both types of balance simultaneously.
90 degrees apart. As a general rule, most vehicles are more sensitive
9. Cycle the balancer with the assembly at to static imbalance than to dynamic imbalance, with
each location. as little as 0.50-0.75 oz capable of inducing a
10. Take the balancer readings: vibration in some vehicles. Vibration induced by
Specification static imbalance will cause a vertical or BOUNCING
motion of the tire.
Variation: 0.25 oz or less
Dynamic imbalance results in a side-to-side motion
Tire Balancing Guidelines of the tire. This motion is referred to as SHIMMY.
Static and dynamic balance are two kinds of • Balance all four tires as close to ZERO
tire/wheel balance: as possible.
• Carefully follow the wheel balancer
manufacturer’s instructions for proper mounting
techniques to be used on different types
of wheels.
• Regard aftermarket wheels, especially those
incorporating universal lug patterns, as potential
sources of runout and mounting problems.
• Use the correct coated weights on
aluminum wheels.
• Recheck the tire and wheel assemblies for
excessive runout after they have been
corrected and installed.
• Evaluate the vehicle at the complaint speed
and note if the vibration has been corrected.
• If the vibration is still present, or is reduced
but still unacceptable, you may find one of
two possibilities:
- On-vehicle imbalance
95623
- Radial or lateral force variation
• Static balance, also called single plane balance, Correcting On-Vehicle Imbalance
affects the distribution of weights around the On-vehicle imbalance may result from components
wheel circumference. other than the tire and wheel assemblies having
imbalance. An on-vehicle high-speed balance or
replacement of suspected components may be
necessary in order to correct the condition.
Rotors do not have a set tolerance. However, rotors
i i
with more than 0.75 ounce imbalance have the
potential to cause vibration. The rotors can be
inspected for imbalance using either the on-vehicle
or the off-vehicle method as described below:
Checking Rotor Imbalance (On-Vehicle)
1. Support the vehicle rear axle on a suitable
hoist. Refer to Vehicle Lifting and Jacking in
2. Remove the rear tire and wheel assemblies.
Refer to Wheel Removal (Single Wheels) in
Tires and Wheels.
3. Reinstall the wheel nuts in order to retain the
rotors.
Caution: Refer to Work Stall Test Caution In
95624 Cautions and Notices.
• Dynamic balance, or two-plane balance, affects 4. Take the necessary precautions.
the distribution of weight on each side of the
tire/wheel centerline. 5. Run the vehicle at the complaint speed while
inspecting for vibration.
6. if the vibration still exists, perform the Radial Force Variation
following steps:
6.1. Remove the rotors.
6.2. Run the vehicle back to speed.
7. If the vibration is eliminated, perform the
following steps:
7.1. Remove the rotors one at a time.
7.2. Perform the vibration test for each rotor.
7.3. Replace the rotor causing the imbalance.
7.4. Inspect the balance of the new rotor.
Checking Rotor Imbalance (Off-Vehicle)

1. Measure the diameter and the width of the
rotor.
2. Mount the rotor on a balancer in the same
manner as a wheel.
Im portant: The rotors can only be inspected for
static imbalance. Ignore the dynamic imbalance
reading.
Radial force variation is the difference in the stiffness
3. Inspect for static imbalance. of a tire as the tire rotates and contacts the road.
The tire and wheel assemblies have some variation
On-Vehicle Balancing Procedure due to splices in the tire plies. These splices do not
The vibration problem may not be correctable with cause a problem unless the force variation is
the components removed from the vehicle. An excessive. These STIFF SPOTS in the tire (1) can
on-vehicle high-speed balancer may be required in deflect the tire and wheel assembly upward as the
order to balance the tire and wheel assemblies while assembly contacts the road.
still mounted on the vehicle. On-vehicle balancing If the tire has only one stiff spot, the spot will deflect
will balance the hubs and the rotors simultaneously, the spindle once per each revolution of the tire and
and will compensate for any residual runout wheel assembly, thus causing a first-order tire/wheel
encountered as a result of mounting the tire and vibration. If the tire has two stiff spots, the spots
wheel assemblies on the vehicle as opposed to cause a second-order vibration. First- and
off-vehicle balancing. second-order tire/wheel vibrations are the most
common to occur as a result of radial force variation.
Follow the on-vehicle balancer manufacturer Third-, fourth-, or higher orders are possible but
operator’s manual for specific instructions while rarely occur.
keeping the following tips in mind:
The most effective way to minimize the possibility of
Balancing Tips force variation as a factor in tire and wheel assembly
vibrations is to ensure that the tire and wheel
• Do not remove the off-vehicle balancing assembly runout is at an absolute minimum.
weights. The purpose of on-vehicle balance is However, some tire and wheel assemblies exhibit
to FINE TUNE the assembly balance already vibration-causing force variation even though they
achieved, not to start over again. are within runout and balance tolerances. These
• If the on-vehicle balance calls for more than instances are becoming rare due to tighter
1 ounce of additional weight, split the weight tolerances and higher standards in manufacturing.
between the inboard and outboard flanges of The following two alternatives are available if force
the wheel, so as not to upset the dynamic variation is suspected as a factor in tire and wheel
balance of the assembly that was achieved in assembly vibration complaints:
the off-vehicle balance. • Buff the tires.
• An EVA vibration sensor placed on the fender • Substitute one or more known good tire and
of the vehicle during the on-vehicle balance is wheel assemblies.
an excellent indicator of the amplitude of the The tires may be buffed on a tire matching machine
vibration, and the effect that the balance has that is designed to remove small amounts of rubber
on the vibration. from the outer rows of the tread blocks at the
• Evaluate the vibration after the on-vehicle location of the stiff spots under load. This eliminates
balance in order to determine if the vibration the spindle deflection. This type of equipment is not
currently in widespread use. Do not use a TRUER or
condition has been resolved.
any tool that is designed to make the tire perfectly
round. These tools will not correct the condition.
General Information Vibration Diagnoaie and Correction 0-111
You may substitute one or more known good tire Wheel Hub/Axle Flange Runout
and wheel assemblies when a tire manufacturer is Inspect the wheel hub/axle flange runout when
not available locally. lateral runout occurs during on-vehicle testing but not
Lateral Force Variation during off-vehicle testing. The tolerances provided
are only guidelines. Perform corrections only if the
on-vehicle runout cannot be brought to
within tolerance.
182246
Lateral force variation tends to deflect the vehicle

sideway, or laterally. Lateral force variation Is based 205276
on the same concept as radial force variation. A
SNAKY belt inside the tire may be the cause of 1. Position the dial indicator on the machined
lateral force. The tire substitution method may have surface of the hub, the axle flange, or the rotor,
to be used before tire replacement. outside of the wheel studs.
A lateral force variation condition is rare. The best 2. Rotate the hub in order to find the low spot.
way to eliminate lateral force variation as a factor in 3. Set the dial indicator to zero at the low spot.
tire and wheel vibration conditions is to ensure that 4. Rotate the hub again and check the total
the lateral runout of the tire and wheel assemblies is amount of runout.
at an absolute minimum. Specification (Guideline)
The vehicle will WOBBLE or WADDLE at slow
Runout tolerance: 0.130 mm (0.0050 in)
speeds of 8-40 km/h (5-25 mph) when lateral force
variation is excessive. This condition is usually
related to the first-order of tire and wheel rotation.
Wheel Stud (Stud Circle) Runout 2. Turn the hub to register on each of the studs.
Use the following procedure whenever the off-vehicle 3. Zero the dial indicator on the lowest stud.
radial runout and the on-vehicle radial runout are 4. Rotate the hub again and check the total
significantly different, and earlier attempts to correct amount of runout.
the tire and wheel vibration condition have not Specification (Guideline)
been successful.
Runout tolerance: 0.80 mm (0.030 in)
Correcting Non-Uniform Tires
Use the following two methods to correct tires
which cause a vibration, although the tires are
balanced properly:
1. This method uses an automatic machine that
loads the tire and buffs small amounts of
rubber from high spots on the outer two
tread rows.
• Using this method in order to correct the
tires is usually permanent. This method does
not significantly affect the appearance or the
tire tread life.
• Do not true the tires with a blade-type
machine. This reduces the tread life
substantially, and this often does not
permanently correct the problem.
2. The second method is to dismount the tire and
rotate it 180 degrees on the rim. It is important
that this is be done on the tire and wheel
1. Position the dial indicator in order to contact the assemblies which are known to be causing a
wheel mounting studs. vibration, as it is just as likely to cause good
Measure the stud runout as close to the flange assemblies to vibrate.
as possible.
Correcting Driveline Vibration -

RWD and 4WD
Diagnosis will be much easier once you have
identified a vibration as first-order of driveline rotation
during the road test. Then identify the exact area
that the vibration is coming from and take
proper action.
In most cases, vibration may be reproduced in the
stall, in the stall the vibration may be better or worse
than that experienced during the road test.
The objective is to reduce the vibration to the lowest
point possible in the stall, than evaluate the results
on a road test. Many times, a vibration you were
able to reduce drastically in the stall will be
completely eliminated on the road.
The cause of first-order drive line vibration is usually
excessive runout or an imbalanced component.
The following procedure offers a systematic process
of elimination in order to determine which component
is at fault:
vehicle on a hoist or heavy stands.
Refer to Vehicle Lifting and Jacking in
3. Remove the brake drums. Refer to Brake Drum
in Drum Brakes.
4. Inspect the propeller shaft. The propeller shaft
should be free of undercoating before
continuing this diagnosis.
5. Inspect the propeller shaft or U-joints for any
obvious dents or damage. Dents or damage will
contribute to first-order driveline vibrations.
8. Run the vehicle up to the speed at which the
vibration was most severe. Do not step on the
brake while the brake drums are removed.
9. Note the vibration present, and at what speed.
10. If the vibration is not present, refer to
First-Order Driving Vibration Testing (Torque
Sensitive) in the Road Testing Diagnosis.
11. If the vibration is present, determine which end
of the driveshaft is vibrating the most. Hold
your hand against the pinion nose and the
transmission tailshaft, or hold an EVA vibration
sensor up to each component.
12. If the vehicle is equipped with a two-piece
propeller shaft, inspect the center support
bearing for vibration.
13. If the transmission tail is vibrating, touch the
transmission crossmember under the
transmission mount. If there is no vibration on
the crossmember, then the transmission mount
is working properly.
14. Note which end of the driveshaft is the worst,
and how severe the vibration is. The inspection
will be a reference by which to judge
future progress.
Helpful Hints
Do not fill the propeller shaft with foam, oil, or any
other substance in order to correct a vibration. Filling
the propeller shaft is only effective in reducing an
unrelated condition called Torsional Rattle. Filling the
propeller shaft should only be done in strict
adherence to the procedure outlined in corporate
bulletins that address Torsional Rattle. Failure to
follow the correct procedure will induce a vibration
and/or affect the structural integrity of the propeller
shaft. The propeller shaft will then have to
be replaced.
Propeller Shaft Runout
A propeller shaft or pinion (companion) flange with
excessive runout causes first-order driveline
vibrations. Use the following procedure in order to
measure runout of the propeller shaft (2). The
tolerances are critical for smooth operation of
the driveline.
• Remove excess corrosion of the propeller shaft
surface before checking runout. Also inspect for
damage and dents. Replace dented propeller
shafts. Remove any undercoating from the
propeller shaft before proceeding.
• The measurement procedure that follows
applies to all one-piece and two-piece propeller
shaft assemblies.
The splined end (1 )of a propeller shaft is critical
to the smooth operation of a two-piece propeller
shaft. When checking stub-shaft runout, ensure
that the dial indicator readings are accurate.
Measuring Propeller Shaft Runout
Tools Required
. J8001
• J7872
1. Raise the vehicle on a suitable hoist. Refer to
Lifting and Jacking in General Information.
2. Allow the wheels to spin freely.
3. Attach a J 8001 J 7872
4. Place the transmission in Neutral. Rotate the
pinion flange or transmission yoke by hand
while taking the measurements for runout. The
propeller shaft will turn easier in one direction
than in the other. Removing the wheels and
drums will also help.
• Do not include fluctuations on the
dial indicator due to welds or
surface irregularities.
5. For one piece propeller shafts, if the runout
exceeds the tolerances at one or more points:
5.1. Rotate the propeller shaft 180 degrees in
the pinion flange. Reinstall the propeller
shaft and recheck the measurement.
5.2. If the runout still exceeds the tolerance,
double-check the pinion flange runout
before replacing the propeller shaft.
6. For two-piece propeller shafts, if the runout
exceeds the tolerances at one or more points:
6.1. Measure the rear propeller shaft.
6.2. Mark the position of the rear shaft in the
pinion flange, then remove the rear shaft.
6.3. Measure the front propeller shaft runout
on the tube and the stub shaft.
6.4. Replace the propeller shaft if either
measurement is out of tolerance.
Refer to Specifications
Important: When you replace a propeller shaft,
check the new shaft for runout. Double-check the
pinion flange runout if the replacement shaft runout
is also out of tolerance.
Measuring Pinion Flange Runout
Tools Required
. J8001
. J 23409
• J 35819
1. Place the vehicle on a suitable hoist. Refer to
Vehicle Lifting and Jacking in General
Information. Allow the wheels to rotate freely.
2. Remove the propeller shaft from the
pinion flange.
3. Install the J 35819
Important: The dial indicator will have inverted
readings. You are measuring the inside
diameter of the flange, and not the outside
diameter. The highest reading on the dial
indicator is the low spot. The lowest reading is
the high spot.
4. Rotate the pinion shaft 360 degrees and zero
the dial indicator on the low spot.
5. Rotate the pinion flange again and record the
total runout.
6. If the pinion flange runout is 0.15 mm (0.006 in)
or less, remove the pinion flange
balance weight.
7. If the pinion flange runout is over
0.15 mm (0.006 in) but no less than
0.28 mm (0.011 in), and the runout
compensation weight is at or near the low
spot, then no further action is necessary.
Remove the weight if the runout compensation
weight is not at or near the low spot.
8. If the pinion flange runout is more than
0.28 mm (0.011 in) but no greater than
0.38 mm (0.015 in), and the balance weight is
at or near the low point, then no further action
is necessary. Remove the weight and re-index
the pinion flange until the runout is
0.25 mm (0.010 in) or less if the runout
compensation weight is not at or near the
low spot.
9. Replace the pinion shaft when the runout is
0.25 mm (0.010 in) or less. Then, recheck the
runout. Service replacement flanges do not
have balance weights.
H e lp fu l H in ts
• If necessary, add compensation weights on the
face of the pinion flange dust slinger. These
weights are tack-welded onto the slinger. You
may remove the weights with a die-grinder.
• Carefully remove the spot weld at either end of
the weight.
• Do not remove the weight unless you have
inspected the pinion flange runout and the
procedure calls for weight removal.
• Do not remove any weights on the outboard
edge of the dust slinger. These weights are
present in order to internal axle components.
The weights are not related to the pinion
flange runout.
Correcting Vibration at the Pinion Nose

Most first-order driveline vibrations originate at the
pinion nose end of the driveshaft. Ensure that the
vibrations are at a minimum at this location in order
to achieve acceptable results. Reduce the runout of
the components to a minimum. Balance the driveline
as a system when necessary.
1. Measure the runout of the propeller shaft and
check the tolerance.
2. If the tolerance is excessive, mark the position
of the shaft for future reference and rotate the
shaft 180 degrees.
3. Reinstall the shaft and recheck the runout.
Inspect the level of vibration in order to
determine if the vibration is lower or corrected.
4. If the runout is still excessive, or if the vibration
is still present, refer to Measuring Pinion Flange
Runout. Replace the pinion flange or re-index
182281
the flange 180 degrees if the pinion flange
runout exceeds the tolerance.
Remove and reinstall the pinion flange only
once on axles utilizing a "crush" type sleeve.
Replace the sleeve with a new sleeve if the
sleeve is "crushed". Removing the sleeve
requires removal of the ring and pinion set.
Therefore, replace flanges with excessive
runout. Regardless of the method used,
measure the pinion flange runout in order to
ensure that the flange is within tolerance.
5. Recheck the propeller shaft runout if the
vibration is present after the pinion flange
runout is corrected. If the propeller shaft runout
is still excessive, correct the runout before
doing a driveline system balance. Either replace
the shaft with a shaft that is within tolerance or
sublet the shaft to a reputable independent for
straightening and re-balance. Ensure that the
new or rebuilt shaft is within runout tolerance
before you continue.
6. Once the propeller shaft and pinion flange are
within runout tolerances, check if the vibration
is gone. If the level of the vibration is still
unacceptable, perform a driveline system
balance procedure.
Correcting Vibration at the Transmission
Tailshaft
First-order driveline vibrations that originate at the
transmission end of the propeller shaft are rare. If
the tailshaft of the transmission is vibrating, inspect
the tailshaft housing bushing for wear or damage. A
leaky transmission tailshaft oil seal indicates
bushing problems.
Feel for vibration at the crossmember underneath the
transmission mount. If there is no vibration, the
transmission mount is doing its job of isolating the
vibration from the structure of the vehicle. The
transmission mount is therefore probably not cause
of vibration.
Use the following procedure if you can feel vibration
on the crossmember and the tailshaft bushing, and if
transmission output is normal:
1. Measure the propeller shaft runout. If the runout
is excessive, replace the shaft with one that
has acceptable runout. Alternatively, sublet the
shaft to a reputable independent service shop
in order to have the shaft rebalanced and the
runout corrected.
2. Test drive the vehicle. If the vibration is still
unacceptable, valance the shaft on the vehicle.
Refer to Rear Driveline System Balance.
Correcting Vibration at the Center Support
Bearing
These guidelines apply to the two-piece propeller
shaft only. First-order driveline vibrations that occur
mainly at the center support bearing (2) are usually
the result of excessive runout at the stub (splined)
shaft (3).
Unlike other first-order driveline vibrations, these
vibrations can appear at unusually low speeds of
40 km/h (25 mph) and up.
Follow the following procedure to correct this type
of vibration:
1. Mark the position of the rear propeller shaft at
both ends for proper reassembly. Remove the
rear propeller shaft form the vehicle.
2. Measure the runout of the splines about
12.7 mm (0.5 in) from the end (1).
3. Replace the shaft if the runout exceeds
the tolerances.
Stub shaft/spline runout 0.076 mm (0.003 in)
Troubleshooting Hints
Vibration is eliminated with the correction of the
propeller shaft runout. If some vibration is still
present, perform a vehicle road test. Then, determine
if an on-vehicle system balance is necessary.
Driveline System Balance with Electronic
Vibration Analyzer (EVA)
To pinpoint the source, you must reproduce the
vibration in the service stall and then determine
which component is vibrating the most using
the EVA:
1. Support the vehicle on a suitable hoist or on
safety stands. Ensure that the rear of the rear
axle is at curb height. Do not allow the axle to
hang. Refer to General Information.
to Tires and Wheels.
3. Remove the brake drums. Refer to Brakes.
4. Ensure that the propeller shaft is free of
undercoating. Check for dents or damage to the
propeller shaft or U-joints.
5. Start the engine. Place the transmission in gear
and run at the vehicle speed at which the
vibration occurs at.
Caution: Running a Vehicle on Holst Caution
Determine which end of the propeller shaft is
vibrating the most. Hold the EVA’s sensor against the
pinion nose and the transmission tailshaft assembly.
The higher the amplitude reading, the greater
the vibration.
If the vehicle has a two-piece propeller shaft, check
the center support bearing.
If the transmission tailshaft vibrates, check the
transmission crossmember under the transmission
mount. The vibration should not be present if the
mount is doing its job.
Runout and Balance Testing with the
Electronic Vibration Analyzer (EVA)
Ensure that the runout of the various driveline
components are within specifications, if the runouts
are within specifications, strobe balance the driveline.
The EVA is able to simplify the balancing process,
using the following procedure:
1. Use the EVA in order to determine which end
of the propeller shaft has the most vibration.
2. Mark the end of the propeller shaft (1) that has
the most vibration at four points, 90 degrees
apart. Number the marks 1 through 4 (2).
3. Mount the EVA sensor onto the bottom of the
following components:
• The differential housing
• The center bearing support (for two-part
propeller shafts)
• The transmission tailshaft assembly
4. Position the sensor as close to the propeller
shaft as possible. Ensure that the UP side of
the sensor faces up. Ensure that the sensor
is horizontal.
6. Turn off all engine accessories.
8. Run the vehicle at the speed which causes the
most vibration in the propeller shaft.
9. Hook the timing light clip to the trigger wire.
10. Plug the vibration sensor into Input A of the
EVA. Input B does not have strobe
light capability.
11. Verify that the predominant frequency on the
EVA display matches the frequency of the
original vibration. Use the strobe light only if the
rotation speed of the propeller shaft is the
predominant frequency.
12. The EVA displays a series of questions in order
to select the correct filter. Press YES in order
to select the desired filter. Ensure that the
frequency is in the middle of the filter range.
Use the full range only as a last resort.
13. The display shows the test frequency, the
amplitude and the filter range. The driveline is
balanced when the amplitude is near two. In
some cases a slightly higher amplitude will
provide adequate balance.
14. Point the timing light at the propeller shaft. The
strobe effect will appear to freeze the propeller
shaft. Note which of the numbered marks is at
the bottom of the propeller shaft, or the 6
o’clock position. This position is the light spot.
15. Turn the engine off.
16. Install a weight directly on the light spot.
18. Run the vehicle at peak vibration speed.
19. Strobe the propeller shaft again.
The propeller shaft is balanced if the strobe image is
erratic and the amplitude is near two.
The propeller shaft is not balanced if one of the
following conditions exist:
• The weight and the original light spot are at the
6 o’clock position.
The above condition means that there is not
enough weight on the propeller shaft. In order
to correct the balance, add a second weight
next to the first weight. Inspect the balance
again using the strobe light.
If the weights are now between 90 and
3 o’clock positions) too much weight exists. In
order to correct the balance, split the two
weights equally on either side of the original
light spot in order to produce a total weight
between one and two weights (between 0 and
120 degrees apart). Inspect the balance again
using the strobe light. Adjust the weights
as necessary.
• The weight and original light spot are 90 to
3 o’clock positions).
The above condition means that one weight is
too much. In order to correct the balance, split
the two weights equally on either side of the
original light spot in order to produce a total
weight less than one (between 120 and
180 degrees apart). Inspect the balance again
using the strobe light. Adjust the weights
as necessary.
• The weight and the original light spot are within
180 degrees of the 6 o’clock position.
Move weight towards the 6 o’clock position.
Inspect the balance again using the strobe light.
Adjust the weight as necessary. Refer to the
previous two conditions.
If the shaft will not balance using two weights, then
place a third weight on the light spot. Split the first
182137 two weights in order to produce a total weight
between two and three weights.
If three weights fail to balance the driveline, then
replace the propeller shaft.
When the propeller shaft balances, road test the
vehicle in order to verify that the vibration
is eliminated.
Driveline System Balance without the
Electronic Vibration Analyzer
The following procedure is designed to fine-tune the
balance of the propeller shaft while it is mounted in
the vehicle. The procedure also is able
correct residual imbalance of the remaining
driveline components.
Prior to balancing the driveline system, verify that the
propeller shaft and the pinion flange runout are
within specification.
Do not overheat the engine when performing
this procedure.
vehicle on a hoist or on safety stands. Do not
allow the axle to hang. Refer to Vehicle Lifting
and Jacking in General Information.
3. Remove the brake drums. Refer to Brake Drum
in Drum Brakes.
4. Determine which end of the propeller shaft has
the most vibration in order to identify where to
begin installing the hose clamps.
5. Mark the end of the propeller shaft (1)
which has the most vibration at
four points, 90 degrees apart. Number
the marks 1 through 4 (2).
Troubleshooting Hints
The following procedure uses a trial and error
method of determining where to place the hose
clamps on the shaft. Use the following tips in order
to help locate the clamps:
1. Because the imbalance may be related to
propeller shaft runout, begin installing the
clamps at the low point of the propeller
shaft runout.
2. When the plant workers balance the propeller
shaft, they use weights in graduated
increments: 1/16 oz, 1/8 oz, etc. If the stock
weight is too light or too heavy, place the hose
clamp either directly in line with or opposite to
the stock weight.
The last method involves road testing the vehicle at
a speed which the vibration is felt.
1. Carefully hold a piece of chalk up to the very
end of the propeller shaft. Barely touch the
chalk to the shaft.
2. Shut the engine off in order to stop the
propeller shaft from rotating. Do not step on the
brake pedal. Do not put the transmission
in Park.
3. Inspect the chalk mark.
If you performed the above procedure correctly, the
chalk mark will indicate the heavy spot on the shaft.
The heavy spot deflected downward and touched the
chalk. If the chalk mark circle the entire shaft, touch
the chalk more gently to the shaft. Ensure that the
chalk touches only the heavy spot. Once the heavy
spot is located, place the hose clamp 180 degrees
opposite to the chalk mark. Then perform the
following steps:
1. Place the hose clamp at the light spot, or at
any of the four points marked previously.
2. Test drive the vehicle at the speed at which the
vibration occurred. Record any changes in
the vibration.
3. Move the clamp to the other positions.
4. Test drive the vehicle each time the clamp is
moved. Record any changes in vibration. Note
which position gives the best balance.
If the vibration does not change at all, or gets worse,
then one clamp is too light or too heavy.
• If the vibration did not change at all,
then repeat the procedure using two
clamps together.
• If the vibration got worse, repeat the procedure
using two clamps separated. Separate the
clamps to reduce the spinning weight.
Continue the trial and error procedure using different
weights in different locations until you achieve the
best balance. If more that three clamps aligned in
the same position are required, then replace the
propeller shaft.
If you are able to reduce the vibration in the stall,
but are unable to eliminate the vibration completely,
perform a road test on the vehicle. A slight vibration
noticeable in the stall may not be noticeable on
the road.
Propeller Shaft Balance Weights

When using clamps in order to balance a propeller
shaft with the total wight method, the correction
weight required will often be a fraction or a multiple
of one hose clamp. Use the following phasing
procedure with two hose clamp in order to accurately
place any required amount between zero weights
(0.0 total weight) to two weights (2.0 total weight).
Ensure that the clamps are located with even spaces
on either side of the light spot, or 180 degrees
opposite the heavy spot.
The following table contains the weight amounts in
terms of the total weight and the included angle
(spread) between the clamps. Refer to Specifications.
182176
The main objective of this section is to correct the
conditions that interfere with the proper cancellation
effect of the U-joints. The most common condition,
especially where the where launch shudder is
concerned, is incorrect driveline working angles.
However, other factors may aggravate the condition.
Address these factors before you attempt to measure
or correct driveline working angles:
• Worn, failed, damaged, or improperly installed
U-joints
• Worn, collapsed, or improper powertrain mounts
• Incorrect vehicle trim height adjustment for the
front suspension. This condition aggravates
launch shudder.
• Incorrect trim height adjustment for the rear
suspension.
• Trim height inspection includes trim heights that
are too low or too high. Vehicles equipped with
aftermarket lift kits, vehicles that are constantly
loaded with cargo, and custom conversion vans
all fit in this category. On rear drive vehicles,
the pinion nose tilts upward as the rear trim
height is lowered.
If a second-order driveline vibration exists after these
conditions are corrected, measure and correct the
driveline angles.
If the complaint is present only with cargo in the
vehicle, perform the measurements with the vehicle
fully loaded. Once a second-order driveline vibration
has been corrected with the vehicle loaded, the
vibration may reappear with the vehicle unloaded.
The reverse of this is also true. You may have to
reach a compromise with the customer in this case.
Driveline Working Angles

Tools Required
• J 38460 Digital Inclinometer
. J 23498-A
. J 23498-20
Driveline working angle does not refer to the angle
of any one shaft, but to the angle that is formed by
the intersection of two shafts, as shown.
The procedure for measuring and correcting driveline
working angles depends on whether the vehicle is
equipped with a one or two-piece propeller shaft.
You need a J 38460 Digital Inclinometer
. The J 23498-A
• The J38460 Digital Inclinometer
• Use J 23498-20
To verify the accuracy of the adapter, check the
angle of an angle of an accessible joint with the
inclinometer prior to assign it on an inaccessible
joint.
Preliminary Checks
Raise the vehicle on a suitable hoist or on safety
stands. Ensure that the rear axle is supported at
curb height and that the wheels are free to spin.
Refer to Vehicle Lifting and Jacking in General
Information. Place the transmission in Neutral. Make
sure the vehicle has a full tank of fuel or the
equivalent amount of weight in the rear to simulate a
full tank. 3.8 liters of gasoline (one gallon) weighs
approximately 2.8 kg (6.2 lb).
Checking Phasing of U-joints
Inspect the propeller shaft for correct phasing. This
means that the front and rear U-joints are directly in
line or parallel with each other so that proper
cancellation takes place.
1. Rotate the propeller shaft so that the propeller
shaft rear U-joint bearing cap (1) is vertical
as shown.
2. Ensure that the front bearing cap (1) is
also vertical.
3. Place the inclinometer on the propeller shaft
rear U-joint bearing cap in order to ensure that
both U-joints are vertical.
4. Set the indicator line above the sight glass on
15 (the horizontal reference) and rotate the
propeller shaft until the bubble centers in the
sight glass. This brings the rear U-joint
to vertical.
5. Remove the inclinometer without disturbing the
setting. Leave the setting on 15 and install the
inclinometer on the front U-joint. The bubble
should remain centered plus or minus
3 degrees if the shaft is properly phased.
102325
The out of phasing of the single-piece propeller shaft
is very unusual. If the shaft is visibly out of place,
the end yokes are welded on in the wrong position,
or the shaft is damaged due to twisting. In either
case, replace the propeller shaft before continuing
with this procedure.
Measuring the Working Angles
The working angle of a U-joint is the difference
between the angles formed when two shafts
intersect. One piece propeller shaft systems have
two working angles, the front and the rear.
• The two working angles should be equal within
1/2 of a degree.
• The working angles themselves should not
exceed 4 degrees.
• The working angles themselves should not be
equal to zero because a zero working angle will
cause premature U-joint wear due to lack of
rotation of the U-joints. 182180
The angle of the propeller shaft and the rear axle

pinion form the rear working angle (2). The angle of
the propeller shaft and the transmission output shaft
form the front working angle (1).
The angles of these components are most accurately
measured from the U-joint bearing caps. The bearing
caps should be free of corrosion or foreign material
to ensure accurate readings. Remove any snap rings
that may interfere w it the correct placement of the
inclinometer. Do not forget to reinstall them after you
take the measurements.
Take the measurements from the same side of the
propeller shaft to maintain consistent angle
measurements (either driver or passenger side).
it is extremely helpful to record the readings on a
diagram like the one shown as you proceed through
the measurements.
182332
Evaluation
The two working angles in a one-piece propeller
shaft system should be equal to within 1/2 of a
degree for effective cancellation.
Measuring IWo-Piece Propeller Shaft System
Working Angles
Introduction
Two-piece propeller shaft systems have three
working angles instead of two as in
one-piece systems.
• The first angle is the front working angle. It is
formed by the angle of the output shaft of the
transmission and the angle of the front
propeller shaft.
• The second angle is the middle working angle.
It is formed by the angle of the front propeller
shaft and the angle of the rear propeller shaft.
• The third angle is the rear working angle. It is
formed by the angle of the rear propeller shaft
and the angle of the pinion yoke of the
rear axle.
This system has an odd joint that does not have
another joint to provide cancellation. Therefore, the
rear working angle and the middle working angle act
as a pair of joints to cancel each other out, like in
one-piece propeller shaft systems.
The front angle is considered the odd joint because
it does not have another joint to provide cancellation.
Because of this, the working angle of the odd joint
must be kept at or under 1/2 or a degree.
Keep the working angle of this odd joint to a
minimum so that there are not any great fluctuations
in speed that need to be canceled out. The front
joint is used as the odd joint because the front joint
angle does not change with suspension bounce,
rebound, or axle windup. For this reason, think of
the front propeller shaft of a two piece system as an
extension of the transmission output shaft.
General Information Vibration Piagnoeie and Correction 0-127
IWo-Piece Propeller Shaft Phasing
The setup and measurement techniques are identical
to that of a one-piece propeller shaft system. First,
check for proper phasing:
1. Turn the rear shaft so the rear U-joint is
straight up and down. Ensure that the front
U-joint of the rear propeller shaft is also straight
up and down.
2. Rotate the shafts 90 degrees so that the front
propeller shaft front U-joint is straight up and
down. Ensure that the front propeller shaft is
also straight up and down (actually part of the
slip yoke on the rear shaft).
If the two U-joints of the front propeller shaft are not

in this phase, the two halves of the propeller shaft
may have been assembled incorrectly.
IWo-Piece Propeller Shaft Lateral Alignment
The procedure for lateral alignment of a two-piece
propeller shaft is used for launch shudder or any
second-order, driveline vibrations. Adjust the lateral
alignment before you measure and adjust the
driveline angles.
1. Raise and suitably support the vehicle on a
hoist. Refer to General Information.
2. Look down the front of the propeller shaft.
3. If the propeller shaft is not straight, or if the
center bearing support is off to one side,
relocate center support bearing to make the
propeller shaft assembly as straight as
possible. Ensure that you do not create a
ground-out condition against the exhaust or
another component. 182343
If launch shudder or second-order driveline

vibration is still present, measure and correct the
driveline angles.
Measuring Two-Piece Propeller Shaft
Working Angles
This procedure is essentially the same as for
one-piece propeller shafts. You must, however, take
into account the third angle.
1. Place the inclinometer on the propeller shaft
bearing cap (1).
6499
2. Center the bubble in the sight glass and record
the measurement. The bearing cap must be
straight up and down to obtain accurate
measurement. Enter the measurements on
your diagram.
3. Rotate the propeller shaft 90 degrees and place

the inclinometer on the transmission output
yoke bearing cap. Again, the bearing cap must
be straight up and down to obtain an
accurate measurement.
4. Center the bubble in the sight glass and record
the measurement.
5. Subtract the smaller reading from the
larger reading to obtain the front U-joint
working angle.
Evaluation
The working angle is within tolerance, following the
rule that the working angle of an odd joint in a
two-piece joint system is 1/2 degree or less. Notice
that in each of the good examples that the front
working angle (FWA) is 1/2 degree or less and is
treated as a separate joint. The middle working
angle (MWA) and rear working angle (RWA) are
subtracted and the difference (DIFF) is 1/2 degree
or less. The middle and rear joints may cancel
each other.
Correcting Working Angles
In order to change the working angles, shim the
components up or down. Look closely at the existing
angles. Use the existing angles and the shims in
order to achieve the correct working angles.
182361
Compared to horizontal or true level, the components
located at the rear of the vehicle are usually lower
than the components located at the front of the
vehicle. This condition is called 'down in the re a r. If
a component with a down in the rear angle is
shimmed up at the rear, then the shim will bring the
component closer to the horizontal (zero). Alternately,
if a component with a down in the rear angle is
shimmed down, then the component will move
farther from the horizontal (zero).
Rear Axle Wind-Up
Rear axle wind-up may cause launch shudder even
when all of the working angles are within
specifications. Rear axle wind-up occurs when heavy
torque during acceleration causes the pinion nose to
point upward. In order to compensate for axle
wind-up, tip the pinion nose downward. Install the
axle shims incrementally, performing a road test after
each shim. Add shims until the road test indicates
that the shudder is eliminated.
Rear Axle Shims
Wedge shims of different sizes are available through
GMSPO and independent suppliers for the purpose
of shimming the rear axle angle. GM shims are
available in two, three and four degrees.
Caution: Never attem pt to shim a rear axle using
anything except shims that are designed for this
purpose. Failure to do so will result In the shims
falling out and a loss o f vehicle control and that
could cause personal Injury.
Install the shims (5) in order to increase or decrease
the angle of the rear axle pinion. Install the shims
between the leaf spring (3) and the spring seat.
Depending on the design of the suspension (leaf
spring on top or underneath the axle), and the
direction of the desired change, install the shims with
either the thick side toward the front of the vehicle or
toward the rear of the vehicle.
Important: After installing the shims, ensure that the
U-bolt has two or three threads above the nut.
Ensure also that the center bolt, located in the
spring seat, is long enough to seat in the locator
hole. If these two conditions do not exist, use longer
U-bolts and center bolts. Longer U-bolts and center
bolts are available through local spring shops. 182364
Transmission Shims
If a transmission requires shims, order the shims
through GMSPO.
Installing most shims will change the transmission
angle approximately V2 degree.
When shimming transmissions, use a shim made
from steel stock at the necessary thickness. Ensure
that the shim contacts the full width of the area to
be shimmed. Do not use washers.
Description and Operation

General Description
Vibration Theory
The vehicle designs and the engineering
requirements have undergone drastic changes in this
decade. The following factors drive many of these
requirements:
• Increased fuel costs
• Decreased fuel supplies
• Corporate Average Fuel Economy (CAFE)
• Clean air legislation
• Foreign competition
• Crashworthiness
• Rising customer expectations
The vehicle designs have evolved from the full frame
construction, where multiple isolating body mounts
95585
were used, to the lighter unibody designs of today.
The unibody designs transfer any noise or In the preceding picture, the source is the
vibration faster. unbalanced tire. The transfer path is the route the
The use of heavier V8 engines has been reduced, vibrations travels through the vehicle’s suspension
being replaced with lighter, more fuel-efficient four system into the steering column. The responder is
and six-cylinder engines. During this same period, the steering wheel, which the customer reports as
options such as A/C and PS have become more vibrating. Eliminating any one of these three
popular. These types of options increase the engine elements will usually correct the condition. Decide,
load, resulting in more unwanted noise and vibration. from the gathered information, which element makes
the most sense to repair. Adding a brace to the
The presence/absence of unwanted noise and steering column may keep the steering wheel from
vibration is linked to the customer’s perception of the vibrating, but adding a brace is not a practical
overall vehicle quality. solution. The most direct and effective repair would
Vibration is the repetitive motion of an object, back be to properly balance the tire.
and forth, or up and down. The following conditions
cause most vehicle vibrations:
• A rotating component
• The engine combustion process firing impulses
Rotating components will vibrate with excessive
imbalance or runout. During vibration diagnosis, the
amount of allowable imbalance or runout should be
considered a TOLERANCE and not a
SPECIFICATION. In other words, the less imbalance
or runout the better.
A vibration concern will occur when the firing
impulses of the engine are not properly isolated from
the passenger compartment.
A vibrating component operates at a consistent rate
(km/h, mph, or rpm). Measure the rate of vibration in
question. When the rate/speed is determined, relate
the vibration to a component that operates at an
equal rate/speed in order to pinpoint the source.
Vibrations also tend to transmit through the body
structure to other components. Therefore, just
because the seat vibrates doesn’t mean the source
of vibration is in the seat. Vibration can also produce noise. As an example,
consider a vehicle that has an exhaust pipe
Vibrations consist of the following three elements: GROUNDED to the frame. The source of the
• The source — the cause of the vibration vibration is the engine firing impulses traveling
• The transfer path — the path the vibration through the exhaust. The transfer path is a grounded
travels through the vehicle or bound-up exhaust hanger. The responder is the
frame. The floor panel vibrates, acting as a large
• The responder — the component where the
speaker, which produces noise. The best repair
vibration is felt
would be to eliminate the transfer path. Aligning the 2. Pull down on the edge of the stick and release
exhaust system and correcting the grounded while observing the movement of the stick.
condition at the frame would eliminate the The motion of the stick occurs in repetitive cycles.
transfer path. The cycle begins at midpoint, continues through the
lowest extreme of travel, then back past the
Basic Vibration Terminology midpoint, through the upper extreme of travel, and
The following are the two primary components of back to the midpoint where the cycle begins again.
vibration diagnosis:
The cycle occurs over and over again at the same
• The physical properties of objects rate, or frequency. In this case, about 10 cycles in
• The object’s properties of conducting one minute. If we measure the frequency to reflect
mechanical energy the number of complete cycles that the yardstick
The repetitive up and down or back and forth made in one minute, the measure would be
movement of a component cause most customer 10 cycles x 60 seconds = 600 cycles per
vibration complaints. The following are the common minute (cpm).
components that vibrate: We have also found a specific amount of motion, or
• The steering wheel amplitude, in the total travel of the yardstick from the
very top to the very bottom. Redo the experiment as
• The seat cushion
follows:
• The frame 1. Reclamp the yardstick to the edge of a table,
. The l/P leaving about 25 cm (10 in) hanging over the
Vibration diagnosis involves the following simple edge of the table.
stepwise outline: 2. Pull down on the edge of the stick and release
1. Measure the repetitive motion and assign a while observing the movement of the stick.
value to the measurement in cycles per second The stick vibrates at a much faster frequency:
or cycles per minute. 30 cycles per second (1800 cycles per minute).
2. Relate the frequency back on terms of the
rotational speed of a component that is
operating at the same rate or speed.
3. Inspect and test the components for conditions
that cause vibration.
For example, performing the following steps will help
demonstrate the vibration theory:
1. Clamp a yardstick to the edge of a table,

leaving about 50 cm (20 in) hanging over the
edge of the table.
Cycle
95588
Legend
(1) 1st Cycle
(2) 2nd Cycle
(3) 3rd Cycle
(4) Time
Vibration Cycles in Powertrain Components
Legend
(1) Spindle
(2) Pinion Nose
The word CYCLE comes from the same root as the

word CIRCLE. A circle begins and ends at the same
point, as thus, so does a cycle. All vibrations consist
of repetitive cycles.
Frequency
95590
Legend
(1) Amplitude
(2) Reference
(3) Time in Seconds
(4) 1 Second
Frequency is defined as the rate at which an event The proper term for cycles per seconds is Hertz
occurs during a given period of time. With a (Hz). This is the most common way to measure
vibration, the event is a cycle, and the period of time frequency. Multiply the Hertz by 60 to get the cycles
is one second. Thus, frequency is expressed in or revolutions per minute (rpm).
cycles per second.
Amplitude Amplitude is the maximum value of a periodically
varying quantity. Used in vibration diagnostics, we
are referring it to the magnitude of the disturbance.
A severe disturbance would have a high amplitude; a
1 minor disturbance would have a low amplitude.
Amplitude is measured by the amount of actual
movement, or the displacement. For example,
consider the vibration caused by an out-of-balance
wheel at 80 km/h (50 mph) as opposed to 40 km/h
(25 mph). As the speed increases, the amplitude
increases.
Free Vibration
Free vibration is the continued vibration in the
absence of any outside force. In the yardstick
example, the yardstick continued to vibrate even
after the end was released.
Forced Vibration
Forced vibration is when an object is vibrating
continuously as a result of an outside force.
95593
Legend
(1) Maximum
(2) Minimum
(3) Zero-to-Peak Amplitude
(4) Peak-to-Peak Amplitude
Centrifugal Force Due to an Imbalance
Legend
(1) Location of Imbalance (Degrees)
(2) Centrifugal Force Acting on Spindle
A spinning object with an imbalance generates a Centrifugal force is trying to make the nut fly
centrifugal force. Performing the following steps will outward, causing the pull you feel on your hand. An
help to demonstrate centrifugal force: unbalanced tire follows the same example. The nut
1. Tie a nut to a string. is the imbalance in the tire. The string is the tire,
wheel, and suspension assembly. As the vehicle
2. Hold the string. The nut hangs vertically due
speed increases, the disturbing force of the
to gravity.
unbalanced tire can be felt in the steering wheel, the
3. Spin the string. The nut will spin in a circle. seat, and the floor. This disturbance will be repetitive
(Hz) and the amplitude will increase. At higher
speeds, both the frequency and the amplitude will
increase. As the tire revolves, the imbalance, or the
centrifugal force, will alternately lift the tire up and
force the tire downward, along with the spindle, once
for each revolution of the tire.
Natural or Resonant Frequency Resonance
95595
The natural frequency is the frequency at which an Legend

object tends to vibrate. Bells, guitar strings, and (1) Frequency - cps
tuning forks are all examples of objects that tend to
(2) Suspension Frequency
vibrate at specific frequencies when excited by an
external force. (3) Unbalanced Excitation
Suspension systems, and even engines within their (4) Point of Resonance
mounts, have a tendency to vibrate at certain (5) Problem Speed
frequencies. This is why some vibration complaints
occur only at specific vehicle speeds or engine rpm. All objects have natural frequencies. The natural
The stiffness and the natural frequency of a material frequency of a typical automotive front suspension is
have a relationship. Generally, the stiffer the material, in the 10-15Hz range. This natural frequency is the
the higher the natural frequency. The opposite is result of the suspension design. The suspension’s
also true. The softer a material, the lower its natural natural frequency is the same at all vehicle speeds.
frequency. Conversely, the greater the mass, the As the tire speed increases along with the vehicle
higher the natural frequency. speed, the disturbance created by the tire increases
in frequency. Eventually, the frequency of the
unbalanced tire will intersect with the natural
frequency of the suspension. This causes the
suspension to vibrate. The intersecting point is called
the resonance.
The amplitude off a vibration will be greatest at the
point of resonance. While the vibration may be felt
above and below the problem speed, the vibration
may be felt the most a the point of resonance.
Dam ping
95597
Legend
(1) Low Damping
(2) High Damping
Damping is the ability of an object or material to
dissipate or absorb vibration. The automotive shock
absorber is a good example. The function of the
shock absorber is to absorb or dampen the
oscillations of the suspension system.
0-138 Vibration Diagnosis and Correction General information
Beating (Phasing)
Two separate disturbances that are relatively close O rder

together in frequency will lead to a condition called Order refers to how many times an event occurs
beating, or phasing. A beating vibration condition will during one revolution of a rotating component.
increase in intensity or amplitude in a repetitive
fashion as the vehicle travels at a steady speed.
This beating vibration can produce the fam iliar
droning noise heard in some vehicles.
Beating occurs when two vibrating forces are adding
to each other’s amplitude. However, two vibrating
forces can also subtract from each other’s amplitude.
The adding and subtracting of amplitudes in similar
frequencies is called beating. In many cases,
eliminating either one of the disturbances can correct
the condition.
95600
For example, a tire with one high spot would create

a disturbance once for every revolution of the tire.
This is called first-order vibration.
EVA Basic Hookup
1. Inspect that the software cartridge is correctly
inserted at the bottom of the unit. (The
cartridge usually remains there at all times.)
2. Connect the vibration sensor cord into either
input A or B.
3. Line up the connector so that the release
button is at the bottom.
Important: Do not twist the connector. The
sensor should remain plugged into the unit at
all times.
4. Push the connector into the input until the
connector clicks and locks in place.
5. Plug the power cord into a 12-volt power feed
in order to turn the EVA on. (There is no
ON-OFF switch.)
To Disconnect the sensor, press the release button
and gently pull the connector straight out.
95601
An oval-shaped tire with two high spots would create EVA Sensor Placement
a disturbance twice for every revolution. This is
called second-order vibration. Three high spots would
be third-order, and so forth. Two first-order vibrations
may add or subtract from the overall amplitude of
the disturbance, but that is all. Two first-order
vibrations do not equal a second-order. Due to
centrifugal force, an unbalanced component will
always create at least a first-order vibration.
Electronic Vibration Analyzer (EVA)
Proper EVA sensor placement is critical in order to

take proper vibration readings. The sensor can be
placed anywhere on the vehicle where vibrations are
felt. Use putty or a hook and loop fastener in order
to hold the sensor in place on non-ferrous surfaces,
such as the surface of the steering column.
The J 38792 Electronic Vibration Analyzer (EVA) is

specifically designed to diagnose vibrations. This
hand-held device is similar to a scan tool. A
standard 12-volt power feed supplies the power. The
vibration sensor, or the accelerometer, is at the end
of a 6 m (20 ft) cord. The vibration sensor can be
mounted virtually anywhere on the vehicle where a
vibration is felt.
Freeze
Pressing the FREEZE button on the keypad
activates the freeze function, which locks the display
of data. The display shows FRZ at the top. The
freeze function is useful when conducting an
acceleration/deceleration test in which the significant
amount of vibration registers only for a very short
time. Pressing EXIT or the FREEZE button again
deactivates the freeze function.
Record/Playback
The displayed vibration information can be recorded
for later playback. The EVA retains stored data for
about 70 hours after the unit has been unplugged
from a power source. Data is recorded as
SNAPSHOTS of vibration information. Each snapshot
consists of 10 different frames. Up to 10 of these
snapshots can be recorded.
Press RECORD in order to record a snapshot. The
95604 screen will display R? in order to request a tag
number between 0 and 9. These tag numbers are
A magnet is supplied in order to hold the sensor to the individual frames of the snapshot recording. New
ferrous surfaces. data will replace the existing data when a number is
Vibrations are typically felt in an up-and-down chosen that has already been used in order to tag
direction. The sensor is directionally sensitive. a snapshot.
Therefore, place the sensor as flat as possible with Pressing PLAYBACK plays back the recorded data.
the side marked UP facing upward. Place the UP The screen shows P? in order to request the tag
side of the sensor in the exact position every time number for the wanted snapshot. Once the number
for consistent results when repeating the tests or is entered, the snapshot data is displayed: P and the
making a comparison. tag number will appear. Then, an F and a 0 -9 will be
EVA Display displayed in order to indicate which frame of the
snapshot is being displayed.
The freeze function can be used in order to freeze
the display at any point in the sequence during
playback. Individual frames can be viewed in a
forward or backward sequence using the up and
down arrow keys.
The display returns to the active screen when the
recording or playback of a snapshot is finished, or
when EXIT is pressed.
Averaging/Non-Averaging Modes
The EVA normally operates in an averaging mode
that averages multiple vibration samples over a
period of time. The averaging mode minimizes the
effects of sudden vibration that are not related to the
problem (such as form potholes or uneven road
surfaces). Most tests use the averaging mode.
The EVA is more sensitive to vibrations in the
non-averaging mode. The display is more
instantaneous and not averaged over a period of
95605 time. The non-averaging mode is used when
The EVA offers the following main display features, measuring a vibration that exists for only a
all of which are described below: short period of time, and during
• Freeze acceleration/deceleration tests.
Pressing the AVG button switches between the
• Record/Playback
averaging and non-averaging modes. The screen will
• Averaging/Non-averaging modes display AVG.
• Strobe Balancing
Strobe Balancing A replaced or added sensor must be calibrated in
order to function properly with the EVA unit. The
phase shift calibration is performed at the factory
and should not be repeated under normal use.
S en so r C alib ratio n
1. Lay the sensor on a flat stationary surface with
the UP side facing upward.
2. Plug the sensor into either input A or B.
3. Plug the EVA into a 12-volt power supply.
4. After the display initializes, select the
proper input.
5. Press the up arrow key.
6. Press the number 2 three times on the keypad.
The message BURNING will appear, followed
by a request to turn the sensor over.
7. Turn the sensor over.
8. Press any key in order to
commence calibration:
• Calibration will take about 20 seconds.
• The display will return to the active mode
The EVA can strobe balance a rotating component. when calibration is complete.
A trigger wire is located on the top of the EVA, P hase S h ift C alib ratio n
which is used in conjunction with an inductive
pick-up light strobe. The EVA triggers the strobe light 1. Plug the EVA into a 12-volt power supply.
at the same frequency as the vibration. The timing 2. Press the down arrow key on the EVA keypad.
light clips on to the trigger wire. The vibration sensor 3. Press the number 2 three times in order to
must be attached to input A. Input B does not begin calibration:
provide the strobe function.
• Do not press any key until the message ANY
Pressing STROBE starts the strobe balancing KEY TO CONTINUE appears. Pressing a key
function. The EVA will ask a series of questions in will cancel the calibration process.
order to determine the correct filter range: full, low,
• The display will flash numbers for
or high.
5 -6 minutes. (If the numbers flash for more
The low and high ranges prevent other vibrations than 10 minutes, the EVA is defective.)
from interfering with the operation of the strobe light.
. The message BURNING PHASE SHIFT
Use the full range as a last resort only. Press YES
CONSTANTS will appear for one minute.
in order to select a range. Press NO in order to go
on to the next range. The vibration/strobe frequency . The BURNING CENTER FREQUENCIES
must fall within the selected range. LOW=39 HIGH=48 message will appear.
The EVA will display the strobe frequency, amplitude, . The ANY KEY TO CONTINUE message
and filter range. The EVA is now ready to begin the should appear.
strobe balance procedure. 4. Press any key in order to return to the
active mode.
EVA Calibration
The EVA features the following two built in
calibration procedures:
• Sensor Calibration
• Phase Shift Calibration

HVAC Table of Contents 1
SECTION 1
HVAC
Heater and Ventilation .................................... 1A-1 Heater Inlet Hose (Diesel Engines).......... 1A-15
General D e scrip tio n ............................................1A-1 Heater Outlet Hose (4.3L, 5.0L, and
Heater System................................................... 1A-1 5.7L Engines)............................................... 1A-16
Controls...............................................................1A-1 Heater Outlet Hose (7.4L Engine)..... .......1A-16
Temperature Rotary Knob............................ 1A-1 Heater Outlet Hose (Diesel Engines)...... 1A-17
Mode Knob..................................................... 1A-1 A u xilia ry Heater (S uburban)........................... 1A-17
Blower S w itch................................................ 1A-1 Control S w itch................................................. 1A-17
A ir Distribution System..................................... 1A-1 Front Overhead (Aux. Heater and
Temperature Valve and Heater Core.......... 1A-1 A /C )...............................................................1A-17
Mode V alves.................................................. 1A-2 Center Overhead (Aux. Heater and
Operating Modes............................................... 1A-2 A /C )........................................ 1A-18
Vent Mode...................................................... 1A-2 Heater H oses............... 1A-18
Heater M ode.................................................. 1A-2 Front Auxiliary Hose Assembly..................1A-18
Defrost M ode................................................. 1A-2 Rear Auxiliary Hose Assembly...................1A-18
Auxiliary Heater................................................. 1A-2 Heater Core..................................................... 1A-19
Blower S w itch................................................ 1A-2 Blower Motor and Fan................................... 1A-20
D ia g n o s is ..............................................................1A-6 Blower Motor Resistor.................................... 1A-20
Functional T est..................................................1A-6
S p e cifica tio n s.................................................... 1A-24
Heater Output Temperature Check..................1A-6
Fastener Tightening Specifications................1A-24
Preparation..................................................... 1A-6
Special T o o ls..................................................... 1A-24
Temperature Check........................................1A-6
Heater, Ventilation and Air
Insufficient Heating or Defrosting....................1A-6
Conditioning ................................................ 1B-1
Improper Air D elivery........................................1A-6
General D e scrip tio n ............................................1B-1
High or Low Temperature Control E ffort....... 1A-9
CCOT A/C System ............................................ 1B-1
Blower N oise..................................................... 1A-9
Unit Repair Inform ation................................ 1B-2
Excessive Heat.................................................. 1A-9
Controls...............................................................1B-2
On-Vehicle S ervice.............................................. 1A-9
Air Distribution System......................................1B-2
Control Assembly and BlowerS w itch..............1A-9
Ducts And O utlets.........................................1B-2
Control Assembly Lamp B ulb.......................... 1A-9
Refrigeration System.........................................1B-2
Temperature Control Cable............................ 1A-10
Defrost Control Cable..................................... 1A-10 Accum ulator................................................... 1B-2
Blower Motor Resistor.................................... 1A-10 Compressor.................................................... 1B-2
Blower Motor And Fan....................................1A-11 Condenser...................................................... 1B-3
Heater Core..................................................... 1A-11 Expansion Tube (O rifice).............................. 1B-3
A ir Distributor Duct..........................................1A-13 Thermo Expansion Valve (TXV)...................1B-3
Rear Seat Floor Heat Ducts.......................... 1A-13 Evaporator...................................................... 1B-3
Floor A ir Outlet Duct...................................... 1A-14 Heater C ore................................................... 1B-3
Instrument Panel Air Outlet D u ct..................1A-14 High Pressure Relief Valve.......................... 1B-3
Left Side Instrument Panel A ir Outlet Refrigerant-134a............................................ 1B-3
D uct.............................................................. 1A-14 Heater System................................................... 1B-4
Right Side Instrument Panel Air Outlet Relays And Switches........................................1B-4
D uct.............................................................. 1A-14 Blower C ontrols............................................. 1B-4
A ir Lap Outlet D uct.........................................1A-14 Compressor Pressure Switch.......................1B-4
Heater Hoses................................................... 1A-14 High Pressure Cutoff Switch........................1B-4
Heater Inlet Hose (GasolineEngines)....... 1A-14 Pressure Cycling Switch............................... 1B-4
2 Table of Contents HVAC
R efrigerant System D iagnosis..........................1B-5 Heater H oses.................................................. 1B-30

Functional T est.................................................. 1B-5 Heater Core..................................................... 1B-31
Performance T e st..............................................1B-5 Heater Water Valve (If Equipped).................1B-31
Leak Testing.................................................... 1B-12 A ir Distributor Duct..........................................1B-31
Electronic Leak D etector............................1B-12 Mode Actuator................................................. 1B-32
Service Ports/Access Valves......................1B-13 Temperature Actuator......................................1B-32
Evaporator Core...........................................1B-13 Rear A/C System (C 69)................................... 1B-33
Compressor Block Fitting And Shaft On Vehicle S ervice............................................. 1B-33
S e a l...............................................................1B-13 Control Assem bly............................................1B-33
CCOT Air Conditioning System Diagnosis Front Overhead............................ ..1B-33
C harts..............................................................1B-13 Center O verhead.........................................1B-33
Blower N oise................................................... 1B-13 Evaporator Tube Replacement.............. 1B-33
D iagnosis o f A ir C onditioning (H e a ter)...... 1B-14 Compressor And Condenser Hose
A/C Noise D iagnosis........................................ 1B-15 Assem bly................................ 1B-33
A/C O dor D ia g n o sis.............................. 1B-15 Rear Auxiliary Hose Assem bly......................1B-35
R efrigeration System S ervices.......................1B-16 Evaporator Core Replacement......................1B-37
Replacing O-Ring Seals................................. 1B-16 Thermo Expansion Valve (TXV)
Replacing Dual O-Ring Seals........................1B-16 Replacement.................................................. 1B-39
Servicing Dual O-Ring S eals.........................1B-16 Blower Motor Resistor.....................................1B-40
Handling Refrigerant-134a............................. 1B-17 Blower Motor And Fan................................... 1B-40
Handling Refrigerant Lines And F ittings..... 1B-17 Blower Motor Relay.........................................1B-41
Maintaining Chemical S tability.......................1B-18 Auxiliary A/C Temperature A ctuator............. 1B-41
Refrigerant And Oil Capacity.........................1B-18 Auxiliary A/C Mode Actuator.......................... 1B-42
R efrigerant Recovery And R ecycling, S p e c ific a tio n s.................................................... 1B-42
A dding O il, E vacuating and Fastener Tightening Specifications................1B-42
R echarging.................................................... 1B-19 General Specifications.... ...............................1B-43
General Description.........................................1B-19 System Capacities........................................... 1B-43
Adding O il................................... 1B-19 R134a Metric Fitting Sizes............................. 1B-43
Refrigerant Oil Loss Due to a Large Special T o o ls..................................................... 1B-44
Leak...............................................................1B-19 HD6/HT6 Air Conditioning Compressor
On Vehicle S e rvice .............................................1B-19 Service or Unit Repair R-134a.........1D2-1
Compressor...................................................... 1B-19 General D e scrip tio n ..........................................1D2-1
4.3L, 5.0L, and 5.7L Engines....................1B-19 Metric Thread Size Inform ation.....................1D2-3
7.4L Engine.................................................. 1B-20 U nit R epair......................................................... 1D2-3
6.5L Diesel E ngines................................... 1B-20 Minor Compressor Repair Procedures....... 1D2-3
Compressor Sealing W ashers.......................1B-21 Compressor Clutch Plate and Hub
Compressor And Condenser Hose Assem bly......... ............................................ 1D2-3
Assem bly.........................................................1B-21 Compressor Clutch Rotor and/or
Compressor Pressure Switch.........................1B-23 Bearing..........................................................1D2-4
Evaporator Tube.............................................. 1B-23 Compressor Clutch C o il............................. 1D2-7
Blower Motor Relay.........................................1B-24 Major Compressor Repair Procedures........1D2-8
Condenser........................................................1B-24 Compressor Shafts Seal Replacement.... 1D2-8
Accum ulator.....................................................1B-25 Seal Leak Detection......................... 1D2-8
Expansion (Orifice) T ube............................... 1B-26 Compressor Pressure Relief Valve........1D2-10
Front A/C System Only (C60)....................1B-26 Control Switches........................................ 1D2-11
Rear A/C System (C 69)............................. 1B-27 Compressor Leak Testing......................... 1D2-11
Evaporator C ore...... ...................................... 1B-28 Bench-Check Procedures..................... 1D2-11
Blower Motor and F an................................... 1B-29 S pecial T o o ls ................................................... 1D2-12
Blower Motor Resistor Replacement............ 1B-30
Control Assembly and Blower S w itch.......... 1B-30
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION

GENERAL DESCRIPTION
HEATER SYSTEM M ode Rotary Knob
The heater system provides heating, ram air, power The mode rotary knob operates the defrost control
ventilation, and windshield defrosting. Outside air is cable that goes to the left end of the heater module.
drawn from the plenum at the base of the windshield This cable operates a crank lever and shaft that con
into the heater module by the blower fan. Additional trols the position of an air valve in the heater module.
outside air, called ram air, is forced into the heater mod There are detents at 0 *, 90 *, and 180 * to indicate VENT,
ule by the forward movement of the vehicle. Within the FLOOR, and DEFROST mode positions. Air delivery
heater module, the air is heated as required, and then may be blended by placing the rotary control anywhere
routed through ducts to the proper outlets for discharge in between the two desired modes.
into the passenger compartment. A control assembly in
the instrument panel allows the operator to control blow B low er Speed Control
er speed, mode of operation and temperature of the air
coming from the heater system. The blower switch provides a choice of four blower
speeds and OFF. It receives power through the
CONTROLS HTR-A/C FUSE when the ignition is ON. In the LO
position, the circuit continues through the heater wiring
The control assembly in the instrument panel contains
three rotary control knobs: blower speed, mode selec harness to two resistors in the resistor assembly near
tion, and temperature adjustment (Figure 1). Brightness the blower motor.
of the dial illumination is controlled by the instrument When the blower switch is in a medium-speed posi
panel dimmer control. tion, the circuit continues through the heater wiring har
ness to the resistor assembly, but it bypasses one of
Tem perature R otary Knob the two resistors. When the blower switch is in the
When the temperature rotary knob is in the full COLD HIGH position, the circuit continues through the heater
or counter clockwise position, all of the air delivered by wiring harness to the resistor assembly, but it bypasses
the ventilation system is unheated. When the tempera both resistors to provide full power to the blower motor.
ture rotary control is in the full HOT or clockwise posi From the resistor assembly, the circuit goes to the
tion, all of the air passing through the heater module is blower motor terminal to operate the blower motor. The
heated before it is discharged. Intermediate positions of blower motor circuit is completed to ground by a sheet
the temperature rotary knob result in a mixture of heat metal ground wire that connects to a ground terminal on
ed and unheated air to provide more moderate air tem the cowl.
peratures.
AIR DISTRIBUTION SYSTEM
Within the heater module is a series of air valves
called the temperature valve, vent valve, and the
defroster valve. These air valves are hinged parts that
act like doors to direct airflow through various sections
of the heater module to provide the proper airflow for
the selected operating mode. Each air valve is actuated
by a control cable from the heater control assembly.
Tem perature Valve and H eater Core
The temperature of the air coming from the air distri

bution duct is regulated by controlling the relative
amounts of warm and cool air in the airflow coming from
the heater module. The part of the total airflow through
the heater module that is allowed to pass through the
heater core is governed by the temperature valve. The
temperature valve is operated by the temperature con
trol cable, working through a lever on the temperature
valve shaft. The valve defaults to full cold with no cable
Figure 1— C ontrol Assem bly attached.
1A-2 HEATER AND VENTILATION
When the temperature rotary knob in the control H eater Mode
assembly is in the full COLD position, the temperature When the mode rotary knob is in the HEATER posi
valve is positioned to stop all of the airflow through the tion, the defroster valve remains closed. As a result, air
heater core so only unheated air is sent to the air distri from the blower fan is heated and directed to the
bution duct. defroster valve which sends most of the airflow to the
As the temperature rotary knob moves away from the heater duct, with some going to the defroster nozzle.
full COLD position, the temperature control cable opens
the temperature valve to allow an increasing amount of D efrost Mode
air to pass through the heater core. At the same time, When the mode rotary knob is in the DEFROST posi
the temperature valve reduces the amount of unheated tion, the defroster control cable moves the defroster
air that is allowed to enter the mixture. This results in a valve to fully uncover the opening to the defroster noz
very responsive control of the air temperature dis zle and restrict the opening to the heater duct. This
charged through the heater ducts and defroster. delivers maximum airflow to the defroster, with only a
When the temperature rotary knob reaches the full small amount of airflow coming out of the heater duct.
HOT position, the temperature control cable holds the
temperature valve in a position that diverts all of the AUXILIARY HEATER
airflow through the heater core for maximum heating. An auxiliary heater provides additional heating capaci
Hot coolant from the engine is directed through the ty for the rear of the Suburban model.
heater core and returned to the cooling system when This unit operates independently of the standard heat
the engine is running. er and is regulated through its own controls in the
M ode Valves instrument panel (Aux. Heater Models) or roof panel
(Aux. Heater and A/C Models). This system consists of
The heater system provides a choice of three basic
a separate heater core and blower fan unit mounted in
operating modes consisting of VENT, HEATER, and
the rear of the vehicle.
DEFROST.
B low er M otor C ontrol Switch
OPERATING MODES The auxiliary heater blower switch is located in the
instrument panel to the right of the steering column
V ent M ode
(Aux. Heater Models) or the roof panel (Aux. Heater and
When the mode rotary knob is in the VENT position, A/C Models).
the defroster valve and heater valve remain closed. As
a result, air coming from the instrument panel vents
should be nearly the same temperature as the outside
air.
INSUFFICIENT HEATING OR DEFROSTING
Figure 2—Insufficient Heating or Defrosting (1 of 2)

INSUFFICIENT HEATING OR DEFROSTING

(Continued)
Figure 3—Insufficient Heating or Defrosting (2 of 2)

TEMPERATURE CONTROL EFFORT
C0098
Figure 4 —Tem perature C ontrol E ffort D iagnoele Procedure

DIAGNOSIS OF THE HEATER

FUNCTIONAL TEST Tem perature C heck
When the engine is warmed up (after approximately
Before beginning the functional test of the heater sys
20 minutes of operation), the vehicle should be driven.
tem, the vehicle should be idling with the coolant hot
Use an accurate thermometer to determine the temper
and the thermostat open. Coolant temperature should
ature of the outside air and the temperature of the air
be close to 90* C (194* F). During the functional test,
discharged at the floor outlets with the vehicle being
the operating efforts of the mode rotary knob and the
driven at 48 km/h (30 mph). Minimum acceptable heater
temperature rotary knob should be evaluated. If a prob
output temperatures at four different outside air temper
lem is found during any intermediate step of the func
atures are shown in the table below.
tional test, complete the test before the repair is started.
1. Cycle the temperature rotary knob to the extreme
ends of travel on the control assembly dial to Outside Air -18*C -4*C 10*C 24 *C
ensure that the cable is properly adjusted. Temperature (0*F) (25 *F) (50 *F) (75 *F)
2. Move the mode rotary knob to the VENT position. Heater Air 54 *C 59‘ C 64*C 68 *C
• Air should come from the instrument panel out Temperature (130* F) (139 * F) (147* F) (155*F)
lets at nearly the same temperature as the out T2550
side air.
• Air should not come from the floor outlets, the Minimum acceptable heater output temperatures for
defroster nozzles, or the side window defogger outside air temperatures other than those shown can be
outlets. approximated by using the Fahrenheit scale and round
3. Move the mode rotary knob to the HEATER ing off the outside air tem perature to the nearest
position. 5 degrees. For every additional 5 degrees of outside
• Most of the air should come from the floor out temperature, an additional 1.8 degrees of heater output
lets w ith the rem ainder coming out of the temperature should be allowed when the outside tem
defroster nozzles and defogger outlets. perature is below 50 degrees. An additional 1.6 degrees
• Air should not come from the instrument panel of heater output temperature should be allowed for
outlets in the HEATER position. every 5 degrees of outside temperature when the out
4. Move the mode rotary knob from the HEATER posi side temperature is above 50 degrees.
tion to the DEFROST position.
• Most of the air should be discharged onto the INSUFFICIENT HEATING OR
windshield from the defroster nozzles.
• A small amount of air should also be dis DEFROSTING
charged from the floor outlets. The most likely causes of insufficient heating outside
5. Move the temperature rotary knob back to the full the heater system include a low coolant level, a faulty
COLD position and make sure the air temperature thermostat, a partially or fully clogged heater core or
drops back to nearly the temperature of the outside hose, an obstruction to air circulation or an air leak past
air once again. a faulty seal into the passenger compartment. For an
6. Slowly turn the blower switch toward off, stopping organized diagnosis procedure, refer to Figures 2 and 3.
briefly at each intermediate blower speed position
to notice the force of the airflow coming from the IMPROPER AIR DELIVERY
instrument panel center outlets and the sound of If the Functional Test or other diagnosis indicates
the blower. improper air delivery or a failure to shift modes when
• Both the airflow and the blower noise should moving the mode rotary knob, check the attachment of
reduce noticeably at each intermediate step. the affected control cable at the heater module. Make
sure the cable loop is connected to the actuator and the
HEATER OUTPUT cable sheath is retained. This action can be observed
TEMPERATURE CHECK by removing the instrument panel storage compartment
for access.
The heat output of the heater system can be checked
|f the cause of the problem is not discovered, discon
with the following procedure.
nect the control cable at the valve and check the air
P reparation control valve travel and effort. If there is proper valve
With the engine sufficiently cool, the radiator cap travel and effort, check the control cable travel at the
should be removed and the engine started and allowed heater module end while moving the mode rotary knob.
to idle. Heater controls should be set to HEATER mode, If the cable end doesn’t move, check for a broken cable
full HOT temperature and HIGH blower speed. When or control assembly part and for an unattached cable
coolant flow in the radiator is visible through the filler end at the control assembly. Also, check for a sharp
neck, the radiator cap should be installed. kink in the control cable sheath that could cause severe
binding.
BLOWER NOISE
C0099
Figure 5—Blower Noise Diagnosis Procedure (1 of 2)
BLOWER NOISE
(Continued)
C0100
Figure e—Blower Noise Diagnosis Procedure (2 of 2)

HIGH TEMPERATURE CONTROL EXCESSIVE HEAT
EFFORT The most likely cause of excessive heat from the
A kinked control cable, a binding valve or a faulty heater system is an improperly indexed temperature
control assembly are possible causes of excessive tem control cable. Other related causes of excessive heat
perature control rotary knob effort. For an organized include a slipping self-adjusting clip at the temperature
diagnosis procedure refer to Figure 4. control cable end, a loose control cable sheath retainer
or bracket at the bottom of the heater assembly, or a
binding or obstructed temperature air valve. A hot air
BLOWER NOISE leak from the engine compartment to the blower inlet is
A constant air rush noise is typical of all heater sys also a remote possibility.
tems, some may be louder than others. If possible,
check a similar vehicle to determine whether the noise
is typical or excessive.
For diagnosis of excessive blower noise, refer to Fig
ures 5 and 6.
ON-VEHICLE SERVICE
CONTROL ASSEMBLY AND Install o r C onnect (Figure 7)
BLOWER SWITCH 1. Blower switch.

A. Hold the blower switch in position and install the
0 Rem ove o r D isconnect (Figure 7) retaining clip.
B. Install the blower switch rotary knob.
1. Instrument cluster trim plate. Refer to Instrument 2. Cables to the control assembly.
Panel Assembly Replacement in Instrument Panel 3. Electrical connection.
and Gauges. 4. Control assembly to the instrument panel by snap
2. Control assembly by releasing the snap-fit retainers ping in.
with a small screwdriver. 5. Instrument cluster trim plate.
3. Electrical connection. • Check circuit operation.
4. Cables from the control assembly by releasing
retainers. CONTROL ASSEMBLY LAMP
5. Blower switch.
• Remove the blower switch rotary knob and the BULB
retaining clip from the shaft of the blower
switch. Rem ove o r D isconnect
1. Control assembly. Refer to Control Assembly and

Blower Switch in this section.
• Pull the heater control assembly out far enough
to reach the control assembly lamp socket.
2. Bulb and socket.
3. Bulb from socket.
• Pull the bulb straight out from the socket.
Inspect
• Control assembly lamp socket for corrosion and

damage. Clean or replace as necessary.
• Wires for damage and secure connection to the
bulb socket. Repair or replace as necessary.
Install o r Connect
1. New bulb.
• Push the bulb straight into the socket.
2. Bulb and socket.
3. Control assembly.
• Check circuit operation.
TEMPERATURE CONTROL 2. Control assembly. Refer to Control Assembly and
Blower Switch in this section.
CABLE 3. Electrical connector.
4. Defrost cable from the control assembly.
Rem ove o r D isconnect (Figure 8) 5. Defrost cable from the defroster valve.
1. Roll instrument panel back. Refer to Instrument Install or Connect (Figure 8)

Panel Assembly Replacement in Instrument Panel
and Gauges. 1. Index the cable before installing.
2. Control assembly. Refer to Control Assembly and A. Cycle the mode rotary knob to HEATER.
Blower Switch in this section. B. Make sure the defrost door is closed.
3. Electrical connector. 2. Cable to the defrost valve.
4. Tem perature cable from the h e a te r co n tro l A. Snap the cable onto the valve.
assembly. B. Secure the cable by snapping the cable into the
5. Temperature cable from the temperature valve. heater case.
A. Release cable from the temperature valve by 3. Defrost cable to the control assembly.
squeezing retainer. • Route the cable in the same location as
B. Squeeze post and lift cable end to remove. removed.
4. Electrical connector.
+4- In stall o r C onnect (Figure 8) 5. Control assembly.
6. Instrument cluster trim plate.
1. Index the cable before installing.
A. Cycle the temperature rotary knob to full COLD. BLOWER MOTOR RESISTOR
B. Make sure the temperature door is closed.
2. Cable to the temperature valve. |+ + | Rem ove o r D isconnect (Figure 9)
A. Snap the cable onto the valve.
B. Secure the cable by snapping it into the heater 1. Negative battery cable. Refer to Battery Disconnect
case. Caution in General Information.
3. Temperature cable to the control assembly. 2. Roll instrument panel back. Refer to Instrument
• Route the cable in the same location as Panel Assembly Replacement in Instrument Panel
removed. and Gauges.
4. Electrical connector. 3. Plenum tray.
5. Control assembly. 4. Electrical connector.
6. Roll instrument panel fonward. 5. Screws.
6. Resistor.
DEFROST CONTROL CABLE
■ ► 4- Install or C onnect (Figure 9)
Rem ove o r D isconnect (Figure 8)
1. Instrument cluster trim plate. Refer to Instrument NOTICE: Refer to Fastener Notice In Cau-
Panel Assembly Replacement in Instrument Panel tlons and Notices.
and Gauges.
Figure 8— Tem perature and D efrost C ontrol Cable Figure 9— B low er M otor R esistor
When Installing resistor to the
N O T IC E :
heater case, do not let the resistor colls con
tact each other. Improper system operation or
vehicle damage could result
1. Resistor.
2. Screws.
£l Tighten
• Screws to 1.4 N-m (12 lb in).

4. Plenum tray.
5. Roll instrument panel forward.
6. Negative battery cable.
BLOWER MOTOR AND FAN

^"►l Rem ove o r D isconnect (Figures 10 and 11)
Figure 10— H eater Case (1 of 2)
1. Negative battery cable. Refer to Battery Disconnect
Caution in General Information.
2. instrument panel storage compartment. Refer to
Instrument Panel Assembly Replacement in Instru
ment Panel and Gauges.
3. Front screw from right door sill plate.
4. Right hinge pillar trim panel. Refer to Hinge Pillar
Trim Panel Replacement in Interior Trim.
5. E le ctrica l connectors from blow er m otor, as
necessary.
6. Bolt from right lower IP support.
7. Blower motor cover.
8. Blower motor cooling tube.
9. Blower motor flange screws and ferrules.
10. Blower motor.
• Pull the blower motor forward carefully to avoid
distorting the blower fan.
• May be necessary to pry back right side of
instrument panel.
Inspect
• Blower motor terminals for distortion. Clean cor

rosion from the terminals or replace the blower 5. Bolt to right lower IP support.
motor as necessary. 6. E le c tric a l c o n n e c to rs to b lo w e r m otor, as
• Flange of the blower motor for damage or dis necessary.
tortion that could cause an air leak. Repair as 7. Right hinge pillar trim panel.
necessary. 8. Front screw into front door sill plate.
• Blower fan for damage and distortion. 9. Instrument panel storage compartment.
■ M- In stall o r C onnect (Figures 10 and 11)
1. Blower motor.
• Guide the blower motor and blower fan into HEATER CORE
position, being careful not to catch the blower
fan on protruding parts. |+-»| Rem ove o r D isconnect (Figures 10 and 11)
2. Blower motor flange ferrules and screws.•
Tighten 1. Engine coolant. Refer to Draining and Filling Cool

ing System in Engine Cooling.
• Blower motor mounting screws to 2.1 N.m 2. Instrument panel storage compartment. Refer to
(20 lb in). Instrument Panel Assembly Replacement in Instru
3. Blower motor cooling tube. ment Panel and Gauges.
3. Electrical connectors, as necessary. the heater case to the cowl (Figure 11).
4. Center floor air distribution duct. 14. Two nuts on the engine side of the cowl holding the
5. Hinge pillar trim panels. Refer to Instrument Panel heater case to the cowl (Figure 11).
Assembly Replacement in Instrument Panel and 15. Heater case.
Gauges. • It may be necessary to have an assistant when
6. Blower motor cover. removing heater case.
7. Blower motor. Refer to Blower Motor and Fan in 16. Heater cover.
this section. • Remove seven screws that hold cover to the
8. S teering colum n. R efer to S teering Colum n heater case.
Replacem ent in Steering W heel and Column
17. Heater core from retainer.
On-Vehicle Service.
9. Roll instrument panel back. Refer to Instrument -► 4- Install o r C onnect (Figures 10 and 11)
and Gauges. 1. Heater core into retainer.
10. C oolant recovery reservoir. Refer to Coolant
• Install seven screws that hold heater cover to
Recovery Reservoir in Engine Cooling. heater case.
11. Heater hoses. Refer to Heater Hoses in this
2. Heater cover.
section.
12. Screw on interior side of cowl, near the evaporator • Make sure heater cover is properly sealed.
pipe (if equipped) while holding heater case to the 3. Heater case.
cowl (Figure 10). • May be necessary to have an assistant when
13. Four screws on the engine side of the cowl holding installing heater case.
4. Nuts.
Legend
(1) Air Distributor Duct (7) Knee Bolster
(2) Side Window Defogger Duct (8) Knee Bolster Mounting Screw
(3) Instrument Panel Outlet Air Duct (Right) (9) Side Window Defogger Duct
(4) Instrument Panel Outlet Air Duct (Center) (10) Lap Air Outlet
(5) Instrument Panel Outlet Air Duct (Center) (11) Lap Air Outlet Hose
(6) Instrument Panel Outlet Air Duct (Left) (12) Air Distributor Duct Mounting Screw
Figure 12-— A ir D istribution Ducts
5. Screws. Install o r Connect (Figure 12)
|$ (| T ig h te n 1. Duct to instrument panel.

2. Duct mounting screws.
• Screws on engine side of the cowl to 1.9 N-m
(17 lb in). S Tighten
• Nuts to 2.8 N-m (25 lb in).
• Screw on interior side of the cowl to 11 N-m • Screws to 1.9 N-m (17 lb in).
(97 lb in). 3. Roll instrument panel forward.
6. Heater hoses. 4. Radio.
7. Coolant recovery reservoir. 5. Instrument cluster trim plate.
8. Roll instrument panel forward. 6. Negative battery cable.
9. Steering column.
10. Blower motor. REAR SEAT FLOOR HEAT
12. Hinge pillar trim panels. DUCTS
13. Center floor air distribution duct.
14. Electrical connectors, as necessary. Rem ove o r D isconnect (Figure 13)
15. Instrument panel storage compartment.
16. Engine coolant. 1. Seats. Refer to Front Seat Replacement in Seats.
• Check the system for leaks. 2. Floor storage compartment. Refer to Floor Storage
Compartment Replacement in Interior Trim.
AIR DISTRIBUTOR DUCT 3. Grilles from outlet ducts.
4. Front carpet section. Refer to Front Carpet Section
E3 R e m o v e o r D is c o n n e c t (F ig u re 1 2 )
in Interior Trim.
5. Remove retaining tape.
1. Negative battery cable. Refer to Battery Disconnect 6. Locating tab from the floor pan.
Caution in General Information. 7. Ducts by lifting the rear section of the ducts and
2. Instrument cluster trim plate. Refer to Instrument pulling gently backward.
Install o r Connect (Figure 13)
and Gauges.
3. Radio. Refer to Radio Replacement in Audio
Systems. 1. Ducts by lifting the rear section of the ducts and
4. T ilt back instrument panel assembly. Refer to pushing gently forward.
Instrument Panel Assembly Replacement in Instru 2. Locating tab to the floor pan.
ment Panel and Gauges. 3. Retaining tape.
5. Duct mounting screws. 4. Front carpet section.
6. Duct from instrument panel. 5. Grilles to the outlet ducts.
• Squeeze the retainer in the component carrier 6. Floor storage compartment.
compartment to release the duct. 7. Seats.
Figure 13— Rear S eat Floor H eat Ducts Figure 14— Floor A ir O utlet D uct
FLOOR AIR OUTLET DUCT LAP AIR OUTLET DUCT
Rem ove o r D isconnect (Figure 14) Rem ove o r Disconnect (F ig u re 12)
1. The screw from the floor air outlet duct. 1. The left knee bolster. Refer to Instrument Panel
2. The floor air outlet duct. Assembly Replacement in Instrument Panel and
-H - In stall o r C onnect (Figure 14)
Gauges.
2. The lap outlet duct from the instrument panel by
1. The floor air outlet duct. compressing the retainers.
2. The screw to the floor air outlet duct.
Install or C onnect (Figure 12)
Si Tighten
1. The lap outlet duct to the instrument panel.
• Screw to 1.9 N.m (17 lb in). 2. The left knee bolster.
INSTRUM ENT PANEL AIR DUCT HEATER HOSES

Left S ide Instrum ent Panel A ir O utlet Duct
H eater In let Hose (4.3L, 5.0L, 5.7L and 7.4L
E Rem ove o r D isconnect (Figure 12)
Engines)
1. The instrument panel bezel. Refer to Instrument Tool Required:
Panel Assembly Replacement in Instrument Panel J 38723 Heater Line Quick Connect Separator
and Gauges.
2. The air outlet duct from the bezel. Expand the Rem ove o r D isconnect (Figures 15 and 18)
retainers to remove the air outlet.
1. Engine coolant. Refer to Draining and Filling Cool
0 In stall or C onnect (Figure 12)
2. Inlet hose from generator bracket.
1. The air outlet duct to the instrument panel.
3. Inlet hose at fender clip.
2. The instrument panel bezel.
4. Inlet hose clamp at heater core, water shut off
R ight S ide Instrum ent Panel A ir O utlet Duct valve or tee fitting.
E Rem ove o r D isconnect (Figure 12) • Loosen the clamp enough to slide the damp
away from the fitting on the inlet hose.
1. The instrument panel storage compartment. Refer
5. Inlet hose from heater core.
to Instrument Panel Assembly Replacement in
6. Push inlet hose into connector and insert J 38723
Instrument Panel and Gauges.
or equivalent into connector to release locking tabs.
2. The air outlet duct from the instrument panel.
7. Pull retainer and hose from heater inlet connector.
B In stall o r C onnect (Figure 12)
Inspect
1. The air outlet duct to the instrument panel.
2. The instrument panel storage compartment. • O-ring sealing surface on hose/pipe.
[ 2 | Adjust 6. Engine coolant.
• Check the system for leaks.
• If replacing heater inlet connector, remove H eater In let Hose (D iesel Engines)
retainer from hose and discard, as new connec
tor is equipped with retainer. M Rem ove o r D isconnect (Figures 16 and 18)
• If replacing hose, remove retainer from hose
and reinsert in connector. 1. Engine coolant. Refer to Draining and Filling Cool
• If reusing hose and connector, retainer can ing System in Engine Cooling.
remain in place on hose. 2. Inlet hose from generator bracket.
3. Inlet hose mounting nuts.
0 Install o r C onnect (Figures 15 and 18) 4. Inlet hose clamp at heater core.
• Loosen the clamp enough to slide the damp
1. Push hose into connector until retainer tabs lock. away from the fitting on the inlet hose.
• P u ll back on hose to check fo r p ro pe r 5. Inlet hose from heater core.
engagement. 6. Push inlet hose into connector and insert J 38723
2. Inlet hose to heater core, water shut off valve or or equivalent into connector to release locking tabs.
tee fitting. 7. Pull retainer and hose from heater inlet connector.
3. Inlet hose damp.
4. Inlet hose mounting screw. Inspect
R e fe r to F a s te n e r N o tic e In
N O T IC E : • O-ring sealing surface on hose/pipe.
0 A djust
|^ | Tighten
• If replacing heater inlet connector, remove
• Screw to 30 N.m (22 lb ft). retainer from hose and discard, as new connec
5. Inlet hose to fender clip. tor is equipped with retainer.
Legend
(1) Heater Inlet Hose (5) Hose Clamp
(2) Hose Clamp (6) Heater Outlet Hose Clip
(3) Hose Clamp (7) Inlet Hose Mounting Nut
(4) Heater Outlet Hose
Figure 16— H eater Hose Routing— (D iesel Engines)
• If replacing hose, remove retainer from hose 4. Outlet hose from heater core.
and reinsert in connector. 5. Outlet hose mounting screw.
• If reusing hose and connector, retainer can 6. Outlet hose from generator bracket.
remain in place on hose. 7. Outlet hose clamp from water pump.
8. Outlet hose from water pump.
E Install or Connect (Figures 16 and 18)
I* * ! Install o r C onnect (Figure 15)
1. Push hose into connector until retainer tabs lock.
• Pull back on hose to check for proper engage 1. Outlet hose to water pump.
ment. 2. Outlet hose clamp to water pump.
2. Inlet hose to heater core. 3. Outlet hose to generator bracket.
3. Inlet hose clamp. 4. Generator bracket mounting screw.
4. Inlet hose mounting screw.
Refer to Fastener Notice In Cau
N O TIC E :
N O T IC E : R e fe r to F a s te n e r N o tic e In tions and Notices.
[^ | Tighten
• Screw to 30 N.m (22 lb ft).

• Screw to 30 N.m (22 lb ft). 5. Outlet hose to heater core.
5. Engine coolant. 6. Outlet hose clamp to heater core.
• Check the system for leaks. 7. Outlet hose to fender clip.
8. Engine coolant.
Heater Outlet Hose (4.3L, 5.0L and 5.7L Engines) • Check the system for leaks.
E Remove or Disconnect (Figure 15) H eater O utlet Hose (7.4L Engines)
1. Engine coolant. Refer to Draining and Filling Cool |*"» | Rem ove o r D isconnect (Figure 17)
2. Outlet hose from fender clip. 1. Engine coolant. Refer to Draining and Filling Cool
3. Outlet hose clamp from heater core, water shut off ing System in Engine Cooling.
valve or tee fitting.
2. Hose clamps.
3. Outlet hose from fender clip.
4. Outlet hose from heater core.
5. Outlet hose from radiator.
0 Install or Connect (Figure 17)
1. Outlet hose to radiator.

2. Outlet hose to heater core.
3. Outlet hose to fender clip.
4. Hose clamps.
5. Engine coolant.
Heater Outlet Hose (Diesel Engines)
0 Remove or Disconnect (Figure 16)

2. Hose clamps from radiator and heater core connec
tions. Legend
3. Outlet hose from outlet hose clip. (1) Heater Inlet Hose Connector
4. Outlet hose from the engine. (2) Retainer Locking Tabs
5. Hose clamps from the outlet hose. (3) Retainer Release Tabs
(4) Retainer
[-►4-| Install or Connect (Figure 16) (5) Heater Inlet Hose
Figure 18— Q uick C onnect H eater In let C onnector
1. Hose clamps to the outlet hose.
2. Outlet hose to the engine.
3. O utlet hose to the radiator and heater core
connections.
4. Outlet hose to the outlet hose clip.
5. Engine coolant.
AUXILIARY HEATER (SUBURBAN)

CONTROL SWITCH
I* * ! Rem ove o r D isconnect (Figure 19)
1. Instrument cluster trim. Refer to Instrument Panel

Assembly Replacement in Instrument Panel and
Gauges.
2. Electrical connectors.
3. Control switch from instrument cluster trim.
0 In stall o r Connect (Figure 19)
1. Control switch to instrument cluster trim.

3. Instrument cluster trim.
Front O verhead (A ux. H eater and A /C )
R em ove o r Disconnect (Figure 20)
1. Overhead console. Refer to Overhead Console

Replacement in Interior Trim.
3. Control assembly from overhead console. Figure 1 9 -A u x llia ry H eater C ontrol Switch
•Hr In stall o r Connect (Figure 20) HEATER HOSES
1. Control assembly to overhead console. Front A uxiliary Hose Assem bly
3. Overhead console.
E3 Rem ove or Disconnect (Figures 22 through 24)
• Raise the vehicle and support with suitable safety

C enter O verhead (A ux. H eater and A /C )
stands.
Rem ove o r D isconnect (Figure 21) 1. Engine coolant. Refer to Draining and Filling Cool
1. Bezel. 2. Right front wheelhouse. Refer to Wheelhouse Pan
2. Control assembly from roof panel. el Replacement in Sheet Metal and Fiberglass.
3. Electrical connectors. 3. Bolts.
4. Hose clamps.
In stall o r C onnect (Figure 21) 5. Heater inlet hose from tee fittings.
6. Heater outlet hose at tee fitting.
2. Control assembly to roof panel. Install or C onnect (Figures 22 through 24)
3. Bezel.
• Check circuit operation. 1. Heater outlet hose to tee fittings.
2. Heater inlet hose to tee fittings.
3. Hose clamp bolts.
N O T IC E :
3 Tighten
. Bolts to 17 N.m (13 lb ft).

4. Right front wheelhouse.
5. Engine coolant.
• Lower the vehicle.
Rear Auxiliary Hose Assembly
Tool Required:
J 38723 Heater Line Quick Connect Separator
|+ + | Remove or Disconnect (Figures 24 and 25)
• Raise the vehicle and support with suitable safety

Figure 20— Front O verhead A uxiliary C ontrol Sw itch stands.
2. Bolts.
3. Rear hose assembly from front hose assembly
(Figure 25).
• Push rear hose assem bly into fro nt hose
assembly and insert J 38723 or equivalent into
hose to release locking tabs.
4. Rear hose assembly from auxiliary heater core.
• Push rear hose assembly into auxiliary heater
core and insert J 38723 or equivalent into hose
to release locking tabs.
Install or Connect (Figures 24 and 25)
1. Rear hose assem bly to fro nt hose assem bly

(Figure 25).
• Push rear hose assem bly into front hose
assembly until retainer tabs lock.
2. Rear hose assembly to auxiliary heater core.
• Push rear hose assembly into auxiliary heater
core until retainer tabs lock.
Figure 21— Center Overhead Auxiliary Control Switch 3. Bolts.
HEATER CORE
Rem ove or D isconnect (Figure 26)

2. Rear quarter interior trim, as necessary. Refer to
Quarter Trim Panel Replacement in Interior Trim.
3. Right rear quarter trim panel. Refer to Quarter Trim
Panel Replacement in Interior Trim.
4. Right rear wheelhouse. Refer to Wheelhouse Panel
Replacement in Sheet Metal and Fiberglass.
5. Auxiliary heater hoses from heater core. Refer to
Heater Hoses in this section.
6. Electrical connectors, as necessary.
7. Drain valve.
8. Bolts.
9. Nuts.
10. Heater module.
Figure 23— A uxiliary H eater Hose W ater Flow 11. Blower motor, if necessary.
12. Heater case cover.
N O T IC E :
13. Heater core.
Cautions and Notices.•
+«■ Install o r C onnect (Figure 26)
Tighten
1. Heater core.
• Bolts to 17 N.m (13 lb ft). 2. Heater case cover.
4. Engine coolant. 3. Blower motor, if necessary.
• Lower the vehicle. 4. Heater module.
• Check the system for leaks. 5. Nuts.
Figure 24— A u xiliary H eater Hose A ssem bly R outing (Front)
6. Bolts. Install o r C onnect (Figure 27)
Tighten 1. Blower motor.

2. Blower motor fan.
• Bolts to 1.5 N.m (13 lb in). 3. Blower motor fan retaining nut.
• Nuts to 10 N.m (89 lb in). 4. Screws.
7. Drain valve.
8. Electrical connectors, as necessary. ^ Tighten
9. Auxiliary heater hoses to heater core.
10. Right rear wheelhouse. • Screws to 1.4 N.m (12 lb in).
11. Right rear quarter trim panel. 5. Electrical connectors, as necessary.
12. Engine coolant. 6. Right rear quarter trim panel.
• Check the system for leaks. 7. Negative battery cable.
8. Check circuit operation.
BLOWER MOTOR AND FAN
BLOWER MOTOR RESISTOR
0 Rem ove o r D isconnect (Figure 27)
4
( —►[ Rem ove o r D isconnect (Figure 27)
Caution in General Information. 1. Negative battery cable. Refer to Battery Disconnect
2. Right rear quarter trim panel. Refer to Quarter Trim Caution in General Information.
Panel Replacement in Interior Trim. 2. Right rear quarter trim panel. Refer to Quarter Trim
3. Electrical connectors, as necessary. Panel Replacement in Interior Trim.
4. Screws. 3. Electrical connectors, as necessary.
• Position blower motor in order to remove blower 4. Screws.
motor fan. 5. Blower motor resistor.
5. Blower motor fan retaining nut.
6. Blower motor fan.
7. Blower motor.
Legend
(1) Auxiliary Heater Hose Clip (3) Auxiliary Heater Hose Clip Screw
(2) Auxiliary Inlet and Outlet Heater Hoses (4) Auxiliary Heater Core
Figure 25— A uxiliary H eater Hose A ssem bly Routing (R ear)
Install o r C onnect (Figure 27)
1. Blower motor resistor.

2. Screws.
Tighten
• Screws to 1.4 N-m (12 lb in).

4. Right rear quarter trim panel.
6. Check circuit operation.
(1) Auxiliary Heater Case Mounting Bolt (4) Auxiliary Heater Case Mounting Nut
(2) Auxiliary Heater Case Mounting Nut (5) Auxiliary Heater Case
(3) Drain Valve
Figure 26— A uxiliary H eater Case
Legend
(1) Auxiliary Heater Case (4) Blower Motor Resistor Mounting Screw
(2) Blower Motor (5) Blower Motor Resistor
(3) Blower Motor Mounting Screw (6) Auxiliary Heater Core
Figure 27— A uxiliary B low er M otor Fan and R esistor
SPECIFICATIONS
FASTENER TIG HTENING SPECIFICATIONS
A pplication N.m Lb ft Lb in
Air Inlet Valve-to-lnstrument Panel Screw 1.9 — 17
Alternator Bracket Mounting Screws 30 22 —
Auxiliary Heater Module Mounting Bolts 1.5 — 13
Auxiliary Heater Module Mounting Nuts 10 — 89
Blower Motor Mounting Screw 2.1 — 20
Blower Motor Resistor Mounting Screw 1.4 — 12
Control Assembly Mounting Screw 1.6 — 14
Cowl panel-to-Heater Case Mounting Screw 1.9 — 17
Defroster Nozzle Mounting Screw 1.9 — 17
Defroster Nozzle-to-Heater Case Mounting Screw 1.4 — 12
Distributor Duct Mounting Screw 1.9 — 17
Floor Air Outlet Duct Screw 1.9 — 17
Front Auxiliary Hose-to Frame Mounting Screw 17 13 —
Heater Case-to-Cowl Panel mounting Nut 2.8 — 25
Heater Case-to-Cowl Panel Mounting Screw 11 — 97
Rear Auxiliary Hose Clip-to-Frame Mounting Bolts 17 13 —
Right Vent Cable-to-Heater Case 1.4 — 12
SPECIAL TOOLS
J 38723
1. HEATER UNE QUICK CONNECT SEPARATOR
V3437
HEATER, VEMTILATION, AND AIR CONDITIONING IB-1
SECTION 1B
HEATER, VENTILATION, AND AIR

CONDITIONING
GENERAL DESCRIPTION
COOT A/C SYSTEM When an air conditioning mode is selected, electrical
energy is supplied to the compressor clutch coil. As the
The cycling clutch orifice tube (CCOT) refrigerant sys compressor reduces the evaporator pressure to approxi
tem is designed to cycle a compressor on and off to mately 175 kPa (25 psi), the pressure switch opens,
maintain desired cooling and to prevent evaporator de-energizing the compressor clutch. As the system
freeze-up. Passenger compartment comfort is main equalizes and the pressure reaches approximately
tained by the tem perature selector on the control 315 kPa (46 psi), the pressure switch contacts close,
assembly. re-energizing the clutch coil. This cycling continues and
Control of the refrigeration cycle (on and off operation maintains evaporator discharge air tem perature at
of the compressor) is done with a switch that senses approximately 1 *C (33 * F).
low side pressure as an indicator of evaporator pres Because of this cycling, some slight increases and
sure. The cycling pressure switch is the freeze protec decreases of engine speed/power may be noticed under
tion device in the system and senses refrigerant certain conditions. This is normal. The system is
pressure on the suction side of the system. This switch designed to cycle to maintain desired cooling, thus pre
is located on a standard service low-side fitting. During venting evaporator freeze-up.
air temperatures of 16-26'C (60-80’ F), the equalized Additional compressor protection results from the
pressures within the charged air conditioning system will operating characteristics of the low-side cycling pres
close the contacts of the pressure switch. Refer to sure system. If a massive discharge occurs in the low
Figure 1 for an overview of system components. side of the system, or the orifice tube becomes plugged,
A. HIGH PRESSURE VAPOR 1. COMPRESSOR, A/C

B. HIGH PRESSURE LIQUID 2. CONDENSER, A/C
C. LOW PRESSURE UQUID 3. EVAPORATOR, A/C
D. LOW PRESSURE VAPOR 4. ACCUMULATOR, A/C
5. SWITCH, PRESSURE CYCLING
6. BAG. DESSICANT
7. HOLE, OIL BLEED
8. ORIFICE, A/C CONDENSER
V1392
Figure 1— System Com ponents

IB -2 HEATER, VENTILATION, AND AIR CONDITIONING
low-side pressures could be insufficient to close the Placing the control anywhere in between the major
contacts of the pressure switch. In the event of a low detents results in air output blending between the two
charge, insufficient cooling accompanied by rapid com modes. The recirculation mode is not available anytime
pressor clutch cycling w ill be noticed at high air DEFROST is selected, or while air is being blended out
temperatures. the defrost outlets.
When the engine is turned OFF with the air condition Automatic recirculation will occur when compressor
ing system operating, the refrigerant in the system will head pressures exceed 2275 kPa (350 psi) and disable
flow from the high-pressure side of the expansion tube after head pressures reach 1724 kPa (250 psi). When
(orifice) to the low-pressure side until the pressure is activated, it cannot be manually disabled by the MAX
equalized. This may be detected as a hissing sound for button.
30 to 60 seconds and is a normal condition.
The air conditioning systems that are available for this AIR DISTRIBUTION SYSTEM
vehicle are described below: Airflow control through the HVAC module is regulated
• C60—Front Manual Controls, HVAC System by electronically-actuated doors. At various positions of
• C69—Rear Roof Mounted, HVAC System the rotary knobs on the control assembly, mode doors
mix and direct cooled, heated, and outside air through
U nit R epair Inform ation
the air distribution duct.
For bench repair of the Harrison HT-6 air conditioning
compressor, refer to HD6/HT6 Air Conditioning Com Ducts and O utlets
pressor Service Or Unit Repair R-134a. A one-piece air distributor duct directs air to the pas
senger compartment. It attaches to the instrument panel
CONTROLS with snap-in style retainers and three screws.
In case of poor air output, check the air distributor
The air conditioning system on C/K models is elec
duct for obstructions such as leaves, dirt, or objects that
tronically controlled. Three backlit, rotary knobs provide m ay have fa lle n in to it fro m th e p a s s e n g e r
full control of the system. These rotary knobs control
compartment.
blower speed, air temperature, and mode of operation.
Two push-to-latch buttons select recirculation mode for REFRIGERATION SYSTEM
maximum cooling and control over the air conditioning
compressor. A ccum ulator
The blower speed rotary control has four fan speeds The sealed accum ulator assembly connects to the
and an off position. When the blower fan is turned off, evaporator outlet pipe. It functions as a liquid/vapor sep
all HVAC operations turn off also. arator that receives refrigerant vapor, some liquid refrig
The temperature rotary control has 180* of travel. A erant and refrigerant oil from the evaporator. It only
detent at the full cold-end of travel engages recircula allow s re frig e ra n t vapor and o il to flo w to the
tion. Operating the system with the temperature control compressor.
placed in this detent will result in maximum cooling. Air At the bottom of the accumulator is desiccant that
inside the passenger compartment will be recirculated acts as a drying agent for moisture that may have
through the blower case. Outside air use will be mini entered the system. An oil bleed hole is also located
mal. Recirculation can also be manually selected by near the bottom of the accumulator outlet pipe to pro
pushing the RECIRC button. vide an oil return path to the compressor.
The mode rotary control has three major detents to A low-side pressure service fitting is located on the
indicate VENT, FLOOR, and DEFROST mode positions. accumulator. A similar service fitting is provided for
mounting the cycling pressure switch. It is not neces
sary to discharge the system to replace the switch. The
accum ulator is serviced only as a replacem ent
assembly.
C om pressor
The Harrison HT-6 compressor is belt driven by the
engine crankshaft through the compressor clutch pulley.
The compressor pulley rotates freely, without turning the
compressor shaft, until an electromagnetic clutch coil is
energized. When voltage is applied to energize the
clutch coil, a clutch plate and hub assembly are drawn
rearward toward the pulley. The magnetic force locks
the clutch plate and pulley together as one unit to drive
the compressor shaft.
All replacement compressors from service parts will
have 240 ml (8 fl oz) of oil in the crankcase. When
replacing compressors, drain the oil from the old com
pressor into an approved container, and note the
amount drained. You must also drain the oil from the
new compressor, then fill the new compressor with new
oil in the same amount that was drained from the old
compressor.
HEATER, VENTILATION, AND AIR CONDITIONING IB -3
Condenser E vaporator
The condenser assembly in front of the radiator con The evaporator cools and dehumidifies the air before
sists of coils that carry the refrigerant, and cooling fins, it enters the vehicle. High pressure liquid refrigerant
that provide rapid transfer of heat. Air passing through flows through the orifice tube (front system) or TXV
the condenser cools the high-pressure refrigerant vapor (rear system) into the low-pressure area of the evapora
causing it to condense into a liquid. tor. The heat in the air passing through the evaporator
core is lost to the cooler surface of the core, thereby
Expansion (O rifice) Tube cooling the air. As the process of heat loss from the air
The plastic expansion tube, with its mesh screen and to the evaporator core surface is taking place, any
orifice is located in the condenser outlet pipe in all mod moisture (humidity) in the air condenses on the outside
els except models with rear air conditioning (RPO C69). surface of the evaporator core and is drained off as
Models equipped with rear air conditioning use a water.
Y-shaped junction block in the tube between the con
denser and the front evaporator. The junction block is H eater Core
located near the right side of the radiator support. The In any air conditioning mode, the heater core heats
expansion tube is located between the junction block the cool, dehumidified air to achieve the desired tem
and the front evaporator. Refer to Evaporator Tube perature. The position of the control assembly tempera
under On-Vehicle Service— Rear A/C System in this ture rotary knob determines how much heat is added to
section, for more information and component locator the incoming air.
views.
The orifice tube provides a restriction to the high-pres High Pressure R elief Valve
sure liquid refrigerant in the liquid line, metering the flow The compressor is equipped with a pressure relief
of refrigerant to the evaporator as a low-pressure liquid. valve as a safety factor. Under certain conditions, the
The expansion tube and orifice are protected from con refrigerant on the discharge side may exceed the
tamination by filter screens on both inlet and outlet designed operating pressure. Exceeding this pressure
sides. The tube is serviced only as a replacement limit may cause refrigerant loss out of the pressure
assembly. relief valve. To prevent refrigerant loss or compressor
When the engine is turned OFF with the air condition damage, the high pressure cutoff switch opens automat
ing operating, the refrigerant in the system will flow from ically at approximately 3036 kPa (440 psi). When the
the high-pressure side of the expansion tube (orifice) to switch opens, current to the compressor clutch is inter
the low-pressure side until the pressure is equalized. rupted. Any condition that causes the switch to open will
This may be detected as a faint sound of liquid flowing keep the compressor from operating.
(hissing) for 30 to 60 seconds and is a normal
R efrigerant-134a
condition.
When system diagnostics indicate a restricted expan
C A U T IO N : A v o id b re a th in g A /C R e frig e r
sion tube, it may not be necessary to replace it. Metal
an t-1 3 4a and lu b rica n t v ap o r and m ist. Expo
chips, flakes, or slivers found on the screen may be
su re m ay irrita te eyes, n o se, and th ro at. To
removed with compressed air. The expansion tube may
rem ove R -134a from th e A /C system , use ser
be reused if:
v ic e eq u ip m en t c e rtifie d to m eet th e req u ire
• The plastic frame is not broken.
m e n ts o f S A E J 2 2 1 0 (R -1 3 4 a r e c y c lin g
• The expansion tube is not damaged or plugged.
e q u ip m en t). If a c c id e n ta l s ystem d is ch a rg e
• The screen material is not torn.
o ccu rs, v en tila te th e w o rk a rea b efo re resum
• The screen is not plugged with fine gritty material.
in g s e rv ic e . A d d itio n a l h e a lth a n d s a fe ty
Therm al Expansion Valve (TXV) in fo rm atio n m ay be o b tain ed fro m th e re frig
The rear air conditioning system uses a Thermal eran t and lu b rican t m an u factu rers.
Expansion Valve (TXV). The valve consists of the capil
lary tube, body, actuating pins, seat and orifice. At the Like the coolant in the engine cooling system, the
high pressure liquid inlet, a fine mesh screen prevents refrigerant is the substance in the air conditioning
dirt, filings or other foreign material from entering the system that absorbs, carries, and then releases heat.
valve orifice. Although various substances are used as refrigerants in
When the valve is connected in the system, high other types of refrigeration systems, some automotive
pressure liquid refrigerant enters the valve through the a ir c o n d it io n in g s y s te m s use a ty p e c a lle d
screen from the condenser and passes on to the seat Refrigerant-12 (R-12).
and orifice where it changes into a low pressure liquid. This vehicle uses Refrigerant-134a (R-134a). It is a
The low pressure liquid leaves the valve and flows non-toxic, non-flammable, clear, gas.
into the rear evaporator core where it absorbs heat from While the R-134a A/C system is very similar to an
the rear evaporator core and changes to a low pressure R-12 A/C system, the differences in the refrigerant,
vapor and leaves the rear evaporator core. The capillary lubricants, and service equipment are important.
tube is clamped to the low pressure vapor line just
below the outlet of the rear evaporator. The capillary
tube is held in contact with the rear evaporator outlet
tube by a metal clip placed near the end of the tube.
1B-4 HEATER, VENTILATION, AND AIR CONDITIONING
NOTICE: R-134a refrigerant is not compati With high blower speed selected, No. 1 and No. 2
ble with R-12 refrigerant in an air condition blower relays are off. Relay No. 3 is on, and provides a
ing system. R-12 in an R-134a system will parallel battery feed circuit to the blower motor.
cause com pressor failure, refrigerant oil
sludge, or p o o r a ir conditioning system Compressor Pressure Switch
performance. This system is equipped with a compressor pressure
sw itch th a t is n o rm a lly open. It a c tiv a te s at
Refrigerant-134a carries a charge of a special lubri 2069-2482 kPa (300-360 psi) and releases at 1724 kPa
cant called polyalkaline glycol (PAG) refrigerant oil. GM (250 psi).
(PAG) refrigerant oil has a slight blue tint. The oil is Its function is to drive the recirculation door to the
hydroscopic (absorbs water from the atmosphere). Store closed position to reduce the system load and decrease
it in closed containers. system high-side pressure.
High Pressure Cutoff Switch
HEATER SYSTEM The system is also equipped with a high pressure
The air conditioning system operates on the reheat cutoff switch. This switch is normally closed, and opens
principle in that all the air passing through the system is at 2827-3103 kPa (410-450 psi) to interrupt the voltage
chilled almost to a freezing temperature and then to the compressor clutch coil. This will stop the com
reheated to a more comfortable temperature before it is pressor from cycling and prevent the pressure relief
discharged into the passenger compartment. valve from discharging refrigerant and oil.
The dehumidified air is reheated as it passes through
the heater core in the air conditioning module. The heat Pressure Cycling Switch
er is warmed by engine coolant passing through the The refrigeration cycle (on and off operation of the
tubes of the heater core. This heat is transferred to the compressor) is controlled by a switch that senses the
heater core fins and given off to the air flowing past the low-side pressure as an indicator of evaporator temper
fins. The position of the air temperature valve in the air ature. The pressure cycling switch is the freeze protec
conditioning module determines how much of the total tion device in the system and senses refrigerant
airflow is allowed to pass through the heater. In turn, pressure on the suction side of the system. This switch
this determines the warmth of the total airflow dis is mounted on a standard service low-side fitting. This
charged into the passenger compartment. The heater switch also provides compressor cutoff during cold
water valve (on models so equipped) stops the flow of weather.
coolant to front heater core under certain conditions. Additional compressor protection results from the
This results in im proved a ir conditioning system operating characteristics of the low-side pressure
performance. cycling system. If a massive discharge occurs in the low
side of the system, or the orifice tube becomes plugged,
RELAYS AND SWITCHES low-side pressures could be insufficient to close the
contacts of the pressure switch. In the event of a low
Blower Controls charge, insufficient cooling accompanied by rapid com
Battery voltage is supplied at all times to the No. 1 pressor clutch cycling will be noticed at high outside
blower relay through the HTR A/C fuse and the RED (ambient) air temperatures.
wire. When the control assembly is OFF, all blower If replacement of the pressure cycling switch is nec
relays are de-energized. In this state there is no voltage essary, it is important to note that this may be done
path through the relay contacts to the blower motor. The without removing the refrigerant charge. A service fitting
blower motor does not run. is located in the pressure switch fitting. During replace
With low blower speed selected, current flows through ment of the pressure switch, a new O-ring seal must be
the No. 1 relay, to the top of the resistor board (A) and in sta lle d and the sw itch assem bled to 4.5 N-m
both resistors. (40 lb in).
With medium #1 blower speed selected, current flows
through the No. 1 relay, to the No. 2 relay, to the center
of the resistor board (A) and one resistor to the motor.
With medium #2 blower speed selected, current flow
is the same as in medium #1 in addition, a parallel
current path goes through resistor (B) and No. 3 blower
relay to the blower motor. This provides a parallel path
with a value less than one alone, but more voltage than
for medium #1 blower speed.
REFRIGERANT SYSTEM DIAGNOSIS

FUNCTIONAL TEST 5. Record ambient temperature at the vehicle.
6. Record relative humidity. Use a psychrometer or
To aid in determining whether or not the air condition consult the local weather bureau.
ing, electrical, air, and refrigeration systems are operat
ing properly, refer to Performance Test in this section. m Im p o rta n t
For additional electrical diagrams and diagnostic infor
mation, refer to Engine Controls, Transmission Diagno • Make sure to record relative humidity and ambi
sis, and Electrical Diagnosis for these models. ent temperature conditions at time of test.
1. Operation of the air conditioning blower at all 7. Close doors or windows.
speeds, in any position except OFF and engage • For models with rear A/C, turn rear A/C ON.
ment of the compressor clutch indicates that the 8. Press the A/C button, adjust blower speed to HI,
electrical circuits are functioning properly. and temperature to full COLD.
2. The same hand-felt temperature of the evaporator 9. Open the air conditioning outlets.
inlet pipe and the accumulator surface of an oper 10. Install J 21213-A or equivalent into the right center
ating system indicates a properly charged system. air conditioning outlet.
3. Operation of the air conditioning control head to 11. Place transmission in PARK or NEUTRAL.
distribute air from the designed outlets indicates 12. Start engine, stabilize engine speed at 2000 RPM,
proper functioning. and start the timer.
13. Run the air conditioning system until outlet air
PERFORMANCE TEST reaches the lowest temperature (about 3 minutes).
Tool Required: 14. Record the outlet air temperature and high side and
J 21213-A Four Jack-Dual Range Temperature low side pressures.
Tester or Equivalent 15. Turn the engine off and compare the readings. Nor
1. Park the vehicle inside or in a shaded area. mally operating air conditioning systems should not
2. Open doors or windows to ventilate the interior. exceed the levels shown in Figure 3.
3. Vent engine exhaust if necessary.
4. Open the hood and install ACR4 high and low side
pressure gages.
MAXIMUM MAXIMUM RIGHT MAXIMUM
RELATIVE AMBIENT LOW SIDE ENGINE CENTER AIR HIGH SIDE
HUMIDITY AIR 1rEMP PRESSURE SPEED OUTLET TEMP PRESSURE
(%) •F •C PSIG kPaG (rpm) *F *C PSIG kPaG
20 70 21 24 165 2000 44 7 285 1965
80 27 25 172 45 7 290 2000
90 32 28 193 49 9 314 2165
100 38 28 193 50 10 320 2206
30 70 21 25 172 2000 43 6 287 1979
80 27 26 179 45 7 293 2020
90 32 28 193 50 9 320 2206
100 38 31 214 53 12 328 2262
40 70 21 25 172 2000 45 7 290 2000
80 27 28 193 49 9 315 2172
90 32 28 193 51 11 325 2241
100 38 37 255 59 15 361 2489
50 70 21 26 179 2000 45 7 290 2000
80 27 28 193 50 10 320 2206
90 32 32 221 54 12 330 2275
100 38 40 276 64 18 370 2551
60 70 21 27 186 2000 46 8 300 2069
80 27 28 193 50 10 320 2206
90 32 36 248 58 14 355 2448
100 38 45 310 68 20 409 2820
70 70 21 28 193 2000 49 9 315 2172
80 27 28 193 51 11 325 2241
90 32 38 262 62 17 363 2503
80 70 21 28 193 2000 50 10 320 2206
80 27 32 221 54 12 330 2275
90 32 41 283 65 18 377 2600
T3204
Figure 3— System Performance Test
If a malfunction in the refrigerant system is suspected 4. Air ducts for leaks or restrictions. Low airflow rate
due to abnorm al system pressures, inspect the may indicate a restricted evaporator core.
following: 5. Compressor clutch for slippage.
1. Outer surfaces of radiator and condenser cores. 6. Drive belt for improper tension.
Make sure airflow is not blocked by dirt, leaves, or 7. Accumulator for plugging.
other foreign material. Check between the con 8. Expansion (orifice) tube for plugging.
denser and radiator as well as the outer surfaces. If the problem is not found, continue with diagnostic
2. Evaporator core, condenser core, hoses, tubes, procedures in Figures 4 through 8.
etc., for restrictions or kinks.
3. Refrigerant leaks.
C.C.O.T. SYSTEM AIR CONDITIONING DIAGNOSIS

INSUFFICIENT COOLING “CHART A”
Figure 4— CCOT Air Conditioning System Diagnosis Procedure (1 of 5)


INSUFFICIENT COOLING “CHART B”
C0104
Figure S— CCOT Air Conditioning System Disgnosis Procedure (2 of 5)
HEATER, VENTILATION, AND AIR CONDITIONING 1B-9
C.C.O.T. SYSTEM AIR CONDITIONING DIAGNOSTICS

INSUFFICIENT COOLING “CHART C”
C0041
Figure 6— CCOT Air Conditioning System Diagnosis Procedure (3 of 5)


INSUFFICIENT COOLING “CHART D”
C0035
Figure 7—CCOT Air Conditioning System Diagnosis Procedure (4 of 5)


INSUFFICIENT COOLING “CHART E”
C0038
Figure 8—CCOT Air Conditioning System Diagnosis Procedure (5 of 5)

LEAK TESTING The successful use of this and any other elec
tronic leak detector depends greatly upon the scan
C A U T IO N : A v o id b re a th in g A /C R e frig e r rate and upon carefully following the manufactur
a n t-1 3 43 and lu b rican t vap o r o r m ist. Expo er’s instructions regarding calibration, operation,
s u re m ay irrita te eyes, nose, and th ro at. To and maintenance. Each joint must be completely
rem ove R -134a fro m th e A /C system , use ser circled moving at 25-51 mm (1-2 inches) per sec
v ic e e q u ip m en t certifie d to m eet th e req u ire ond with the tip of the probe as close to the sur
m e n ts o f S A E J 2 2 1 0 (R -1 3 4 a r e c y c lin g face as possible but no more than 6 mm
eq u ip m en t). If accid en tal d isch arg e occurs, (0.25 inches) away and without blocking the air
v e n tila te th e w o rk a rea b efo re resum ing ser intake (Figure 10). A leak is indicated when the
v ic e . A d d itio n al h ealth and s afety inform ation audible tone goes from a steady 1-2 clicks per
m ay b e o b ta in e d fro m th e re frig e ra n t and second to a solid alarm. Adjust the balance knob
lu b ric a n t m an u factu rers. fre q u e n tly to m a in tain the 1-2 c lic k s per
second rate.
A refrigerant leak test should be performed on the
system whenever a leak is suspected and after perform m Im portant
ing a service operation that disturbs the components,
lines, or connections. Many methods and special tools • Halogen leak detectors are sensitive to wind
are available for this purpose; however, no matter which shield washing solutions, many solvents and
tool is used, care and diligence are the biggest keys to cleaners, and some adhesives used in the vehi
success. cle. Prevent a false warning by making sure
surfaces are clean. Also, surfaces should be
E lectronic Leak D etector dry, since ingestion of liquids will damage the
Tool Required: detector.
J 39400 Electronic Leak Detector
This type of leak detector has been found to be
the most useful tool in locating refrigerant leaks.
The J 39400 is a small unit that operates on 12V
DC and provides an audible signal that increases
in frequency as R-134a is detected (Figure 9).
Make sure the instrument is properly calibrated,
according to the included instructions, and that the
detector is used in the proper setting for the type
of refrigerant being tested. The detector GAS
switch should be placed in the R-134a setting prior
to use.
The most common leaks are found at the refrig
erant fittings or connections. This may be caused
by improper torque, damaged O-ring seals, lack of
lubricant on O-ring seals, or dirt/debris across the
O-ring seals. Even the smallest piece of lint from
cotton gloves or shop cloths can create a leak
path across an O-ring seal.
V3715
R E FR IG E R A N T LIN E
Figure 9— E lectronic Leak D etector Figure 10— A/C Leak Scan M ethod
The evaporator inlet and outlet, accumulator C om pressor B lock Fitting and S haft Seal
inlet and outlet, condenser inlet and outlet, all 1. Blow shop air behind and in front of the compres
brazed and welded areas, areas showing signs sor clutch/pulley for at least 15 seconds.
of damage, hose couplings, compressor rear 2. Wait 1-2 minutes.
head, and housing joints may be tested using 3. Probe the area in front of the pulley. If the detector
this procedure. goes to a solid alarm, a leak has been found.
m Im portant CCOT AIR CONDITIONING

• Always follow the refrigerant system around in a SYSTEM DIAGNOSIS CHARTS
continuous path so that no areas of potential Refer to Figures 4 through 8 for diagnosis of the
leaks are missed. Always test all the above CCOT air conditioning system.
areas to make sure the entire system is leak
free, even when one leak is already found. BLOWER NOISE
A constant air rush noise is typical of high-speed
C A U TIO N : T ake c are to p reven t perso n al in ju blower operation. Some systems and modes may be
ry th a t c o u ld o c c u r w h en to u c h in g a h o t noisier than others. If possible, check another similar
en g in e w h ile te s tin g . T ests should be done vehicle to determine whether the noise is typical or
w ith th e en g in e O FF and as co o l as p o ssib le. excessive.
Do n o t o p erate th e d etecto r in a co m b u stib le Sit in the vehicle with the doors and windows closed.
atm o sp h ere s in ce its sen so r o p erates a t high With the engine running, run the blower on HIGH speed
te m p eratu re. with the temperature set for maximum cooling. Cycle
through the blower speeds, modes, and temperature
Service Ports/A ccess Valves settings to find where the noise does not occur. Try to
The primary seal for the service ports is the sealing define the types of noise.
cap. This cap contains a specially designed O-ring seal • Noise is constant, but decreases with blower speed
or gasket that provides a leak-free seal. Should the cap reduction. Typical noises are a whine, tick/click,
be loose, missing, or the wrong cap used, it will result in flutter, or scrape.
the loss of refrigerant charge. • Noise is only at startup or intermittent. This noise
may occur at cold am bients and low blower
E vaporator Core speeds. Typical noise is a squeal/screech.
One of the most difficult leaks to find is in the evapo • Noise is constant at high blower speeds in certain
rator core. To leak test the core: modes, but can be eliminated at lower blower
1. Turn the blower fan on HIGH for 15 or more sec speeds in other modes. Typical noises are a flutter
onds; then turn it off. or rumble.
2. Wait 10 minutes. If the noise persists, remove the blower assembly and
3. Remove the blower motor resistor. Refer to Blower check for obstructions or foreign material causing noise
Motor Resistor in this section. and remove. If no obstructions are found and the noise
4. Insert the leak detector probe as close to the evap is still heard, replace the blower assembly.
orator as possible. If the detector goes to a solid
alarm, a leak has been found.
5. If possible, visually inspect the core face with a
flashlight for evidence of refrigerant oil.
IB -1 4 HEATER, VENTILATION, AND AIR CONDITIONING
DIAGNOSIS OF AIR CONDITIONING (HEATER)

PROBLEM PO SSIBLE CAUSE CORRECTION
Inadequate D efrost 1. Obstruction in defroster nozzle. 1. Both defroster nozzle outlets should be
ing inspected. Any foreign objects should
be removed. Any loose instrument pan
el pad that blocks an outlet should be
repaired.
2. Damaged defroster nozzle outlet. 2. The outlet flange should be carefully
reshaped with pliers so the outlet open
ing is uniform. If the outlet flange cannot
be reshaped, the air distributor should
be replaced.
3. Faulty mode actuator. 3. Defroster air valve operation should be
checked. A faulty mode actuator should
be replaced.
4. Insufficient heat. 4. Refer to Insufficient Heating of Passen
ger Compartment in this chart.
Inoperative B low er 1. Blown fuse. 1. The fuse should be replaced.
2. Open circuit. 2. Check the circuit between the ignition
switch and the blower motor, and the
blower motor ground circuit. Repair as
necessary.
3. Faulty blower switch. 3. A fa u lty blow er sw itch should be
replaced.
In su fficien t H eating 1. Incorrect operation of controls. 1. The driver should be advised of proper
of P assenger C om - operation of controls.
partm ent 2. Low engine coolant level. 2. Coolant should be added as needed. A
check should be made for coolant
leaks. The engine should be run to
clear any air locks.
3. Faulty engine thermostat. 3. The thermostat should be checked and
replaced if necessary.
4. Kinked heater hose. 4. Hoses should be checked and kinks
should be s tra ig h te n e d or hoses
replaced as necessary.
5. Obstructed heater core tubes. 5. An obstruction usually causes a swish
ing noise in the core. Any foreign mate
rial should be removed from the core or
the core should be replaced.
6. Faulty blower motor or blower circuit. 6. Faulty wires or connections must be
repaired or replaced. A faulty blower
motor must be replaced.
7. Faulty heater water valve or solenoid or 7. Check that the water valve closes when
control circuit. (If equipped.) temp control is moved to coldest set
ting. If not, check electrical connections
between control head and solenoid and
vacuum lin e connections between
engine and solenoid, and solenoid and
water valve. Water Valve should open
when temp control is moved several
notches off of coldest setting.
C old D rafts on Floor 1. Partially open air inlet valve. 1. The air inlet valve should close properly
in all modes except recirculation mode.
Repairs should be made as necessary.
2. Side door seals damaged or missing. 2. All door seals should be inspected.
Faulty seals should be repaired or
replaced as necessary.
D0277
HEATER, VENTILATION, AND AIR CONDITIONING IB -1 5
A/C NOISE DIAGNOSIS

NOISE DESCRIPTION SOURCE SOLUTION RECOMMENDATION
CHECK
1. MOAN (OCCURS AT A SPE COMPRESSOR. A. GROUNDOUTS.
CIFIC RPM, LESS AT OTHER B. LOOSE BRACKETS BOLTS.
SPEEDS). C. EXHAUST SYSTEM GROUND.
D. LOW BELT TENSION.
E. COMP. TORQ. CUSHION (TATC)
ON HT6 ONLY.
F. SOFTER HOSE MATERIAL.
2. GROWL (IDLE). COMPRESSOR. GROUNDOUTS ON ALL A/C LINES
AND COMPONENTS.
3. GROWL (ALL SPEEDS). COMPRESSOR. ALL LINE CLAMPS AND ANCHOR
POINTS (REMOVE TO CHECK).
4. CHATTER (IDLE). COMPRESSOR. SYSTEM REFRIG. CHARGE AND
OIL (ADD 1/2# R134A AND 3 oz.
PAG OIL, CHECK EFFECT.
5. W HINE (ALL SPEEDS) OR 1. COMPRESSOR. a. PULLEY BRG. WITH A/C ON
GRIND. 2. P/S PUMP. AND OFF.
3. GENERATOR. b. IN T E R F E R E N C E AT A L L
ROTATING POINTS OF PULLEY
(CHECK WITH BELT ON AND
OFF).
6. SQUEAL (ALL SPEEDS). 1. COMPRESSOR. A. BELT ALIGNMENT.
2. P/S PUMP. B. TENSIONER TORQUE.
3. GENERATOR. C. B E LT C O N D IT IO N (E D G E
WEAR FOR RUBBING).
7. HISS, GURGLE OR PERCOLA 1. ORIFICE TUBE. OCCURS AT A/C SHUT DOWN
TION. 2. TXV (THERMAL EXPANSION (NORMAL CONDITION, NOISE
VALVE). SUBSIDES AFTER SHORT TIME
PERIOD).
8. CHIRP OR THUMP. COMPRESSOR CLUTCH. OCCURS WHEN A/C CYCLES ON
(COMPRESSOR CLUTCH ENGAG
ES OR DISENGAGES). APPLY
ANTI-SEIZE COMPOUND TO
CLUTCH FACE (VERY LIGHT COAT
OF MOLY KOTE OR PERMATEX
2000).
9. KNOCK. COMPRESSOR. A. LOOSE BRACKET BOLTS.
B. BELT TENSIONER.
A/C ODOR DIAGNOSIS

PROBLEM POSSIBLE CAUSE CORRECTION
M usty Sm ell 1. Water leaks (body). 1. Seal body.

2. Evaporator drain. 2. Clean drain.
3. Mold/miidew. 3. Clean evaporator.
C oolant Sm ell 1. Anti-freeze. 1. Heater core.

2. Heater pipe/hoses.
R efrig eran t Leak 1. Refrigerant oil. 1. Evaporator core.
NOTE: MOLD/MILDEW ODOR PROBLEM — Under certain climate and operating conditions a musty odor develops
from mold growth in the evaporator core face. This odor is generally temporary and as climate conditions
change will disappear and repair on its own. However, if odor persists, it will become necessary to remove
evaporator core and clean the face with appropriate cleaner.
D0290
IB -1 6 HEATER, VENTILATION, AND AIB CONDITIONING
REFRIGERATION SYSTEM SERVICES

Before attempting any service that requires opening • Use J 38042 dual O-ring tube separator to separate
the refrigerant lines or components to the atmosphere, the joint while loosening the female nut.
the technician should be thoroughly familiar with the • Whenever a fitting joint is opened, replace the
information under Handling Refrigerant-134a, Handling O-rings with new ones.
Refrigerant Lines and Fittings, and Maintaining Chemi • Use a nonmetallic tool when removing O-rings to
cal Stability in this section. Very carefully follow the prevent the chance of damaging the seal surface.
instructions in the Refrigerant Recovery and Recycling, • Avoid excessive stretching and twisting of replace
Adding Oil, Evacuating and Recharging Procedures in ment O-rings.
this section, for the unit being serviced. • Align the end forms for pilot-to-bore insertion, then
push together completely.
REPLACING O-RING SEALS • Application of a small amount of 525 viscosity
Install new GM-approved service replacement air con refrigerant oil will ease insertion.
ditioning O-ring seals whenever a joint or fitting is disas
sembled, except when the O-ring seals are provided on B Im portant
new replacement components. Unless service replace
ment O-ring seals bearing the specified part numbers • Dual O-ring fittings are different in size from
are used, excessive leakage of Refrigerant-134a may standard A/C fitting O-rings.
occur. Refer to the part number for identification.
Coat air conditioning O-ring seals with 525 viscosity
refrigerant oil just before installation. Slip them onto the
flange tube to ensure proper locating and sealing. To
prevent the possibility of swelling and a reduction in
sealing effectiveness, do not soak O-ring seals in refrig
erant oil. Before installation, O-ring seals and fittings
should be examined to make sure they have not been
nicked or deformed. Replace nicked or deformed parts
to prevent refrigerant leakage.
REPLACING DUAL O-RING

SEALS
Install new GM-approved service replacement air con
ditioning O-ring seals whenever a joint or fitting is disas
sembled, except when the O-ring seals are provided on
new replacement components. Unless service replace
ment O-ring seals bearing the specified part numbers
are used, excessive leakage of Refrigerant-134a may
occur. Refer to the part number for identification.
This vehicle uses GM’s dual O-ring joint design in the Figure 11— Proper O-Ring Installation
system. This design increases the durability of the joint
seal by providing a second O-ring seal. The dual O-ring
design consists of:
• An aluminum-alloy, externally threaded fitting which
is brazed or welded to an aluminum tube.
• A free-spinning, plated steel internally threaded nut.
• A precision machined, male-piloted aluminum tube
end which accommodates two O-rings.
SERVICING DUAL O-RING

SEALS
Tool Required:
J 38042 Dual O-Ring Tube Separator
When servicing the dual O-ring joint, the follow
ing procedure should be followed:
• Completely recover refrigerant from system. Refer
to Refrigerant Recovery and Recycling, Adding Oil,
Evacuating and Recharging Procedures in this
section.
Figure 12—Improper O-Ring Installation

• Dual O-ring fittings require that the aluminum • All metal tubing lines should be free of dents or
nut be tightened to a torque of 24 N.m (18 lb ft). kinks to prevent loss of system capacity due to line
Before installation, O-ring seals and fittings restriction.
should be examined to make sure they have • The flexible hose lines should never be bent to a
not been nicked or deformed. Replace nicked or radius of less than four times the diameter of the
deformed parts to prevent refrigerant leakage. hose.
• The flexible hose lines should never be allowed to
HANDLING REFRIGERANT-134a come within a distance of 6.5 mm (2.5 inches) of
the exhaust manifold.
C A U T IO N : A vo id b re a th in g A /C re frig e ra n t
• Flexible hose lines should be inspected regularly
and lu b rican t v ap o r o r m ist. Exposure m ay
for leaks or brittleness and replaced with new lines
irrita te e ye s , n o se, and th ro a t. T o rem ove
if deterioration or leaking is found.
R -1 3 4a fro m th e A /C s y s te m , u se s e rv ic e • When disconnecting any fitting in the refrigerant
eq u ip m en t c e rtifie d to m eet th e requirem ents system, the system must be discharged of all
o f SAE J2210 (R -134a recyclin g equipm ent). If
Refrigerant-134a. However, proceed very cautious
accid en tal system d isch arg e o ccu rs, ven tila te
ly, regardless of the gage readings. Open very
w o rk area b efo re resum ing s ervice. A d dition
slowly, keeping your face and hands away so that
a l h e a lth a n d s a fe ty in fo rm a tio n m ay b e
no injury can occur. If pressure is noticed when a
obtained fro m re frig e ra n t and lu b rican t m anu
fitting is loosened, allow it to bleed off very slowly.
factu rers.
| ^ l Im portant N O TIC E:Alcohol should never be used in

the refrigeration system In an attem pt to
• R-12 refrigerant and R-134a refrigerant must never remove moisture. Damage to system compo
be mixed, even in the smallest of amounts. They nents could occur.
are incompatible with each other. If the refrigerants
are mixed, compressor failure is likely to occur. • If any refrigerant line is opened to the atmosphere,
• Use only specified lubricant (PAG) for the R-134a it should be immediately capped to prevent the
A/C system and R-134a components. If lubricants entrance of moisture and dirt. These contaminants
other than those specified are used, compressor can cause internal compressor wear or plugged
failure is likely to occur. All fittings and O-ring seals lines in the condenser and evaporator core and
should be coated with clean 525 viscosity refriger expansion (orifice) tubes or compressor inlet
ant oil to provide a leak-proof seal and to aid in screens.
assembly and disassembly. • Remove sealing caps from subassemblies just
• Do not store or heat refrigerant containers above before making connections for final assembly. Use
52*C(125*F). a small amount of clean 525 viscosity refrigerant oil
• Do not heat a refrigerant container with an open on all tube and hose joints. Use new O-ring seals
flame. If the container must be warmed, place the dipped in 525 viscosity refrigerant oil when assem
bottom of the container in a pail of warm water. bling joints. The oil will aid in assembly and help to
• Do not intentionally drop, puncture, or incinerate provide a leakproof joint. O-ring seals and seats
refrigerant containers. must be in perfect condition because a burr or a
• Refrigerant will displace oxygen, so make sure to piece of dirt can cause a refrigerant leak. Refer to
work in well-ventilated areas to prevent suffocation. Figures 11 and 12 for additional information.
• Do not introduce compressed air to any refrigerant
container or refrigerant component, because con
tamination will occur.
• If it is necessary to carry a container of Dot CFR
Refrigerant-134a in a vehicle, do not carry it in the
passenger compartment.
All Refrigerant-134a disposable (colored Blue) con
tainers are shipped with a heavy metal screw cap to
protect the valve and safety plug of the container from
damage. It is good practice to replace the cap after
each use of the container to continue protection.
HANDLING REFRIGERANT
LINES AND FITTINGS
Im portant
• Before opening the refrigeration system to the

atmosphere, make sure the work area is well venti
lated. Welding or steam-cleaning operations should
not be done on or near refrigeration system lines or
other air conditioning parts on the vehicle. Figure 13— Using the Two-Wrench Method
The following general practices should be followed to
ensure chemical stability in the system:
1. Whenever it becomes necessary to disconnect a
hose connection, wipe away any dirt or oil at or
near the connection to eliminate the possibility of
dirt entering the system. Both sides of the connec
tion should be capped, plugged, or taped as soon
as possible to prevent the entrance of dirt and
moisture. (Remember that all air contains moisture.
Air that enters any part of the refrigeration system
will carry moisture with it, and the exposed surfac
es will collect the moisture quickly.)
2. Keep tools clean and dry. This includes the Mani
fold Gage Set and all replacement parts.
3. When adding polyalkaline glycol (PAG) refrigerant
oil, the container/transfer tube through which the oil
will flow should be exceptionally clean and dry.
Refrigerant oil must be as moisture-free as possi
ble.
4. When it is necessary to open an air conditioning
Figure 14— R efrigerant Line Installation system, have everything needed ready so that as
little time as possible will be required to perform the
• It is important to use the proper wrenches when operation. Do not leave the air conditioning system
making connections on O-ring seal fittings. The use open any longer than necessary.
of improper wrenches may damage the connection. 5. Anytime the air conditioning system has been
The opposing fitting should always be backed up opened, it should be properly evacuated before
with a wrench to prevent distortion of connecting recharging.
lines or components (Figures 13 and 14). When
connecting the flexible hose connections, it is REFRIGERANT AND OIL
important that the swaged fitting and the flare nut,
as well as the coupling to which it is attached, be
CAPACITY
held at the same time using three different wrench The refrigerant system requires refrigerant and oil in
es to prevent turning the fitting and damaging the the quantities listed below:
seat. 1. Refrigerant-134a.
Tighten tubing connections to the specified torque. • Pickup Models (except Crew Cab) with C60-
Refer to Specifications in this section. 0.91 kg (2.0 lb).
• Crew Cab, Suburban, and Utility Models with
MAINTAINING CHEMICAL C60- 1.02 kg (2.25 lb).
• Suburban and Four Door Utility Models with
STABILITY C69- 1.81 kg (4.0 lb).
The life and efficient operation of the air conditioning 2. Polyalkaline Glycol (PAG) Refrigerant Oil.
system depends upon the chemical stability of the • Front Air Conditioning System (C60) - 240 ml (8
refrigerant system. When foreign materials, such as dirt, fl oz).
air, or moisture, contaminate the refrigeration system, • Front and Rear Air Conditioning System (C69) -
they change the stability of the Refrigerant-134a and 330 ml (11 fl oz).
polyalkaline glycol (PAG) refrigerant oil. They will also • Overcharging a system may allow liquid Refrig
affect the pressure-temperature relationship, reduce effi erant-1343 to get into the compressor, causing
ciency, and could cause internal corrosion and abnor compressor noise and damage. Undercharging
mal wear of moving parts. will cause insufficient cooling.
REFRIGERANT RECOVERY AND RECYCLING, ADDING

OIL, EVACUATING AND RECHARGING PROCEDURES
GENERAL DESCRIPTION B. Accumulator—Add 105 ml (3.5 fl oz) of new oil to
the replacement accumulator to compensate for oil
The J 39500 A/C Refrigerant Recovery, Recycling and retained by original accumulator desiccant and bag
Recharging (ACR4) removes the Refrigerant-134a from assem blies. The accum ulator should only be
the vehicle’s A/C system. There is one filtering cycle replaced if leaking due to a perforation, damaged
during recovery plus an automatic multiple pass filtering O-ring seal seat, or damaged threads.
during the evacuation cycle, that assures a constant C. E v a p o ra to r— A dd 90 ml (3 fl oz) of new
supply of clean/dry refrigerant for the A/C system charg refrigerant oil.
ing. Refer to the J 39500 ACR4 manual for operation D. C o n d e n s e r— Add 30 m l (1 fl oz) o f new
and setup instructions. refrigerant oil.
ADDING OIL R efrigerant O il Loss Due to a Large Leak
The Harrison HT-6 compressor system used on all If the refrigerant charge is abruptly lost due to a large
C/K models requires polyalkaline glycol (PAG) refriger refrigerant leak, approximately 90 ml (3 fl oz) of refriger
ant oil in the quantities listed below: ant oil will be carried out of the system suspended in
• Without Aux. A/C - 240 ml (8 fl oz) the refrigerant. Any failure that caused an abrupt refrig
. With Aux. A/C - 330 ml (11 fl oz) erant discharge will experience this oil loss. Failures
New oil quantities must be added to the system dur that allow the refrigerant to seep or bleed off over time
ing component replacement and conditions stated as do not experience this oil loss.
follows: Upon replacement of a component that caused a
• With no signs of excessive oil leakage, add: large refrigerant leak, add 90 ml (3 fl oz) of new polyal
A. All Compressors (drain and measure the oil) kaline glycol (PAG) refrigerant oil plus the desired
• If less than 30 ml (1 fl oz) is drained—add amount of oil for the particular component. Refer to
60 ml (2 fl oz) to the new compressor. Adding Oil in this section.
• If more than 30 ml (1 fl oz) is drained—add
same amount that was drained to the new com
pressor.
ON-VEHICLE SERVICE
COMPRESSOR Install o r C onnect (Figure 15)
4.3L, 5.0L and 5.7L Engines 1. Fill compressor with oil.
E3 Rem ove or D isconnect (Figure 15)

2. Compressor to bracket.

2. Recover refrigerant. Refer to Refrigerant Recovery
and R ecycling, Adding O il, E vacuating and
Recharging Procedures in this section.
3. Drive belt. Refer to Drive Belt Replacement in
Engine Mechanical.
4. Refrigerant hose assembly from compressor. Refer
to Compressor and Condenser Hose Assembly in
this section.
• Cap or plug all open connections.
6. Bolts.
7. Compressor from bracket.
8. Drain and measure compressor oil. Refer to Adding
Oil in this section.
Figure 15— C om pressor M ounting (4.3L, 5.0L, and

5.7L Engines)
3. Compressor mounting bolts. 2. Compressor to bracket.
3. Compressor mounting bolts.
N O TIC E:Refer to Fastener Notice in Cau
tions and Notices. N O TIC E:Refer to Fastener Notice in Cau■
tions and Notices.
Tighten
Tighten
• Bolts to 50 N m (37 lb ft).
4. Electrical connectors, as necessary. • Bolts to 50 N-m (37 lb ft).
5. Refrigerant hose assembly to compressor. 4. Electrical connectors, as necessary.
6. Drive belt. 5. Refrigerant hose assembly to compressor.
7. Negative battery cable. 6. Drive belt.
8. Charge system. Refer to Refrigerant Recovery and 7. Negative battery cable.
Recycling, Adding Oil, Evacuating and Recharging 8. Charge system. Refer to Refrigerant Recovery and
Procedures in this section. Recycling, Adding Oil, Evacuating and Recharging
9. Check system for leaks. Refer to Leak Testing in Procedures in this section.
this section. 9. Check system for leaks. Refer to Leak Testing in
this section.
7.4L Engine

6.5L Diesel Engines

Caution in General Information. 1. Negative battery cable. Refer to Battery Disconnect
2. Recover refrigerant. Refer to Refrigerant Recovery Caution in General Information.
and R ecycling, A dding O il, E vacuating and 2. Recover refrigerant. Refer to Refrigerant Recovery
Recharging Procedures in this section. and R ecycling, Adding O il, E vacuating and
3. Drive belt. Refer to Drive Belt Replacement in Recharging Procedures in this section.
Engine Mechanical. 3. Drive belt. Refer to Drive Belt Replacement in
4. Refrigerant hose assembly from compressor. Refer Engine Mechanical.
to Compressor and Condenser Hose Assembly in 4. Refrigerant hose assembly from compressor. Refer
this section. to Compressor and Condenser Hose Assembly in
• Cap or plug all open connections. this section.
5. Electrical connectors, as necessary. • Cap or plug all open connections.
6. Bolt. 5. Electrical connectors, as necessary.
7. Compressor from bracket. 6. Bolts.
8. Drain and measure compressor oil. Refer to Adding 7. Compressor from bracket.
Oil in this section. 8. Drain and measure compressor oil. Refer to Adding
E3 In stall o r Connect (Figure 16)

Oil in this section.
1. Fill compressor with oil.
Figure 17— Com pressor M ounting (6.5L D iesel

Figure 16—Compressor Mounting (7.4L Engines) Engines)
1. Fill compressor with oil.

2. Compressor to bracket.
3. Compressor mounting bolts.
N O TIC E: Refer to Fastener Notice in Cau
tions and Notices.
Tighten
. Bolts to 50 N-m (37 lb ft).

5. Refrigerant hose assembly to compressor.
6. Drive belt.
8. Charge system. Refer to Refrigerant Recovery and
Recycling, Adding Oil, Evacuating and Recharging
Procedures in this section.
9. Check system for leaks. Refer to Leak Testing in
this section.
Figure 19— Sealing W asher Installation (2 of 2)
COMPRESSOR SEALING
3. Hold block in place, hand tighten bolt.
WASHERS
Tighten
m Im portant
• Bolt to 34 N.m (25 lb ft).
• When installing sealing washers, keep dirt and for
eign material from getting on the sealing surfaces COMPRESSOR AND
of the washers, hose block, or compressor ports.
Clean all sealing surfaces with a lint-free rag. CONDENSER HOSE ASSEMBLY
• Do not reuse sealing washers. Refer to the following figures for the models listed
• Sealing washers do not have to be oiled prior to below:
assembly. • Pickup/Extended Cab Models (4.3L, 5.0L, 5.7L, and
0 Install o r C onnect
7.4L Engines), Figure 20.
• Suburban/Crew Cab Models (7.4L Engines w/o
Aux. Heater or A/C), Figure 20.
1 .I n s ta ll s e a lin g w a s h e r o n to p ilo ts o f • Suburban/Four Door Utility and Crew Cab Models
suction/discharge block fitting. Washers must bot (5.7L Engines w/o Aux. A/C), Figure 20.
tom against surface of block fitting (Figure 18). • All Models (6.5L Diesel Engines w/o Aux. A/C),
2. Install hose block to the compressor. Make sure the Figure 21.
sealing washers are seated within the compressor Tool Required:
machined surfaces (Figure 19). J 38042 Dual O-Ring Tube Separator
0 Rem ove or D isconnect (Figures 20 and 21)

and R ecycling, A dding O il, E vacuating and
3. Grille. Refer to Radiator G rille Replacement in
Sheet Metal.
4. Bolt.
5. Hose assembly from top of compressor.
6. Sealing washers. Refer to Compressor Sealing
Washers in this section.
7. Hose assembly from accumulator using J 38042.
Refer to Servicing Dual O-Ring Seals in this sec
tion.
8. O-ring seals from accumulator hose.
9. Hose assembly from condenser.
10. O-ring seal from condenser hose.
Figure 1$—Sealing Waeher Installation (1 of 2)
Figure 21— C om pressor and C ondenser Hose Assem bly

Install o r Connect (Figures 20 and 21) 2. Electrical connectors, as necessary.
3. Compressor pressure switch.
1. New O-ring seal to condenser hose. 4. O-ring seal.
• Coat O-ring seal with 525 viscosity refrigerant
■ M- Install o r C onnect (Figure 22)
oil.
2. Hose assembly to condenser.
1. New O-ring seal.
N O TIC E:Refer to Fastener Notice in Cau • Coat O-ring seal with 525 viscosity refrigerant
tions and Notices. oil.
|^ | Tighten
2. Compressor pressure switch.
• Hose assembly to 45 N-m (33 lb ft). N O TIC E: Refer to Fastener Notice in Cau
3. New dual O-ring seals to accumulator hose. tions and Notices.
• Coat O-ring seals with 525 viscosity refrigerant
oil. |< \) Tighten
4. Hose assembly to accumulator.
• Compressor pressure switch to 6 N.m (53 lb in).
S Tighten 3. Electrical connectors, as necessary.
• Hose assembly to 24 N.m (18 lb ft).
5. Sealing washers. EVAPORATOR TUBE
6. Hose assembly to the top of the compressor.
7. Bolt. Rem ove or D isconnect (Figure 23)
3 Tighten 1. Negative battery cable. Refer to Battery Disconnect

• Bolt to 34 N-m (25 lb ft). 2. Recover refrigerant. Refer to Refrigerant Recovery
8. Grille. and R ecycling, A dding O il, E vacuating and
9. Negative battery cable. Recharging Procedures in this section.
10. Charge system. Refer to Refrigerant Recovery and 3. Auxiliary heater pipe, if equipped. Refer to Heater
Recycling, Adding Oil, Evacuating and Recharging Hoses in Heater and Ventilation.
Procedures in this section. 4. Coolant recovery reservoir. Refer to Coolant
11. Check system for leaks. Refer to leak Testing in R ecovery R eservoir R eplacem ent in Engine
this section. Cooling.
5. Evaporator tube from evaporator.
COMPRESSOR PRESSURE 6. O-ring seal.
SWITCH 7. Evaporator tube from condenser.
8. O-ring seal.
B Rem ove o r D isconnect (Figure 22) 9. Evaporator tube from clip.

Figure 22— C om pressor Pressure Sw itch

B Install o r Connect (Figure 23)
1. Evaporator tube into clip.

2. New O-ring seal.
oil.
3. Evaporator tube to condenser.
NOTICE: Refer to Fastener Notice in Cau

tions and Notices.
Tighten
• Evaporator tube to 24 N-m (18 lb ft).

4. New O-ring seal.
oil.
5. Evaporator tube to evaporator.
Tighten
• Evaporator tube to 24 N.m (18 lb ft).

6.Coolant recovery reservoir.
7.Auxiliary heater pipe, if equipped.
8.Negative battery cable.
9.Charge system. Refer to Refrigerant Recovery and
this section.
Legend
(1) Blower Motor Resistor Screw
(2) Blower Motor Resistor
(3) Relay Bracket Screw
(4) Blower Motor Relay
Figure 24— B low er M otor R elay/R esistor
0 Install o r C onnect (Figure 24)
1. Relay to relay bracket.

3. Instrument panel compartment.
CONDENSER
|+-»| Rem ove o r D isconnect (Figure 25)

2. Grille. Refer to Radiator G rille Replacement in
BLOWER MOTOR RELAY Sheet Metal.
3. Hood primary latch support.
3 Remove o r Disconnect (Figure 24) 4. Auxiliary cooling fan, if equipped. Refer to Auxiliary
Cooling Fan and Motor Replacement in Engine
1. Negative battery cable. Refer to Battery Disconnect Cooling.
Caution in General Information. 5. Refrigerant hose from condenser. Refer to Com
2. Instrument panel compartment. Refer to Instrument pressor and Condenser Hose Assembly in this sec
Panel Assembly Replacement in Instrument Panel tion.
and Gauges. 6. Evaporator tube from condenser. Refer to Evapora
3. Electrical connectors, as necessary. tor Tube in this section.
4. Relay from relay bracket. • Cap or plug all open connections.
Figure 25— Condenser A ssem bly
7. Bolts. ACCUMULATOR
8. Brackets.
9. Upper insulators. Tool Required:
J 38042 Dual O-Ring Tube Separator
10. Condenser.
• Bend the left grille support outboard to gain
0 Rem ove or D isconnect (Figure 26)
clearance for the condenser removal.
11. Lower insulators.
Install o r C onnect (Figure 25) Caution in General Information.
and R ecycling, Adding O il, E vacuating and
1. Lower insulators.
2. Condenser. Refer to Adding Oil in this section, if
replacing condenser. 3. Electrical connectors, as necessary.
4. Pressure cycling switch.
3. Upper insulators.
5. Refrigerant hose from accumulator using J 38042.
4. Brackets.
Refer to Compressor and Condenser Hose Assem
5. Bolts.
bly in this section.
^ Tighten 6. Accumulator from the evaporator using J 38042.
7. O-ring seals from accumulator.
• Bolts to 4.5 N-m (40 lb in).
| j j Im portant
7. Refrigerant hose to condenser.
8. Auxiliary cooling fan, if equipped.
9. Hood primary latch support. 8. Accumulator bracket screw.
10. Grille. 9. Accumulator.
11. Charge system. Refer to Refrigerant Recovery and 10. Upper and lower accumulator insulators.
Recycling, Adding Oil, Evacuating and Recharging ■M * Install o r Connect (Figure 26)
this section. 1. Upper and lower accumulator insulators.
2. Accumulator. Refer to Adding Oil in this section, if
replacing accumulator.
Figure 26— A ccum ulator
3. Accumulator bracket screw. EXPANSION (ORIFICE) TUBE

N O TIC E :Refer to Fastener Notice in Cau Front A/C System O nly (C 60)
tions and Notices. Tool Required:
J 26549-E Orifice Tube Remover and Installer or
Tighten Equivalent
• Screw to 6 N-m (53 lb in). Rem ove o r D isconnect (Figure 27)

4. New O-ring seals.
• Coat O-ring seals with 525 viscosity refrigerant 1. Recover refrigerant. Refer to Refrigerant Recovery
oil. and R ecycling, Adding O il, E vacuating and
5. Accumulator to the evaporator. Recharging Procedures in this section.
2. Grille. Refer to Radiator Grille Replacement in
Tighten Sheet Metal.
3. Evaporator tube from condenser. Refer to Evapora
• Accumulator to 41 N-m (30 lb ft). tor Tube in this section.
6. Refrigerant hose to accumulator.• 4. O-ring seal.
• Cap or plug the open line.
Tighten 5. Expansion (orifice) tube from the condenser outlet
pipe, using J 26549-E or equivalent.
• Hose to 41 N-m (30 lb ft). • In the event that difficulty is encountered during
7. Pressure cycling switch. the removal of a restricted or plugged expan
8. Electrical connectors, as necessary. sion (orifice) tube, the following procedure is
9. Negative battery cable. recommended:
10. Charge system. Refer to Refrigerant Recovery and A. Remove as much of any impacted residue
Recycling, Adding Oil, Evacuating and Recharging as possible.
Procedures in this section. B. Carefully apply heat with heat gun (hair dri
11. Check system for leaks. Refer to Leak Testing in er, epoxy drier or equivalent) approximately
this section. 7 mm (1/4 inch) from dimples on inlet pipe.
Do not overheat pipe.
Legend
(1) Condenser (3) Orifice Tube
(2) Condenser Outlet Pipe
Figure 27— O rifice Tube Location-M odels w ith C60
C. While applying heat, use expansion tube Rem ove or D isconnect (Figure 28)
removal tools J 26549-E or equivalent to
grip the expansion (orifice) tube. Use a turn 1. Recover refrigerant. Refer to Refrigerant Recovery
ing motion along with a push-pull motion to and R ecycling, Adding O il, E vacuating and
loosen the impacted expansion (orifice) tube Recharging Procedures in this section.
and remove it. 2. The evaporator tube connection near the junction
block (Figure 28). It may be necessary to remove
0 Install or C onnect (Figure 27) the air cleaner assembly on some models.
3. The O-ring seal.
1. Expansion tube into condenser outlet pipe, using • Cap or plug the open line.
J 26549-E or equivalent. 4. Orifice tube from evaporator tube using J 26549-E
2. New O-ring seal. or equivalent.
A. Coat O-ring seal with 525 viscosity refrigerant
oil. + 4* Install or Connect (Figure 28)
B. Insert the short screen end of the new orifice
into the evaporator tube. 1. Orifice tube into evaporator tube using J 26549-E
3. Evaporator tube to condenser. or equivalent.
4. Grille. 2. New O-ring seal.
5. Charge system. Refer to Refrigerant Recovery and • Coat new O-ring seal with 525 viscosity refriger
Recycling, Adding Oil, Evacuating and Recharging ation oil.
Procedures in this section. 3. Evaporator tube connection.
this section. Tighten
R ear A /C System (C69)

• Tube connection to 24 N.m (18 Lb ft).
Tool Required:
J 26549-E Orifice Tube Remover and Installer or
Equivalent
(1) Orifice Tube (4) Seal

(2) Compressor/Condenser Hose (5) Clip
(3) Evaporator Tube (6) Evaporator Tube Junction Block
Figure 28— O rifice Tube Location-M odels with C69
4. Charge system. Refer to Refrigerant Recovery and 9. Blower motor cover.

Recycling, Adding Oil, Evacuating and Recharging 10. Blower motor (60). Refer to Blower Motor and Fan
Procedures in this section. in this section.
5. Check system for leaks. Refer to Leak Testing in 11. S teering colum n. R efer to S teering Column
this section. Replacem ent in Steering W heel and Column
On-Vehicle Service.
EVAPORATOR CORE 12. T ilt back instrument panel assembly. Refer to
Instrument Panel Assembly Replacement in Instru
R em ove o r D isconnect (Figure 29) ment Panel and Gauges.
13. C oolant recovery reservoir. Refer to Coolant
1. Negative battery cable. Refer to Battery Disconnect Recovery Reservoir Replacement in Engine Cool
Caution in General Information. ing.
2. Engine coolant. Refer to Draining and Filling Cool 14. Heater hoses. Refer to Heater Hoses in Heater and
ing System in Engine Cooling. Ventilation.
3. Recover refrigerant. Refer to Refrigerant Recovery 15. Evaporator tube. Refer to Evaporator Tube in this
and R ecycling, A dding O il, E vacuating and section.
Recharging Procedures in this section. 16. Accumulator. Refer to Accumulator in this section.
4. Instrum ent panel. Refer to Instrum ent Panel 17. Screws (52 and 64).
Assembly Replacement in Instrument Panel and 18. Nut (50).
Gauges. 19. Screw (56).
5. Electrical connectors, as necessary. 20. Module assembly (57).
6. Center floor air distribution duct. • May be necessary to have an assistant when
7. PCM and mounting tray (diesel engines only). removing module assembly.
8. Hinge pillar trim panels. Refer to Hinge Pillar Trim 21. Evaporator case bottom cover plate (63).
Panel Replacement in Interior Trim. • Remove the seven screws that hold the cover
plate to the module assembly.
22. Heater core and seal from module assembly. 9. Accumulator.
23. Evaporator case cover (61). 10. Evaporator tube.
• Remove the four screws that hold the case cov 11. Heater hoses.
er to the module assembly. 12. Coolant recovery reservoir.
24. Evaporator core. 13. Instrument panel.
14. Steering column.
Install o r Connect (Figure 29) 15. Blower motor (60).
Evaporator core. Refer to Adding Oil in this section, 17. Hinge pillar trim panels.
if replacing evaporator core. 18. PCM and mounting tray.
2. Evaporator case cover (61). 19. Center floor air distribution duct.
• Install the four screws that hold the case cover 20. Electrical connectors, as necessary.
to the module assembly. 21. Engine coolant.
3. Heater core and seal into module assembly. 22. Negative battery cable.
4. Evaporator case bottom cover plate (63). 23. Charge system. Refer to Refrigerant Recovery and
• Install the seven screws that hold the cover Recycling, Adding Oil, Evacuating and Recharging
plate to the module assembly. Procedures in this section.
5. Module assembly (57). 24. Check system for leaks. Refer to Leak Testing in
• May be necessary to have an assistant when this section.
installing module assembly.
6. Screw (56). BLOWER MOTOR AND FAN
7. Nut (50).
8. Screws (52 and 64). Rem ove or D isconnect (Figure 29)
N O TIC E :Refer to Fastener Notice In Cau 1. Negative battery cable. Refer to Battery Disconnect
tions and Notices. Caution in General Information.
2. Instrument panel compartment. Refer to Instrument
Tighten Panel Assembly Replacement in Instrument Panel
and Gauges.
• Screw (56) to 11 N-m (97 lb in). 3. Front screw from right door sill plate.
• Nut (50) to 2.8 N-m (25 lb in). 4. Right hinge pillar trim panel. Refer to Hinge Pillar
• Screws (52 and 64) to 1.9 N.m (17 lb in). Trim Panel Replacement in Interior Trim.
50. NUT ACCUMULATOR BRACKET MOUNTING

51. BRACKET, A/C ACCUMULATOR
52. SCREW, ACCUMULATOR BRACKET MOUNTING
55. SEAL, AIR DISTRIBUTION DUCT
56. SCREW, MODULE MOUNTING
57. MODULE, HEATHER AND A/C
58. SEAL, AIR INLET
59. SEAL, BLOWER MOTOR MOUNTING
60. MOTOR, BLOWER
61. COVER, EVAPORATOR CASE
62. BRACKET, RELAY
63. PLATE, COVER
64. SCREW, MODULE MOUNTING
52 51 VIEW A
Figure 29—Evaporator/Heater Core Case

5. Electrical connectors from PCM, as necessary. Install or C onnect (Figure 24)
6. PCM and mounting bracket (diesel engines only).
7. Electrical connectors from blower motor (60), as 1. Blower motor resistor (74).
necessary. 2. Screws (73).
8. Bolt from right lower l/P support.
9. Blower motor cover. Tighten
10. Blower motor cooling tube.
11. Blower motor flange screws (59). • Screws (73) to 1.4 N.m (12 lb in).
12. Blower motor (60). 3. Electrical connectors, as necessary.
• Pull the blower motor forward carefully to avoid 4. Plenum tray.
distorting the blower fan. 5. Roll instrument panel forward.
• May be necessary to pry back right side of 6. Negative battery cable.
instrument panel. • Check circuit operation.
Inspect CONTROL ASSEMBLY AND
• Blower motor terminals for distortion. Clean cor BLOWER SWITCH
rosion from the terminals or replace the blower
motor (60) as necessary. |<"»| Rem ove or D isconnect (Figure 30)
• Flange of the blower motor (60) for damage or
distortion that could cause an air leak. Repair 1. Instrument cluster trim. Refer to Instrument Panel
as necessary. Assembly Replacement in Instrument Panel and
• Blower fan for damage and distortion. Gauges.
2. Control assembly.
Install or C onnect (Figure 29) • Release the retainers using a small screwdriver;
then pull the control assembly out from the
1. Blower motor (60). instrument panel.
• Guide the blower motor and blower fan into 3. Electrical connectors, as necessary.
position, being careful not to catch the blower
fan on protruding parts. -►4- Install or Connect (Figure 30)
2. Blower motor flange screws (59).
3. Blower motor cooling tube. 1. Electrical connectors, as necessary.
4. Blower motor cover. 2. Control assembly.
5. Bolt to right lower l/P support. • The control assembly snap-fits to the instrument
6. Electrical connectors to blower motor (16), as nec panel.
essary. 3. Instrument cluster trim.
7. Mounting bracket and ECM. • Check circuit operation.
8. Electrical connectors to ECM, as necessary.
9. Right hinge pillar trim panel. HEATER HOSES
10. Front screw into front door sill plate. For complete replacement procedure, refer to Heater
11. Instrument panel compartment. Hoses in Heater and Ventilation.

|+ + | R em ove o r D isconnect (Figure 24)

2. Roll instrument panel back. Refer to Instrument
and Gauges.
3. Plenum tray.
5. Screws (73).
6. Blower motor resistor (74).
Figure 30—Control Assembly Replacement

HEATER, VENTILATION, AND AIR CONDITIONING IB-31
HEATER CORE AIR DISTRIBUTOR DUCT
For complete replacement procedure, refer to Heater
Core in Heater and Ventilation. Rem ove or D isconnect (Figure 32)
HEATER WATER VALVE (IF 1. Negative battery cable. Refer to Battery Disconnect
EQUIPPED) 2. Instrument panel bezel. Refer to Instrument Panel
Assembly Replacement in Instrument Panel and
Rem ove or D isconnect (Figure 31) Gauges.
3. Radio. Refer to Radio Replacement in Audio Sys
1. Engine coolant. Refer to Draining and Filling Cool tems.
ing System in Engine Cooling. 4. Roll instrument panel back. Refer to Instrument
2. Hose clamps at heater water valve. Panel Assembly Replacement in instrument Panel
• Loosen the clamps enough to slide the clamps and Gauges.
away from the fittings on the valve. 5. Duct mounting screws.
3. Hoses from valve. • Squeeze the retainer in the component carrier
4. Vacuum line from valve. compartment to release the duct.
5. Valve. 6. Duct from instrument panel.
Install or C onnect (Figure 31) -M - Install or C onnect (Figure 32)
1. Vacuum line to valve. 1. Duct to instrument panel.

2. Hoses to valve. 2. Duct mounting screws.
3. Clamps to hoses.
• Slide clamps to previous location beyond retain Tighten
ing bead on water valve fitting.
4. Engine coolant. Refer to Draining and Filling Cool • Screws to 1.9 N m (17 lb in).
ing System in Engine Cooling. 3. Roll instrument panel forward.
Legend
(1) Heater Water Valve (3) Vacuum Line
(2) Hose Clamp (4) Hose
Figure 31—-Heater Water Valve (If Equipped)
1B-32 HEATER, VENTILATION, AND AIR COM Pm ONW G
4. Radio. B. Turn the ignition key to the run position and let
5. Instrument panel bezel. the actuator position itself.
6. Negative battery cable. C. Turn off the ignition key.
D. Remove the actuator from the electrical connec
MODE ACTUATOR tion.
The mode actuator is located on the left side of the
air distribution case (Figure 33). 0 Install or C onnect (Figure 34)
Rem ove o r D isconnect (Figure 34) 1. Mode actuator.

2. Screws.
1. Negative battery cable. Refer to Battery Disconnect 3. Adjuster links to control lever.
Caution in General Information. 4. Electrical connector.
2. Electrical connector. 5. Negative battery cable.
3. Screws. • Check circuit operation.
4. Adjuster links from control lever.
5. Mode actuator. TEMPERATURE ACTUATOR
The temperature actuator is located in the passenger
A djust compartment of the vehicle, on the front of the heater
case (Figure 35).
A. Electrical connector to the actuator.
2. Roll instrument panel forward. Refer to Instrument
and Gauges.
4. Screws.
5. Actuator.
A djust
A. Electrical connector to the actuator.

B. Turn the ignition key to the run position and let
the actuator position itself.
C. Turn off the ignition key.
D. Remove the actuator from the electrical connec
tor.
Install or Connect (Figure 36)
1. Actuator.
2. Screws.
Figure 36— Tem perature A ctuator R eplacem ent 3. Electrical connectors.
4. Instrument panel compartment.
Rem ove or D isconnect (Figure 36) 5. Negative battery cable.
ON-VEHICLE SERVICE—REAR A/C SYSTEM

CONTROL ASSEMBLY 3. Electrical harness from control assembly.
4. Control assembly from overhead console.
Front Overhead
|» + | Rem ove or D isconnect (Figure 37)
1. Control assembly to overhead console.
2. Electrical harness to control assembly.
1. Negative battery cable. Refer to Battery Disconnect 3. Overhead console.
Caution in General Information. 4. Negative battery cable.
2. Overhead console. Refer to Overhead Console • Check circuit operation.
C enter O verhead
Rem ove or D isconnect (Figures 38 and 39)
1. Bezel.
2. Control assembly from roof panel.
3. Electrical harness from control assembly.
Install or C onnect (Figures 38 and 39)
1. Electrical harness to control assembly

2. Control assembly to roof panel.
3. Bezel.
EVAPORATOR TUBE
■+| Rem ove or D isconnect (Figure 40)

2. Evaporator tube from evaporator.
Figure 37— Front O verhead A uxiliary C ontrol Sw itch 3. O-ring seal.
(Suburban) 4. Evaporator tube from condenser.
Figure 38— C enter O verhead A uxiliary C ontrol Figure 40— Front Evaporator Tube Location (M odels
Sw itch (S uburban) w ith Aux. A/C)
Tighten
• Evaporator tube to 24 N-m (18 lb ft).

6. New O-ring seal.
oil.
7. Evaporator tube to evaporator.
Tighten
• Evaporator tube to 24 N.m (18 lb ft).

this section.
COMPRESSOR AND
Figure 39— C enter O verhead A u xiliary C ontrol CONDENSER HOSE ASSEMBLY
Sw itch (Four Door U tility)
Remove or Disconnect (Figures 41 through 44)
5. O-ring seal.
6. Evaporator tube from auxiliary evaporator hose. 1. Recover refrigerant. Refer to Refrigerant Recovery
7. O-ring seal. and R ecycling, Adding O il, E vacuating and
8. Evaporator tube. Recharging Procedures in this section.
2. Bolt.
in stall o r C onnect (Figure 40) 3. Hose assembly from the top of the compressor.
4. Sealing washers. Refer to Compressor Sealing
1. Evaporator tube. Washers in this section.
2. New O-ring seal. 5. Hose from accumulator using J 38042. Refer to
• Coat O-ring seal with 525 viscosity refrigerant Servicing Dual O-Ring Seals in this section.
oil. 6. O-ring seals from accumulator hose.
3. Evaporator tube to auxiliary evaporator hose.• 7. Hose from aux. A/C line using J 38042. Refer to
Servicing Dual O-Ring Seals in this section.
Tighten 8. O-ring seals from hose.
9. Hose from clip.
• Evaporator tube to 24 N-m (18 lb ft). 10. Hose from bracket, if equipped with diesel engine.
4. New O-ring seal. 11. Hose assembly from condenser.
• Coat O-ring seal with 525 viscosity refrigerant 12. O-ring seal.
oil. • Cap or plug all open connections.
Install or C onnect (Figures 41 through 44) 10. Charge system. Refer to Refrigerant Recovery and
1. New O-ring seals to Aux. A/C hose. Procedures in this section.
• Coat O-ring seal with 525 viscosity refrigerant 11. Check system for leaks. Refer to Leak Testing in
oil. this section.
2. Hose assembly to Aux. A/C line.
REAR AUXILIARY HOSE
Tighten
ASSEMBLY
• Hose assembly to 24 N-m (18 lb ft).
3. New O-ring seal to condenser hose. i l l Rem ove or D isconnect (Figures 4 4 and 45)
oil. 1. Recover refrigerant. Refer to Refrigerant Recovery
4. Hose assembly to condenser. and R ecycling, Adding O il, E vacuating and
Tighten 2. Air cleaner assembly.
3. Evaporator tube from auxiliary evaporator hose.
• Hose assembly to 24 N m (18 lb ft). 4. O-ring seal.
5. New O-ring seals to accumulator hose. 5. Refrigerant hose assembly from auxiliary compres
• Coat O-ring seal with 525 viscosity refrigerant sor hose.
oil. 6. O-ring seal.
6. Hose assembly to accumulator. 7. Right front wheelhouse. Refer to Wheelhouse Pan
el Replacement in Sheet Metal.
Tighten 8. Auxiliary evaporator hose from auxiliary evaporator.
9. O-ring seal.
• Hose assembly to 24 N-m (18 lb ft). 10. Auxiliary compressor hose from auxiliary evapora
7. Sealing washers. tor.
8. Hose assembly to top of the compressor. 11. O-ring seal.
9. Bolt. 12. Screws.
13. Hose clips.
Tighten
14. Auxiliary evaporator hose.
15. Auxiliary compressor hose.
. Bolt to 34 N m (25 lb ft).
Figure 41—Compressor and Condenser Hose Assembly (5.7L Engines w/Aux. A/C)
Figure 42—C om pressor and C ondenser Hose A ssem bly (7.4L Engines w /A ux. A /C )
Figure 43—Compressor and Condenser Hose Assembly (6.5L Diesel Engines w/Aux. A/C)
Install o r Connect (Figures 44 and 45) Tighten
1. Auxiliary compressor hose. • Refrigerant hose assembly to 24 N-m (18 lb ft).

2. Auxiliary evaporator hose. 12. Lower the vehicle.
3. Hose clips. 13. New O-ring seal.
4. Screws. • Coat O-ring seal with 525 viscosity refrigerant
oil.
Tighten 14. Evaporator tube to a uxiliary evaporator hose
(Figure 44).
• Screws to 6 Nm (53 lb in).
5. New O-ring seal. Tighten
oil. • Evaporator tube to 24 N m (18 lb ft).
6. Auxiliary compressor hose to auxiliary evaporator. 15. Air cleaner assembly.
^ Tighten Recycling, Adding Oil, Evacuating and Recharging
• Auxiliary compressor hose to 32 N m (24 lb ft). 17. Check system for leaks. Refer to Leak Testing in
7. New O-ring seal. this section.
oil. EVAPORATOR CORE
8. Auxiliary evaporator hose to auxiliary evaporator.
S Tighten
\*--*\ Remove or Disconnect (Figures 46 through 48)
• Auxiliary evaporator hose to 17 N-m (13 lb ft).
9. Right front wheelhouse. 1. Negative battery cable. Refer to Battery Disconnect
10. New O-ring seal. Caution in General Information.
• Coat O-ring seal with 525 viscosity refrigerant 2. Recover refrigerant. Refer to Refrigerant Recovery
oil. and R ecycling, A dding O il, E vacuating and
11. Refrigerant hose assembly to auxiliary compressor Recharging Procedures in this section.
hose. 3. Rear quarter interior trim, as necessary. Refer to
Quarter Trim Panel Replacement in Interior Trim.
10 23
10. TUBE, A/C EVAPORATOR

11. HOSE, A/C COMPRESSOR
AND CONDENSER
19. O-RING
20. HOSE, AUX. A/C EVAPORATOR
21. HOSE, AUX. A/C COMPRESSOR
22. O-RING
23. CLIP, AUX. A/C REAR HOSE
24. SCREW, AUX. A/C REAR HOSE CLIP V IE W A
V2695
Figure 44—Auxiliary Refrigerant Hose Routing (Front of Vehicle)
25. O-RING V IE W C
26. EVAPORATOR, AUX. A/C
V2696
Figure 45— A uxiliary R efrigerant Hose Routing (R ear of Vehicle)
4. Right rear quarter trim panel. Refer to Quarter Trim 10. Pipe insulator.
Panel Replacement in Interior Trim. 11. Evaporator core.
5. Right rear wheelhouse (Suburban only). Refer to
Wheelhouse Panel Replacement in Sheet Metal. Install or C onnect (Figures 46 through 48)
6. Rear heater hoses from auxiliary heater core, if
equipped (Suburban only). Refer to Heater Hoses 1. Evaporator core.
in Heater and Ventilation. 2. Pipe insulator.
7. Auxiliary refrigerant hoses from auxiliary evapora 3. Heater/evaporator case cover screws or clips as
tor. Refer to Rear Auxiliary Hose Assembly in this equipped.
section. • Blower housing to case on Four Door U tility
8. Electrical connectors, as necessary. models
9. Heater/evaporator case cover. • Blower motor to case on Suburban models
• For Suburban models, proceed as follows: 4. Auxiliary case to the vehicle.
A. Remove case clips (Figure 48). 5. Auxiliary refrigerant hoses to auxiliary evaporator.
B. Remove eleven case screws. 6. Rear heater hoses to auxiliary heater core, if
C. Separate case halves. equipped.
• For Four Door Utility models, proceed as follows: 7. Electrical connectors, as necessary.
A. Remove screws securing case to rear quarter 8. Right rear wheelhouse (Suburban only).
sheet metal. 9. Right rear quarter trim panel.
B. Remove blower housing from rear of case. 10. Rear quarter interior trim, as necessary.
C. Remove 10 case clips. 11. Negative battery cable.
D. Separate case halves.
Legend
(1) Auxiliary Heater and A/C Module (5) Blower Motor Resistor
(2) Blower Motor (6) Auxiliary A/C Evaporator Core
(3) Blower Motor Mounting Screw (7) Auxiliary Heater Core
(4) Blower Resistor Mounting Screw
Figure 46— A uxiliary H eater and A/C M odule (S uburban)
THERMAL EXPANSION VALVE

(TXV)
0 R e m o v e o r D is c o n n e c t

3. Evaporator core. Refer to Evaporator Core in this
section.
4. TXV from evaporator core.
• Remove clip retaining the capillary tube to the
suction pipe.
• Remove the TXV from the evaporator inlet pipe.
0 In s ta ll o r C o n n e c t
1. TXV to the evaporator core.

• Install TXV to the evaporator core inlet pipe.
(1) Auxiliary A/C Module • Install the capillary tube to the suction line.
(2) Mounting Screw • Install the capillary tube retaining clip.
(3) Blower Motor 2. Evaporator core. Refer to Evaporator Core in this
(4) Mounting Nut section.
(5) Auxiliary A/C Evaporator Core 3. Charge system. Refer to Refrigerant Recovery and
(6) Case Clips Recycling, Adding Oil, Evacuating and Recharging
(7) Blower Motor Resistor Procedures in this section.
Figure 47— A uxiliary A/C M odule (Four Door U tility) 4. Negative battery cable.
this section.
E3 Rem ove o r D isconnect (Figure 46— Suburban
or Figure 49— Four Door U tility)

4. Blower motor resistor screws.
Install or C onnect (Figure 46— Suburban or
Figure 49— Four D oor U tility)

2. Blower motor resistor screws.
Tighten
• Screws to 1.4 N.m (12 lb in).

(1) Blower Motor Resistor
(2) Auxiliary A/C Module
5. Negative battery cable. Figure 49— B low er M otor R esistor (Four Door
• Check circuit operation. U tility)
BLOWER MOTOR AND FAN 7. Blower motor from blower housing on Four Door
Utility (Figure 51).
Rem ove o r D isconnect (Figures 46, 47, 50 8. Fan cage from the motor (Figure 50).
and 51) Install or Connect (Figures 46, 47, 50 and 51)
1. Negative battery cable. Refer to Battery Disconnect 1. Fan cage to the motor.
Caution in General Information. 2. Blower motor to the blower housing on Four Door
2. Right rear quarter trim panel. Refer to Quarter Trim Utility.
Panel Replacement in Interior Trim. 3. Blower motor (Suburban) or blower housing (Four
3. Electrical connectors. Door Utility) to case.
4. Blower motor screws (Figure 46) on Suburban or 4. Screws.
blower housing screws (Figure 49) on Four Door
Utility. Tighten
5. Cooling tube on Suburban.
6. Blower motor on Suburban or blower housing/motor • Screws to 1.7 N-m (15 lb in) on Suburban or 1.9
assembly on Four Door Utility. N m (18 lb in) on Four Door Utility.
Figure 48— Removing Case Clip (Suburban) Figure 50—Removing Blower Fan Cage (Suburban)
1. Blower motor relay to the bracket.

2. Electrical connector to the blower motor relay.
AUXILIARY A/C TEMPERATURE

ACTUATOR

3. Electrical connector from temperature actuator.
4. Temperature actuator from auxiliary A/C module.
Figure 51— Rem oving Blow er Fan Cage (Four Door -► 4- Install o r Connect (Figure 53)
U tility)
5. Cooling tube (Suburban). 1. Temperature actuator to the auxiliary A/C module.

6. Electrical connectors, as nece’ssary. 2. Screws securing temperature actuator to the auxil
7. Right rear quarter trim panel. iary A/C module.
8. Negative battery cable. 3. Electrical connector to the temperature actuator.
• Check circuit operation. 4. Right rear quarter trim panel.
BLOWER MOTOR RELAY • Check circuit operation.

3. Electrical connector from blower motor relay.
4. Blower motor relay from bracket.
1 2
Legend
(1) Auxiliary A/C Module
(1) Blower Motor Relay (2) Blower Motor Relay
(2) Auxiliary A/C Module (3) Temperature Actuator
Figure 52—Blower Motor Relay (Suburban) Figure 53—Auxiliary A/C Temperature Actuator
AUXILIARY A/C MODE
ACTUATOR
I+ + ) Rem ove o r D isconnect (Figure 54)

3. Electrical connector from mode actuator.
4. Mode actuator from auxiliary A/C module.
-M- install or C onnect (Figure 54)
1. Mode actuator to the auxiliary A/C module.

2. Screws securing mode actuator to the auxiliary A/C
module.
3. Electrical connector to the mode actuator.
Legend
(1) Auxiliary A/C Module Duct
(2) Mode Actuator
Figure 54— A uxiliary A /C M ode A ctuator
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
A pplication N-m Lb ft Lb in
Accumulator Bracket Mounting Screw 6 . — 53
Accumulator to Front Evaporator Connection 41 30 —
Auxiliary Blower Motor Resistor Mounting Screws 1.4 — 12
Auxiliary Refrigerant Hose Mounting Clip Screws 6 — 53
Auxiliary Evaporator to Auxiliary Compressor Hose 32 24 —
Auxiliary Evaporator Hose to Auxiliary Evaporator 17 13 —
Blower Motor Mounting Screws 1.7 — 15
Blower Motor Resistor Mounting Screws 1.4 — 12
Compressor Mounting Bolts 50 37 —
Condenser Mounting Screws 4.5 — 40
Control Head Mounting Screw 1.9 — 17
HVAC Module Mounting Screws 1.9 — 17
Defroster Nozzle Mounting Screws 1.9 — 17
Defroster Nozzle to Heater Case Screws 1.4 — 12
Distributor Duct Mounting Screws 1.9 — 17
Evaporator Tube to Auxiliary Evaporator Hose 24 18 —
Evaporator Tube to Condenser 24 18 —
Evaporator Tube to Front Evaporator 24 18 —
HVAC Module to Cowl Nuts 2.8 — 25
Pressure Cycling Switch to Accumulator 4.5 — 40
Compressor/Condenser Hose to Accumulator 41 30 —
Compressor/Condenser Hose to Auxiliary Compressor 24 18 —
Hose
Compressor/Condenser Hose to Compressor Bolt 34 25 —
Compressor/Condenser Hose to Condenser 24 18 —
GENERAL SPECIFICATIONS
Com pressor Type D isplacem ent
Delphi Thermal HT6 6 Cylinder Axial 10.0 Cu. In.
SYSTEM CAPACITIES
A pplication ml fl oz Kg Lb
Refrigerant R-134A, Pickup with C60 0.91 2
Refrigerant R-134A, Crew Cab, Suburban, and Four 1.02 2.25
Door Utility with C60
Refrigerant R-134A, Suburban and Four Door Utility with 1.81 4.0
C69
Polyalkaline Glycol (PAG) Refrigerant Oil all vehicles 240 8
with C60
Polyalkaline Glycol (PAG) Refrigerant Oil all vehicles 330 11
with C69
R134A METRIC FITTING SIZES

RPO Hex Fitting Size Connection B/U Hex Fitting
(m m ) S ize (m m )
C60/C69 24 Compressor/Condenser Hose to Condenser Inlet —
C60/C69 24 Evaporator Tube to Condenser Outlet —
C60/C69 22 Evaporator Tube to Front Evaporator 20

C60/C69 32 A/C Accumulator to Front Evaporator 27
C60/C69 32 Compressor/Condenser Hose to A/C Accumulator —
C69 24 Aux. Evaporator Hose to Evaporator Tube 20

C69 22 Aux. Evaporator Hose to Aux. Evaporator 16
C69 26 Aux. Compressor Hose to Aux. Evaporator 22
SPECIAL TOOLS
1. FOUR J A C K - DUAL RANGE TEMPERATURE TESTER

2 . ORIFICE TUBE REMOVER AND EXTRACTOR
3. H - 1 0 LEAK DETECTOR
4. DUAL O - RING SEPARATOR
HD6/HT6 AIR CONDITIONING COMPRESSOR 1D2-1
SECTION 1D2
HD6/HT6
AIR C O N D ITIO N IN G COM PRESSOR
SERVICE OR UNIT REPAIR R -134a
GENERAL DESCRIPTION
The H D6/H T6 Autom otive Conditioning Com pressor The compressor connections and die outside o f the compressor
and Clutch Assem bly is a lightweight, six cylinder axial design should be cleaned before any “on vehicle” repairs, or before
consisting of three double ended pistons and weighs 5.8 kg removal of the compressor. The parts must be kept clean at all
(12.7 lbs.) times and any parts to be reassembled should be cleaned with
trichloroethane, naphtha, Stoddard solvent, kerosene or equivalent
and dried with dry air. W hen necessary to use a cloth on any part,
it should be of a non-lint producing type.
The operations described below are based on bench
overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility o f the components. W hen a compressor is
removed from the vehicle for servicing, the amount o f P A G
lubricant remaining in the compressor should be drained,
rn W IT H O U T T O R Q U E measured and recorded. This P A G lubricant should then be
C U S H IO N
discarded and an equal amount of new P A G lubricant added to
HQT O R Q U E the compressor.
C U S H IO N
The service compressor is shipped with 240 m l (8 oz.) of
P A G lubricant. T his lubricant should be drained and retained
Fig. 1 Clutch Driver Designs
for use as replacement lubricant when service procedures
Although this compressor is the same for all vehicle require addition o f new lubricant to compressor. N O TE:
applications, there are differences in installations, mounting Replace only with G M approved P A G oil P/N 12345923.
brackets, pulleys, torque cushions and switches, none o f which M ost m inor repair procedures may be done on the
w ill affect the follow ing overhaul procedures. vehicle without discharging the system. M ajor repair
There are two clutch driver designs for these procedures require that the system be discharged o f refrigerant
compressors. The clutch driver without a torque cushion and
the clutch driver having a thin torque cushion (Fig. 1).
METRIC THREAD SIZE INFORMATION
1. Com pressor to m ounting bracket bolts.
Service compressors are supplied with either the control
Front M lO x 1.5- 6 H
switches assembled in the rear head or a plug may be found
Rear M 8 x l. 2 5 - 6 H
where a control switch is required. If the service compressor
requires control switches, the plug may be removed from the 2. Suction-discharge port screw.
appropriate rear head switch cavity o f the replaced compressor M lO x 1.5- 6 H
and assembled as prescribed in this manual. 3. Com pressor shaft.
W hen servicing the compressor, keep dirt or foreign M 9 x 1.25- 6 H
material from getting on or into the compressor parts and system. 4. Internal hub-clutch drive assembly.
Gean tools and a clean work area are important for proper service. M 2 2 x 1.5- 6 H
1D 2-2 HD6/HT6 AIR CONDITIONING COMPRESSOR
1 — CLUTCH DRIVER
2— ROTOR BEARING
RETAINER
3— PULLEY BEARING
4— PULLEY
5 — CLUTCH COIL
ASSEMBLY
6— SHAFT SEAL PARTS
7— PUMP ASSEMBLY
8— SWITCH O-RING
9— SYSTEM CONTROL
SWITCH
1 0 — HIGH PRESSURE
RELIEF VALVE
11 — RETAINER RING SWITCH
12 — SUCTION/DISCHARGE
PORT SEALING
WASHERS
13 — SPECIAL 134a SUCTION
PORT
1 4 — SPECIAL 134a
DISCHARGE PORT
Compressor — Rear Head

As Viewed In Direction of Arrow “A”
Fig. 2 Compressor Components — Disassembly

HP6/HT6 AIR CONDITIONING COMPRESSOR 1D 2-3
UNIT REPAIR
MINOR COMPRESSOR REPAIR center screw into the remover body to remove the clutch
plate and hub assembly (Fig. 3).
PROCEDURES
Notice: D o not drive or pound on the clutch hub or
THE FOLLOWING OPERATIONS TO THE shaft. Internal damage to compressor may result. The
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR forcing tip on J 33013 -B remover-installer center screw
AND BEARING, AND COIL ARE COVERED AS must be flat or the end o f the shaft/axial plate assembly
-MINOR- BECAUSE THEY MAY BE PERFORMED w ill be damaged.
WITHOUT FIRST RECOVERING REFRIGERANT FROM
3. Remove the shaft key and retain for reassembly.
THE SYSTEM OR REMOVING THE COMPRESSOR
FROM THE VEHICLE.
In stall o r C onnect
The Com pressor Shaft Seal assembly, control switches,
and Pressure Relief Valve may also be serviced W IT H O U T 1. Install the shaft key into the hub key groove (Fig. 4).
R E M O V IN G T H E compressor from the vehicle but these A llow the key to project approximately 3.2mm (1/8")
operations are covered later in this section as M A J O R R E P A IR out o f the keyway. The shaft key is curved slightly to
P R O C E D U R E S because the system must be reclaimed, provide an interference fit in the hub key groove.
evacuated and recharged to complete service. 2. Be sure the frictional surface of the clutch plate and the
Illustrations used in describing these operations show the clutch rotor are clean before installing the clutch plate
compressor removed from the vehicle only to more clearly and hub assembly.
illustrate the various operations. 3. A lign the shaft key with the shaft keyway and place the
clutch plate and the hub assembly onto the compressor
W hen servicing the compressor, remove only the parts
shaft.
that preliminary diagnosis shows are in need of service. Refer
to Figures 2 and 5 for information relative to part names and
location.
Rem oval and installation o f external compressor parts,
and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
Rem ove o r D isconnect
1. Clam p the holding fixture J 33026 in a vise and attach

m J 33013-B HUB AND IT! J 33026 HOLDING
CLUTCH DRIVE PLATE FIXTURE
compressor to holding fixture with thumb screws
ASM. REMOVER
J 33026-1 (Fig. 3). m CLUTCH PLATE
[ 7 | J 33026-1 THUMB AND HUB ASM.
2. W ith center screw forcing tip in place to thrust against
SCREW
the end of the shaft, thread the Clutch Plate and Hub
G 6 0 0 7 0 -1 D 2 -C -R 1
Assem bly Installer-Remover J 33013 -B into the hub.
H old the body of the remover with a wrench and turn the Fig. 3 Clutch Plate and Hub Assembly Removal
N o tic e : If the center screw is threaded fu lly onto
the end o f the compressor shaft, or if the body of the
installer is held and the center screw is rotated, the key
w ill wedge and w ill break the clutch hub.
F I CLUTCH PLATE AND HUB ASSY,
m CLUTCH PULLEY ROTOR
I T l SHAFT KEYWAY
m SHAFT KEY
Q 6 0 0 8 0 -1 D 2 -E K
Fig. 4 Shaft Key, Clutch Plate/Hub Installation
4. Rem ove the forcing tip on J 33013 -B clutch plate and

hub assembly installer-remover center screw and
reverse the body direction on the center screw, as shown
in Figure 5.
7. Remove installer J 33013-B, check for proper positioning
5. Install the clutch plate and hub installer-remover of the shaft key (even or slightly above die clutch hub).
J 33013-B with bearing as shown in Figure 8.
8. Spin the pulley rotor by hand to see that the rotor is not
The body of the J 33013-B installer-remover should be rubbing the clutch drive plate.
backed off sufficiently to allow the center screw to be
threaded onto the end o f the compressor shaft.
COMPRESSOR CLUTCH ROTOR AND/OR
6. H old the center screw with a wrench. Tighten the hex
portion o f the installer-rem over J 33013-B body to press
BEARING
the hub onto the shaft. Tighten the body several turns,
remove the installer and ch eck to see th a t th e shaft Rem ove o r D isconnect
key is s till in p lace in th e keyw ay b efo re
in stallin g th e clu tch plate and hub assem bly to 1. Rem ove the clutch plate and hub assembly as described
its fin al position. The air gap between frictional previously.
surfaces of the clutch plate and clutch rotor should be 2. Rem ove rotor and bearing assembly retaining ring, using
0.50-0.76m m (.020-.030"). snap ring pliers J 6083 (Fig. 6).
1 J 41552 PULLEY ROTOR

AND BEARING PULLER
G 6 0 120-1D 2-E K -R 1
Fig. 8 Removing Pulley Rotor and Bearing Assembly
0 J 41552 (LESS 0 PULLEY ROTOR

FORCING SCREW) -FACE DOWN*
INVERTED AND
USED TO SUPPORT 0 J 9398-A BEARING
HUB OF ROTOR REMOVER
m J 33023-A PULLEY 0 J 41552 PULLER FOR BEARING
0 J 29886 DRIVER
ROTOR AND ENGAGES IN INNER REMOVAL. PULLER
HANDLE
BEARING PULLER CIRCLE OF SLOTS TANGS ENGAGED
IN ROTOR SLO TS.
GUIDE IN ROTOR
G 6013 0 -1 D 2 -C -R 1
G 6 0 1 1 0 -1 D 2 -C -R 1
Fig. 7 installing Pulley Rotor/Bearing Puller Guide Fig. 9 Pulley Rotor Bearing Removal
Remove the forcing screw from J 41552 puller and, with

3. Install pulley rotor and bearing puller guide J 3302 3-A the puller tangs still engaged in the rotor slots, invert the
to the front head (Fig. 7) and install J 41552 pulley rotor assembly onto a solid flat surface or blocks as shown in
and bearing puller down into the inner circle of slots in Figure 9.
the rotor. Turn the J 41552 puller clockwise in the slots in
6. Drive the bearing out of the rotor hub with rotor bearing
the rotor (Fig. 8).
remover J 9 3 9 8 -A and J 29886 universal handle (Fig. 9).
4. H old the J 41552 puller in place and tighten the puller
Notice: It is not necessary to remove the staking in
screw against the puller guide to remove the pulley rotor
front of the bearing to remove the bearing, however, it
and bearing assembly.
w ill be necessary to file away the old stake metal for
5. To prevent damage to the pulley rotor during bearing proper clearance for the new bearing to be installed into
removal the rotor hub must be properly supported. the rotor bore or the bearing may be damaged.
m J 33019-1 BEARING STAKING GUIDE

m RUBBER BAND
[T | J 33019-2 BEARING STAKING PIN
G 6015 0 -1 P 2 -E K -R 1
Fig. 11 Staking Bearing In Rotor Hub Bore
STAKE THREE
(3) LOCATIONS
120* APART
E3 In stall o r C onnect
1. Place the pulley rotor on the J 213 5 2 -A support block to

5 2 0 0 1 6 -1 D2
fully support the rotor hub during bearing installation
(Fig. 10). Fig. 12 Bearing Staked in Place
N o tic e : DO N O T support the rotor by resting the
pulley rim on a flat surface during the bearing 5. W ith the compressor mounted to the J 33026 holding
installation or the rotor face w ill be bent. fixture, position the rotor and bearing assembly on the
front head (Fig. 13).
2. A lig n the new bearing squarely with the hub bore and 6. Position the J 33017 pulley, rotor and bearing installer
using puller and bearing installer J 9481 -A with and J 33 0 2 3 -A puller pilot directly over the inner race of
universal handle J 29886, drive the bearing fully into the the bearing (Fig. 13).
hub (Fig. 10). The installer w ill apply force to the outer
race of the bearing, if used as shown. 7. Position puller crossbar J 8433-1 on the puller pilot
J 33 0 2 3 -A and assemble the two J 33026-2 through bolts
3. Place bearing staking guide J 33019-1 and bearing
and washers through the puller bar slots and thread them
staking pin J 33019-2 in the hub bore as shown in
into the J 33026 holding fixture (Fig. 13). The thread of
Figure 11. Shift the rotor and bearing assembly on the
the through bolts should engage the full thickness of the
J 213 5 2 -A support block to give full support o f the hub
holding fixture.
under the staking pin location. A heavy-duty rubber
band may be used to hold the stake pin in the guide (Fig. 8. Tighten the center screw in the J 8433-1 puller crossbar
11), and the stake pin should be properly positioned in to force the pulley rotor and bearing assembly onto the
the guide after each impact on the pin. compressor front head (Fig. 13). Should the
J 33017 pulley rotor and bearing installer slip off direct
4. U sing care to prevent personal injury, strike the staking
in-line contact with the inner race of the bearing, loosen
pin with a hammer until a metal stake, sim ilar to the
die J 8433-1 center forcing screw and realign the
original, is formed dow n to but not touching the
installer and pilot so that the J 33017 installer w ill
bearing.
properly clear the front head.
N o isy bearing operation and reduced bearing life may
9. Install rotor and bearing assembly retainer ring, using
result if outer bearing race is deformed while staking,
snap ring pliers J 6083 (Fig. 6).
The stake metal should not contact the outer race of the
bearing. Stake three places 120 degrees apart as shown in 10. Reinstall clutch plate and hub assembly as described
Figure 12. previously.
J 8433-3 SCREW
[ | ] J 33023-A PULLER PILOT
® J 33026-2 THROUGH BOLTS
[ f ] PULLEY ROTOR
[U J 33017 PULLEY ROTOR AND BEAR-
ING INSTALLER
0 J 8433-1 CROSS BAR
G 6 0 1 7 0 -1 D 2 -C -R 1
Fig. 13 Installing Pulley Rotor and Bearing Assembly
COMPRESSOR CLUTCH COIL

1. Perform Steps 1 through 4 of “Clutch Rotor and/or

Bearings” removal procedure. M ark clutch coil
term inal location on com pressor fro n t head.
2. Install J 3 3 0 2 3 -A puller pilot on front head of
compressor (Fig. 14). A lso install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 14.
3. Tighten J 8433-3 forcing screw against the puller pilot to
remove the clutch coil.
| » » | In stall o r C onnect
1. Place the clutch coil assembly on the front head with the
terminals positioned at the “marked” location.
2. Place the J 33024 clutch coil installer over the internal
opening o f the clutch coil housing and align installer
with the compressor front head.
3. Center the J 8433-1 puller crossbar in the counter- sunk
center hole of the J 33024 clutch coil installer. Install the
J 33026-2 through bolts and washers through the
ASSEMBLY crossbar slots and thread them into the holding fixture
J 33026 to full fixture thickness (Fig. 15).
□ J 33025 PULLER
,V I G 6018 0 -1 D 2 -C -R 1 4. Thm the center forcing screw of the J 8433-1 puller
Fig. 14 Clutch Coil Assembly Removal crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay “in-line”
during installation.
1 - FRONT HEAD SURFACE 3 - CLUTCH

1— CLUTCH C O IL 3 -S T A K E IN FRONT COIL
2 - STAKE FRONT HEAD 0.28-0.35MM
HEAD (3 PLACES) HOUSING
2 - D R IF T PUNCH DEEP (0.10- 015")
5 2 0 0 2 0 -1 D2 5 2 0 021-1 D 2
Fig. 16 Staking Clutch Coil to Front Head Fig. 17 Details of Stakes in Front Head for Clutch Coil
5. W hen coil is fully seated on the front head, use a 1/8"

diameter drift punch and stake the front head at three
places 120 degrees apart (Fig. 16), to ensure clutch coil
remains in position.
• Stake size should be only one-half the area of the

punch tip and be only approximately
0.28-0.35m m (.010-.015") deep (Fig. 17).
6. Install rotor and bearing assembly and the clutch plate 1 - STEEL SHELL
2 - DOUBLE UP SEAL
and hub assembly as described previously.
5 2 0 0 3 3 -1 D1
Fig. 18 Compressor Shaft Seal
MAJOR COMPRESSOR REPAIR

PROCEDURES
W hen replacing the shaft seal assembly (Fig. 18),

pressure relief valve or control switches (Fig. 19), it w ill be
necessary to recover the refrigerant. Other than clutch repair
procedures, the same holds true for any disassem bly o f the
compressor.
A clean workbench covered with a sheet o f clean paper,

and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of proper clean service tools.
N o tic e : A n y attempt to use\ makeshift or

inadequate service tools or equipment may result in
damage and/or improper compressor operation.
A ll parts required for servicing the internal compressor

are protected by a preservative process and packaged in a
manner w hich w ill eliminate die necessity o f cleaning,
washing or flushing o f the parts. The parts can be used in the COMPRESSOR SHAFT SEAL
internal assembly just as they are removed from the service REPLACEMENT
package. S eals and p ro tective packaging should be le ft
Seal Leak Detection
In tact until ju s t p rio r to in stallatio n .
A shaft seal should not be changed because of small
If the compressor rear head, front head or cylinder and amounts o f oil found on an adjacent surface but only after
shaft assembly is to be serviced or replaced, the oil in the actual refrigerant leakage is found using an approved leak
com pressor must be drained, measured, recorded and replaced. detector, J 39400 or equivalent.
E3 Rem ove o r D isconnect
Caution: Refer to SIR Caution In Cautions

and Notices.
1. Recover the refrigerant using J 39500-G M .
2. Loosen and reposition compressor in mounting brackets,
if necessary.
3. Remove clutch plate and hub assembly from compressor
as described in m inor repairs.
4. Remove the shaft seal retainer ring, using snap ring
pliers J 5403 (Fig. 21).
5. Thoroughly clean inside o f compressor neck area
surrounding the shaft, the exposed portion o f the seal, the
retainer ring groove and the shaft itself. A n y dirt or
foreign material getting into compressor may cause
damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J 2 3 1 2 8 -A into the recessed portion o f the Seal
by turning the handle clockwise. Remove the Seal from
the compressor with a rotary-pulling motion (Fig. 22).
Discard the seal. The handle must be hand- tightened
securely. D o not use a wrench or pliers.
7. Remove and discard the seal seat O -ring from the
compressor neck using O -ring remover J 9553-01,
Figure 20.
8. Recheck the shaft and inside o f the compressor neck for
dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
| y | C lean
• Thoroughly clean O -ring seal groove in front head.

Notice: Seals should not be re-used. A lw ays use a
new specification service seal on rebuild (Fig. 18). Be
sure that the seal to be installed is not scratched or
damaged in anyway. M ake sure that die seal seat and seal
are free o f lint and dirt that could damage the seal surface
or prevent sealing.
| » » | In stall o r C onnect
1. D ip the new seal seat O -ring in clean 525 viscosity

refrigerant oil and assemble onto O -ring installer
J 33011, Figure 20.
2. Insert the O -ring installer J 33011 into the compressor
neck until the installer “bottoms”. Low er the moveable
slide o f the O -ring installer to release the O -ring into the
seal O -ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the O -ring and remove the installer.
3. D ip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A , by turning
Q ] SEAL [ D J 9553-01 \s \ J 33011
handle clockwise. The stamped steel case side o f the
H ] J 23128-A [ D O-RING Q j] J 34614 lip seal must be engaged with knurled tangs of installer
so that flared-out side o f lip seal is facing and
installed towards the compressor. Install seal protector
Fig. 20 Removing and installing Shaft Seal and O-Ring J 34614, in the seal lip and place over the compressor
shaft, Figure 22, and push the seal in place with a
rotary motion or place the seal protector J 34014 over
etiH of ''ornr)rn«<!r.r cV,of* Figure 22, and slide the new
Use the sleeve from O-ring installer J 33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J 39893 on rear head o f compressor and connect gage
charging lines and J 39500-G M Refrigerant Recovery
System. Pressurize suction and high-side o f compressor
with R-134a Refrigerant. Temporarily install (M 9 x 1.25
thread on shaft) nut and, with die compressor in
horizontal position, rotate the compressor shaft in
normal direction of rotation several turns by hand. Leak
test the seal area and correct and leak found. Recover the
refrigerant. Rem ove shaft nut.
6. Remove any excess oil resulting from installing the new
seal parts from the shaft and inside the compressor neck.
7. Install the clutch plate and hub assembly as described in
m inor repair procedures.
Notice: Refer to Fastener Notice in Cautions
and Notices.
8. Reinstall compressor belt and tighten bracket.
9. Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE


Fig. 21 Removing or Installing Shaft Seal and Notices.
Retaining Ring 1. Recover the refrigerant using J 39500-G M .
2. Rem ove old pressure relief valve (Fig. 19).
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the O-ring. Be sure the seal | + + | In stall o r C onnect
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
1. Clean valve seat area on rear head.
J 2 3 1 2 8 -A and the seal protector J 34614.
2. Lubricate O -ring of new pressure relief valve and O -ring
Notice: Handling and care of seal protector is
assembly with new 525 viscosity refrigerant oil. Install
important. If seal protector is nicked or the bottom
new valve and torque in place, 9.0 N *m (6.1 lb s.-ft)
flared, the new seal may be damaged during installation.
4. Install the new seal retainer ring with its flat side against 3. Evacuate and recharge the system.
the Seal, using Snap-Ring Pliers J 5403. See Figure 21. 4. Leak test system.
Fig. 22 Removing or Installing Shaft Seal

HP6/HT6 AIR CONDITIONING COMPRESSOR 1P 2 -1 1
CONTROL SWITCHES 6. If an external leak is present, perform die necessary

corrective measures and recheck for leaks to make
Figure 20 certain the leak has been corrected.
Rem ove o r D isconn ect 7. Recover the refrigerant.
8. Disconnect both hoses from the test plate J 39893.

and Notices. 9. A d d 90 m l (3 oz.) new P A G lubricant to the compressor
assembly. Rotate the complete compressor assembly
1. Recover the refrigerant. (not the crankshaft or drive plate hub) slow ly several
2. Disconnect the electrical connector from the switch in turns to distribute oil to all cylinder and piston areas.
the rear head of compressor.
10. Install a M 9 x 1.25 threaded nut on the compressor
3. Remove the switch retaining ring using J 5403 internal crankshaft if the drive plate and clutch assembly are not
snap ring pliers. installed.
4. Remove the switch from the compressor. 11. U sing a box-end wrench or socket and handle, rotate the
5. Remove old O -ring seal from the switch cavity using compressor crankshaft or clutch drive plate on the
J 9553-01 O -ring removal tool. crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
If existing control switch is reinstalled in the compressor,
a new O -ring seal must be used and preferably a new retainer 12. U sing J 39500-G M Refrigerant Recovery System,
ring should also be used. A new switch kit has the O -ring and connect J 9893 the charging station high-pressure line to
retainer ring included. the test plate high-side connector.
In stall o r C onnect 13. U sing J 39500-G M Refrigerant Recovery System,

connect the charging station low-pressure line to the low
pressure port of the test plate J 39893. O il w ill drain out
1. Check switch cavity and O -ring groove in the rear head
o f the compressor suction port if the compressor is
for dirt or foreign material and clean as necessary. Install
positioned with the suction port downward.
a new O -ring coated with clean refrigerant oil into
groove in switch cavity. 14. Attach the compressor to the J 33026 holding fixture and
2. Lubricate the control switch housing with clean mount the compressor in a vise so that the compressor
refrigerant oil and carefully insert switch into switch w ill be in a horizontal position and the shaft can be
cavity until switch bottoms in cavity. turned with a wrench.
3. U sing J 9533-1 snap ring pliers install switch retaining 15. U sing a wrench, rotate the compressor crankshaft or
ring with high point of curved sides adjacent to switch drive plate hub ten complete revolutions at a speed o f
housing. Be sure retaining ring is properly seated in approximately one-revolution per second. T u n in g die
switch cavity retaining groove. Leak test according to compressor at less than one-revolution per second can
bench test procedure. result in a lower pump-up pressure and disqualify a good
pumping compressor.
COMPRESSOR LEAK TESTING 16. Observe the reading on high-pressure gage at the
completion of the tenth revolution of the compressor.
(EXTERNAL AND INTERNAL)
The pressure reading for a good pumping compressor
Bench-Check Procedure should be 690 kPa (100 psi) or above. A pressure reading
o f less than 620 kPa (90 psi) would indicate one or more
1. Install test plate J 39893 on rear head of compressor. suction and/or discharge valves leaking an internal leak,
or an inoperative valve, and the refrigerant must be
2. U sin g J 39500-G M Refrigerant Recovery System, attach
recovered and the compressor disassembled and
center hose o f manifold gage set on charging station to a
checked for cause of leak. Repair as needed, reassemble
refrigerant drum standing in an upright drum.
and repeat the pump-up test. Externally leak test.
3. Connect charging station high and low pressure lines to
corresponding fittings on test plate J 39893. Suction port 17. W hen the pressure pump-up test is completed, recover
(low-side) of compressor has large internal opening. the refrigerant from the high-side and remove the test
Discharge port (high-side) has smaller internal opening plate J 39893.
into compressor and deeper recess. 18. Tilt the compressor so that the compressor suction and
4. Open low pressure control, high pressure control and discharge ports are down. D rain the P A G lubricant from
refrigerant control on charging station to allow the compressor.
refrigerant vapor to flow into compressor.
19. Allow the compressor to drain for 10 minutes, then refill
5. U sing a leak detector, check for leaks at pressure relief with the proper amount of P A G lubricant, per oil balance
valve, rear head switch location, compressor front and procedure in section IB of the service manual. The P A G
rear head seals, center cylinder seal, through bolt head lubricant may be poured into the suction port. If further
gaskets and compressor shaft seal. After checking, shut assembly or processing is required, a shipping plate or
off low pressure control and high-pressure control on test plate J 39893 should be installed to keep out air, dirt
charging station. and moisture until the compressor is installed.
1D 2-12 HP6/HT6 AIR CONDITIONING COMPRESSOR
1 — J 5403 SNAP RING PLIERS 13 — J 33013 HUB & DRIVE PLATE REMOVER
& INSTALLER
2 — J 6083 SNAP RING PLIERS
14 — J 39500-GM R134a A/C REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING
3 — J 29886 DRIVER HANDLE
SYSTEM (ACR4)
4 — J 8433-1 PULLER BAR 15 — J 33017 PULLEY & BEARING ASSEMBLY

INSTALLER
5 — J 8433-3 FORCING SCREW
16 — J 33019 BEARING STAKING TOOL
6 — J 9398-A BEARING REMOVER
17 — J 41552 PULLEY PULLER
7 — J 9481-A BEARING INSTALLER
18 — J 34614 SHAFT SEAL PROTECTOR
8 — J 9553-01 “0 ” RING REMOVER 19 — J 33023 PULLER PILOT
9 — J 39893 PRESSURE TESTING CONNECTOR 20 — J 33024 CLUTCH COIL INSTALLER ADAPTER
1 0 — J 23 12 8-A SEAL SEAT REMOVER & 21 — J 33025 CLUTCH COIL PULLER LEGS
INSTALLER
22 — J 34992 COMPRESSOR HOLDING FIXTURE
11 — J21 35 2-A SUPPORT BLOCK 23 — J 39400 LEAK DETECTOR
1 2 — J 33011 “0 ” RING INSTALLER 24 — J 39037 HIGH-SIDE CHARGE VALVE SOCKET
Fig. 23 Compressor Overhaul — Special Tools

Chassis/Body Electrical Table of Contents 1
SECTION 8
Chassis/Body Electrical
Electrical Diagnosis ......................................8A-2-0 Splicing Twisted/Shielded Cable.................. 8A-5-7

In tro d u ctio n ...................................................... 8A-2-0 Repairing Connectors.................................... 8A-5-8
Diagnostic Information.................................. 8A-2-0 Terminal R epair............................................. 8A-5-9
Section/Page Num ber.................................. 8A-2-0 Diode Replacement..................................... 8A-5-10
Schem atics.................................................... 8A-2-1 Acceptable Diode Replacement.................8A-5-11
Component Locations.................................. 8A-2-2 Heated Oxygen Sensor (H02S) Repair... 8A-5-12
Harness Connector Faces........................... 8A-2-3 OBD II Cicuit Repairs................................. 8A-5-12
Other Information...........................................8A-2-3 GMSPO Service P arts................................8A-5-12
VIN References..........................................8A-2-3 10 Power D istrib u tio n ................................... 8A-10-0
Service Parts Inform ation....... ................. 8A-2-3 Component Location Table........................ 8A-10-7
Abbreviations.............................................. 8A-2-4 11 Fuse B lock D e ta ils.................................. 8A-11-0
Power Distribution..................................... 8A-2-4 IP Fuse Block.............................................. 8A-11-1
Fuse Block Details.................................... 8A-2-6 Underhood Fuse-Relay Center.................. 8A-11-3
Ground Distribution.................................. 8A-2-7 Convenience Center.................................... 8A-11-5
S ym bols............................................................ 8A-3-0 Component Location Table..... .................8A-11-28
Electrostatic Discharge (ESD) Sensitive 14 G round D is trib u tio n ..............................8A-14-0
Devices..................................................... 8A-3-0 Component Location Table...................... 8A-14-19
Handling Procedures................................ 8A-3-0 17 A uxilia ry B a tte ry.................................... 8A-17-0
Measuring Procedures..............................8A-3-0 Component Location Table........................ 8A-17-1
Supplemental Inflatable Restraint (SIR) 34 Cruise C o n trol.......................................... 8A-34-0
System ...................................................... 8A-3-0 Component Location Table........................ 8A-34-3
On-Board Diagnostics II (OBD II) Diagnosis - Cruise Control......................... 8A-34-4
Sym bol...................................................... 8A-3-1 Troubleshooting H ints:.............................8A-34-4
Vacuum Motors And D evices..................... 8A-3-4 Gasoline Engine Cruise Control Is
Troubleshooting P rocedures....................... 8A-4-0 Inoperative.......................................... 8A-34-5
Basic Knowledge Required..........................8A-4-0 Gasoline Engine Cruise Control Does
Troubleshooting Tools.................................. 8A-4-1 Not Disengage With The Actuation
Troubleshooting Tests.................................. 8A-4-2 Of The Brake P edal...........................8A-34-8
Intermittant And Poor C onnections............8A-4-4 Gasoline Engine Cruise Control Will
Checking Terminal Contact......................... 8A-4-5 Not Resume/Accelerate/Tap-Up...... 8A-34-8
Detecting Electrical Interm ittants................ 8A-4-6 Diesel Engine Cruise Control
Digital Multimeter (DMM) Connectors.........8A-4-6 Inoperative.... ......................................8A-34-9
Additional Information................................... 8A-4-7 Diesel Engine Cruise Control Does
Repair P rocedures.................... 8A-5-0 Not Disengage With The Actuation
Electrical Repairs.......................................... 8A-5-0 Of The Brake Pedal.........................8A-34-10
Circuit Breakers............................................ 8A-5-0 Diesel Engine Cruise Control Will
Circuit Protection.......................................... 8A-5-0 Not Resume/Accelerate/Tap-Up..... 8A-34-11
Fuses.............................................................8A-5-0 Circuit O peration....................................... 8A-34-11
Fusible Links................................................. 8A-5-2 Gasoline Engines................................... 8A-34-11
Repairing Short Circuits Caused By Diesel Engines....................................... 8A-34-12
Damaged Wire Insulation....................... 8A-5-2 40 H orns.......................................................... 8A-40-0
Splicing Copper Wire Using C lips..............8A-5-3 Component Location Table........................ 8A-40-1
Splicing Copper Wire Using Crimp And Diagnosis - H orns....................................... 8A-40-2
Seal Splice Sleeves................................8A-5-5 Troubleshooting Hints:.............................8A-40-2
Crimp And Seal Splice Sleeve Chart........ 8A-5-6 Horn(s) Inoperative..................................8A-40-2
2 Table of Contents Chassis/Body Electrical
Horn(s) Sound Continuously Without Blower Motor Inoperative In Med-2

Horn Switch Depressed..................... 8A-40-3 (Heater With Or Without A /C )......... 8A-63-11
Circuit Operation................................... 8A-40-3 Blower Motor Inoperative In Med-1
50 Data L in k C onnector (DLC) Pin (Heater With Or Without A /C ).........8A-63-12
A ssig n m e n t............................................... 8A-50-0 Blower Motor Inoperative In Lo
Component Location Table........................ 8A-50-1 (Heater With Or Without A /C ).........8A-63-12
Diagnosis - DLC Pin Assignment..............8A-50-2 Blower Motor Only Operates In Hi
Troubleshooting H ints:.............................8A-50-2 (Heater With Or Without A /C ).........8A-63-12
Data Line(s).......................................... 8A-50-2 Blower Motor Operates Continuously
Scan Tool Will Not Communicate At Any Speed (Heater With Or
With Components On Uart Data Without A /C )..................................... 8A-63-13
Line (Ckt 800).....................................8A-50-3 Auxiliary Blower Motor Inoperative
Scan Tool Will Not Communicate With (Heater Without A /C )....................... 8A-63-14
Component On Class-2 Data Line Auxiliary Blower Motor Inoperative
(Ckt 1807) PCM/VCM....................... 8A-50-4 In Hi (Heater Without A/C).............. 8A-63-14
Scan Tool Will Not Communicate With Auxiliary Blower Motor Inoperative
Electronic Brake Control Module In Med (Heater Without A /C )..........8A-63-15
(Ebcm) (Ckt 7 99 )...............................8A-50-5 Auxiliary Blower Motor Inoperative
Transfer Case Control Module (Teem) In Lo (Heater Without A /C ).............8A-63-16
W ill Not Flash DTC’s (Ckt 1568)..... 8A-50-6 Auxiliary Blower Motor Only Operates
Circuit Operation......................................... 8A-50-6 In Hi (Heater And/Or A /C ).............. 8A-63-17
61 D e fog g er...................................................8A-61-0 Auxiliary Blower Motor Operates
Component Location Table....................... 8A-61 -2 Continuously At Any Speed
Diagnosis - Rear Window Defogger.........8A-61-4 (Heater Without A /C )....................... 8A-63-17
Troubleshooting H ints:........................... 8A-61-4 Auxiliary Blower Motor Inoperative
Defogger.............................................. 8A-61-4 (Heater With A /C ).............................8A-63-18
Heated Outside Rearview M irrors.... 8A-61-4 Auxiliary Blower Motor Inoperative
Rear Window Defogger Inoperative In Hi (Heater With A/C)................... 8A-63-19
But Grid Tests Good......................... 8A-61-4 Auxiliary Blower Motor Inoperative
LH Heated Outside Rearview Mirror In Med (Heater With A /C )............... 8A-63-20
Element Inoperative............................8A-61-5 Auxiliary Blower Motor Inoperative
RH Heated Outside Mirror Element In Lo (Heater With A /C ).............. 8A-63-21
Inoperative........................................... 8A-61-6 Auxiliary Blower Motor Operates
Both Heated Outside Rearview Mirror Continuously At Any Speed
Elements Inoperative......................... 8A-61-6 (Heater With A /C ).............................8A-63-22
Circuit Operation.......................................... 8A-61-6 Auxiliary Blower Switch At Auxiliary
Defogger................................................8A-61-6 HVAC Control Module Functions When
Heated Power Outside Rearview Auxiliary Blower Switch At Front
M irror............................................... 8A-61 -6 Auxiliary HVAC Control Module
63 HVAC B low er C o n trol............................8A-63-0 Is Not In The Auxiliary Position
Component Location Table........................ 8A-63-6 (Heater With A /C ).............................8A-63-24
Diagnosis - HVAC Blower Control.............8A-63-9 Auxiliary Blower Switch At Auxiliary
Troubleshooting Hints: HVAC Control Module Does Not
(Front Blow er)............................ 8A-63-9 Control The Auxiliary Blower When
Troubleshooting Hints: Selected (Heater With A /C )............ 8A-63-25
(Auxiliary Blower)................................8A-63-9 Auxiliary Blower Motor Inoperative At
Troubleshooting Hints: (G eneral)...........8A-63-9 Any Speed (A/C W ithout H eater).. 8A-63-25
Blower Motor Inoperative Auxiliary Blower Motor Inoperative
(Heater With A /C )...............................8A-63-9 In Hi (A/C Without Heater)..............8A-63-26
Blower Motor Inoperative Auxiliary Blower Motor Inoperative
(Heater Without A /C )......................... 8A-63-9 In Med (A/C Without H eater)..........8A-63-27
Blower Motor Inoperative In High Auxiliary Blower Motor Inoperative
(Heater With Or Without A /C ).........8A-63-11 In Lo (A/C Without Heater)............8A-63-28
Auxiliary Blower Motor Operates Front Auxiliary HVAC Control

Continuously At Any Speed Switch/Module Does Not
(A/C Without Heater)...................... 8A-63-29 Control Rear D oors..........................8A-65-14
Auxiliary A/C Control Switch Functions Rear Auxiliary Mode Door Motor
When The Front Auxiliary A/C Inoperative From Front Control
Control Switch Is Not In The Rear M odule...............................................8A-65-14
Position (A/C Without Heater)....... 8A-63-31 Rear Auxiliary Temperature Door
Auxiliary A/C Control Switch Does Motor Inoperative From Front
Not Operate The Auxiliary Blower Control M odule................................. 8A-65-15
When Selected (A/C Without Rear Auxiliary Mode Door Motor
H eater)...............................................8A-63-31 Inoperative From Rear Control
Circuit Operation........................................ 8A-63-32 M odule...............................................8A-65-15
Front Blower C ontrols....................... 8A-63-32 Rear Auxiliary Temperature Door
Auxiliary Blower Controls Motor Inoperative From Rear
(Heater Without A /C )................... 8A-63-32 Control M odule................................. 8A-65-16
Auxiliary Blower Controls Circuit O peration....................................... 8A-65-17
(Heater With A/C)......................... 8A-63-32 Front Ventilation Controls..................... 8A-65-17
Auxiliary Blower Controls Rear Auxiliary Ventilation C ontrols.... 8A-65-17
(A/C W ithout H eater)................... 8A-63-32 76 A udible W a rn in gs...................................8A-76-0
64 HVAC C om pressor C o n tro l................... 8A-64-0 Component Location Table....................... 8A-76-1
Component Location Table........................ 8A-64-4 Diagnosis - Audio Alarm Module..............8A-76-2
Diagnosis - Air Conditioning Troubleshooting Hints:............................ 8A-76-2
Compressor Controls..............................8A-64-6 No Audible Warning Alarm Functions... 8A-76-3
Troubleshooting H ints:.............................8A-64-6 Fasten Belts Warning Alarm Fails On...8A-76-3
A/C Compressor Clutch Does The Fasten Safety Belts Warning
Not Engage......................................... 8A-64-7 Alarm Fails O ff................................... 8A-76-4
Circuit Operation........................................ 8A-64-10 Lamps-On Warning Alarm Fails On...... 8A-76-4
65 HVAC A ir D elivery And Lamps-On Warning Alarm Fails O ff...... 8A-76-4
Tem perature C o n tro ls ..............................8A-65-0 Fasten Safety Belts Indicator
Component Location Table........................ 8A-65-5 Fails Off............................................... 8A-76-4
Diagnosis - HVAC Air Delivery Fasten Safety Belts Indicator
And V entilation....................................... 8A-65-6 Fails O n ............................................. 8A-76-5
Troubleshooting Hints: Front.................. 8A-65-6 Key-In Warning Alarm Fails O ff............ 8A-76-5
Troubleshooting Hints: Rear Auxiliary... 8A-65-6 Key-In Warning Alarm Fails O n............ 8A-76-5
Troubleshooting Hints: General..............8A-65-6 The Overspeed Warning Alarm Is
Front Ventilation Controls Inoperative... 8A-65-7 Inoperative......................................... 8A-76-6
Front Mode Door Motor Inoperative.... 8A-65-7 Circuit O peration.........................................8A-76-7
Front Temperature Door Motor Overspeed Warning A larm .....................8A-76-7
Inoperative........................................... 8A-65-8 Fasten Safety Belts Warning Alarm......8A-76-7
Recirculation Door Motor Fails In Key-In Warning A larm ........................... 8A-76-7
Vent Position....................................... 8A-65-9 Lamps-On Warning Alarm ..................... 8A-76-7
Recirculation Door Motor Fails In 81 Instrum ent C lu ste r..................................8A-81 -0
Recirculation P osition........................ 8A-65-9 Component Location Table....................... 8A-81 -8
Front Mode Door Motor Operates Diagnosis - Instrument C luster................ 8A-81-12
With Front Blower Switch O ff..........8A-65-10 Troubleshooting H ints:...........................8A-81-12
Rear Ventilation Controls Diagnostic Coverage Table...................... 8A-81-13
Inoperative......................................... 8A-65-10 Fuel Gauge Is Inaccurate
Rear Auxiliary Mode Door (Single Tank)..................................... 8A-81-14
Inoperative......................................... 8A-65-11 Fuel Gauge Indicates Full Or Above
Rear Auxiliary Temperature Door Full At All Times (Single Tank)..... 8A-81-15
Inoperative......................................... 8A-65-12 Fuel Gauge Indicates Empty When
Rear Auxiliary HVAC Control There Is Fuel In The Tank
Switch/Module Does Not (Single Tank)..................................... 8A-81-15
Control Rear D oors......................... 8A-65-13
Fuel G au g e Indicates Em pty At All Tachometer.............................................8A-81 -28

Tim es (Dual T an k s)............................... 8 A -8 1 -1 6 PRNDL Indicator.................................... 8A-81-28
Fuel G a u g e Indicates Full At All Check Gauges Lamp........................... 8A-81 -28
Tim es (Dual T an k s)............................... 8 A -8 1 -1 7 84 E lectrochrom atic Rearview M irror
Fuel G a u g e Is Inaccurate W ith C om pass.......................................... 8A-84-0
(Dual T an k s).............................................8 A -8 1 -1 8 Component Location Table.................. 8A-84-1
Vehicle Runs O ut O f Fuel At Diagnosis - Electrochromatic Mirror,
H alf-F ull/R ear Tank Is Full At Electronic Com pass...............................8A-84-2
All Tim es (Dual T a n k s )........................8 A -8 1 -1 9 Troubleshooting H ints:.............................8A-84-2
Fuel G au g e Does Not C hange System Check.......................................... 8A-84-2
Position O n S cale (Dual T a n k s)..... 8 A -8 1 -2 0 Electrochromatic Mirror Does Not
Tem perature G a u g e Indicates Hot Lighten Or Darken Properly.............. 8A-84-2
(In R ed Z o n e O r C heck G auges Electrochromatic Mirror/Electronic
Lam ps Is Illuminated) W ith Engine Compass -Inoperative D isplay..........8A-84-3
Coolant Below Norm al Operating Electrochromatic Mirror Inoperative
Tem perature And Ignition Switch In Reverse.......................................... 8A-84-3
In R un............................... 8A-81-20 Circuit O peration......................................... 8A-84-3
Temperature Gauge Indicates Cold Compass Display..................................... 8A-84-3
All The T im e .....................................8A-81-20 Setting The Compass Zone................... 8A-84-3
Temperature Gauge Is Not 91 W iper/W asher: P ulse.................. 8A-91-0
Accurate............................................ 8A-81-20 Diagnosis - Wiper/Washer: Pulse.............. 8A-91-1
Oil Pressure Gauge Is Not Accurate Troubleshooting H ints:.............................8A-91-1
Under Normal Operating Wipers Inoperative In Any M ode...........8A-91-2
C onditions......................................... 8A-81-21 Wipers Inoperative At High Speed........8A-91 -2
Oil Pressure Gauge Indicates Low Wipers Inoperative At Low Speed.........8A-91-3
Pressure (In Red Zone Or At 0) NoDelay In The Pulse (Delay) M ode... 8A-91-3
When Oil Pressure Is Normal....... 8A-81-21 Wipers Will Not Shut O ff.........................8A-91-4
Oil Pressure Gauge Indicates Low Washer Not Operative.... ........................8A-91-4
Pressure (In Red Zone Or 80 With Circuit O peration......................................... 8A-91 -5
No Fluctuation) At All Tim es..........8A-81 -21 Wipers (P ulse)......................................... 8A-91 -5
Voltmeter Is Not A ccurate...................8A-81-21 Washer (Pulse W iper).............................8A-91 -5
Low Coolant Level Indicator Does 92 Rear W iper/W asher............................. 8A-92-0
Not Light With Low Coolant Level Component Location Table........................ 8A-92-1
(Diesel O nly)....................................8A-81-22 Diagnosis - Rear W iper/W asher....... ........ 8A-92-2
Low Coolant Level Indicator Lamp Troubleshooting H ints:.............................8A-92-2
Lights When Coolant Level Is Not Rear Wiper Inoperative In Any Mode... 8A-92-2
Low (Diesel O nly)........................... 8A-81-22 Rear Wiper Inoperative In Pulse
Speedometer/Odometer Inoperative... 8A-81-22 Speed...................................................8A-92-2
Speedometer/Odometer Is Rear Wiper Inoperative In Lo Speed ... 8A-92-3
Inaccurate......................................... 8A-81-23 Rear Wiper Will Not Turn Off Or
Tachometer Inoperative (G asoline).... 8A-81-24 Park......................................................8A-92-3
Tachometer Inoperative (Diesel)..........8A-81-24 Rear Washer Inoperative.........................8A-92-3
Tachometer Is Inaccurate.................... 8A-81-25 Circuit O peration......................................... 8A-92-4
PRNDL Indications Are Incorrect Rear Pulse Wiper/Washer S ystem ........8A-92-4
Or Not Present But Automatic W iper............................. 8A-92-4
Transmission Function Norm ally.... 8A-81-25 Washer................................................... 8A-92-4
PRNDL Module Input Test Table........ 8A-81 -26 100 H eadlights..............................................8A-100-0
Circuit Operation.......................................8A-81-27 Component Location Table...................... 8A-100-2
Fuel G auge........................................... 8A-81-27 Diagnosis - Headlamps.............................8A-100-3
Oil Pressure Gauge............................. 8A-81-27 Troubleshooting H ints:................... 8A-100-3
Temperature Gauge............................. 8A-81-27 Low And High Beam Headlamps
Voltm eter.................................. 8A-81-27 Inoperative........................................ 8A-100-4
Low Engine Coolant Level Indicator... 8A-81-27 Low Beam Headlamps Inoperative......8A-100-4
Speedometer And O dom eter..............8A-81-28 High Beam Headlamps Inoperative.... 8A-100-4
LH Headlamp High/Low Beam Daytime Running Lamps (DRL)

Inoperative........................................ 8A-100-5 Are Operational At All Tim es...... 8A-102-12
RH Headlamp High/Low Beam Daytime Running Lamps (DRL)
Inoperative........................................ 8A-100-5 Indicator Is Inoperative.................. 8A-102-13
LH Low Beam Headlamp Circuit O peration..................................... 8A-102-13
Inoperative........................................ 8A-100-6 Headlamps........................................... 8A-102-13
LH High Beam Headlamp Fog Lamps........................................... 8A-102-13
Inoperative........................................ 8A-100-6 Daytime Running Lamps (DRL)....... 8A-102-14
RH Low Beam Headlamp 110 E xterior Lam ps......................................8A-110-0
Inoperative........................................ 8A-100-6 Component Location Table.......................8A-110-8
RH High Beam Headlamp Diagnosis - Exterior Lights......................8A-110-13
Inoperative........................................ 8A-100-7 Troubleshooting H ints:.........................8A-110-13
High Beam Indicator Inoperative Exterior Lamps..................................... 8A-110-13
But High Beam Headlamps Cargo Lam ps.................... .................. 8A-110-13
O perate................................... 8A-100-7 Tail/Stop-Turn Lamps Inoperative
High Beam Headlamps Remain (Suburban/Utility)............................ 8A-110-13
On After Headlamp Switch Tail/Stop-Turn Lamps Inoperative
A ctuation........................................... 8A-100-7 (Pickup)............................................8A-110-14
Low Beam Headlamps Remain Tail/Stop-Turn Lamps Inoperative
On After Headlamp Switch On One Side................................... 8A-110-15
A ctuation........................................... 8A-100-7 Park/Turn Lamps Inoperative............. 8A-110-15
Headlamps Remain On With Turn Signals/Hazard Flashers
Headlamp And Panel Dimmer Inoperative...................................... 8A-110-16
Switch O ff.......................................... 8A-100-7 Turn Signals Inoperative On
Circuit Operation........................................ 8A-100-7 One Side..........................................8A-110-17
102 H eadlam ps: D aytim e R unning Roof Marker Lamps Inoperative....... 8A-110-17
L a m p s ....................................................... 8A-102-0 Clearance / Endmarker Lamps
Component location Table....................... 8A-102-5 Inoperative...................................... 8A-110-18
Diagnosis - Headlamps: Daytime One License Lamp Inoperative.......... 8A-110-18
Running Lam ps.................................... 8A-102-7 Both License Lamps Inoperative...... 8A-110-19
Troubleshooting H ints:...........................8A-102-7 LH Center High Mounted Stoplamp
Low And High Beam Headlamps (CHMSL) Inoperative......................8A-110-19
Are Inoperative.................................8A-102-7 RH Center High Mounted Stoplamp
Low Beam Headlamps Are (CHMSL) Inoperative......................8A-110-19
Inoperative......................................... 8A-102-7 Center High Mounted Stoplamps
High Beam Headlamps Are (CHMSL) Inoperative......................8A-110-19
Inoperative......................................... 8A-102-7 CHMSL Lamps Are On With
One Low Beam Or High Beam Brake Pedal Released....................8A-110-20
Headlamp Inoperative...................... 8A-102-7 LH Turn Signal Indicator
High Beam Indicator Inoperative........ 8A-102-9 Inoperative...................................... 8A-110-20
High Beam Headlamps On With RH Turn Signal Indicator
Headlamp And Panel Dimmer Inoperative.......................................8A-110-20
Switch Off.......................................... 8A -102-9 Cargo Lamps Inoperative................... 8A-110-20
Fog Lamps Are Inoperative.................. 8A-102-9 Circuit O peration..................................... 8A-110-21
One Fog Lamp Inoperative...............8A-102-10 Tail/Stop-Turn, Marker, Endgate
Fog Lamp Indicator Inoperative....... 8A-102-10 Clearance, Park/Tum And License
Fog Lamps Remain Lit With Fog Lam ps..............................................8A-110-21
Lamp Switch O ff.............................8A-102-11 Stoplam ps.............................................8A-110-21
Daytime Running Lamps (DRL) Turn Signal Lam ps.............................. 8A-110-21
Are Inoperative................................ 8A-102-11 Hazard Lam ps..................................... 8A-110-21
Daytime Running Lamps (DRL) Cargo Lam ps........................................8A-110-21
Do Not Disable With Parking Spot Lamps...........................................8A-110-21
Brake Engaged...............................8A-102-12 Roof W iring...........................................8A-110-21
Grille Lamps..........................................8A-110-22
6 Table of Contents Chassls/Body Electrical
112 Backup L ig h ts ..................................... .8A-112-0 DRL/Radio Override Switch

Component Location Table...................... 8A-112-1 Illumination Does Not D im .............. 8A-117-7
Diagnosis - Backup Lights........................8A-112-2 Automatic Transfer Case Select
Troubleshooting H ints:...........................8A-112-2 Switch Illumination Does
LH and RH Back Up Lamps Not Dim..............................................8A-117-7
Are Inoperative.................................. 8A-112-2 Front/Rear Auxiliary HVAC Control
Circuit Operation........................................ 8A-112-2 Lamp Illumination Inoperative......... 8A-117-8
Backup Lam ps....................................... 8A-112-2 Transfer Case Mode Selector Lamp
114 In te rio r Lam ps...................................... 8A-114-0 Illumination Inoperative.....................8A-117-8
Component Location Table.................... 8A-114-10 HVAC Control Switch Lamp
Diagnosis - Interior Lamps......................8A-114-14 Illumination Inoperative.....................8A-117-9
Troubleshooting H ints:.........................8A-114-14 Rear Auxiliary Heater Switch Lamp
Overhead Console/Courtesy/Dome Illumination Inoperative.................... 8A-117-9
Lamp(s) Inoperative........................8A-114-14 Rear Window Wiper/Washer Switch
Overhead Console/Courtesy/ Dome Lamp Illumination Inoperative......... 8A-117-9
Lamp(s) Remain O n ...................... 8A-114-15 Radio Lamp Illumination
Illuminated Entry System Inoperative Inoperative...................................... 8A-117-10
(Dome Lamps O perative).............. 8A-114-16 Liftgate Release Switch Lamp
Illuminated Vanity Mirror Illumination Inoperative.................. 8A-117-10
Inoperative....................................... 8A-114-16 Cargo Lamp Switch Lamp
Cigar Lighter Inoperative.................... 8A-114-16 Illumination Inoperative...................8A-117-11
IP Compartment Box Lamp Fog Lamp Switch Lamp Illumination
Inoperative......................... ............. 8A-114-16 Inoperative.......................................8A-117-11
Underhood (Reel) Lamp Operative....8A-114-17 Audio Alarm Module Lamp
Component Illumination Lamps Illumination Inoperative...................8A-117-11
Inoperative....................................... 8A-114-17 Transfer Case Select Switch Lamp
Circuit Operation...................................... 8A-114-17 Illumination Inoperative.................. 8A-117-12
Underhood Reel Lam p........................8A-114-17 Inflatable Restraint IP Module
Component Illumination Lamps.......... 8A-114-17 Enable Switch Lamp Illumination
Illuminated E ntry.................................. 8A-114-17 Inoperative...................................... 8A-117-12
117 Instrum ent Panel D im m in g ................... 8A-117-0 Active Transfer Case Select Switch
Component Location Table...................... 8A-117-2 Lamp Illumination Inoperative...... 8A-117-13
Diagnosis - Instrument Panel DRL/Radio Override Switch (Police
Dimming.................................................8A-117-4 Package, Z56) Lamp Illumination
Troubleshooting H ints:...........................8A-117-4 Inoperative...................................... 8A-117-13
Instrument Panel Lamp(s) Are Radio, PRNDL, Inflatable Restraint
Inoperative......................................... 8A-117-4 IP Module Enable, Transfer Case
Radio Illumination Does Not Dim........ 8A-117-5 Select Switch, and DRL/Radio
Rear Window Wiper/Washer Switch Overide Illumination Lamps Do Not
Illumination Does Not D im .............. 8A-117-5 Go Bright In Parade Mode............8A-117-14
Liftgate Release Switch Illumination Radio Illumination Does Not Go
Does Not D im ................................... 8A-117-5 Bright In Parade Mode.................8A-117-14
Cargo Lamp Switch Illumination PRNDL Illumination Does Not Go
Does Not D im ................................... 8A-117-6 Bright In Parade Mode.................8A-117-14
Fog Lamp Switch Illumination Inflatable Restraint IP Module Enable
Does Not D im ................................... 8A-117-6 Switch Illumination Does Not Go
Audio Alarm Module Illumination Bright In Parade Mode.................8A-117-15
Does Not D im ................................... 8A-117-6 Transfer Case Select Switch
Transfer Case Select Switch Illumination Does Not Go Bright
Illumination Does Not D im .............. 8A-117-6 In Parade Mode.............................. 8A-117-15
Inflatable Restraint IP Module DRL/Radio Override Switch (Police
Enable Switch Illumination Package, Z56) Illumination Does
Does Not D im ................................... 8A-117-7 Not Go Bright In Parade Mode ....8A-117-15
Chasais/Body Electrical Table of Contents 7
Circuit Operation...................................... 8A-117-16 Power Door Locks Only Work

Interior Lamps Dim m ing......................8A-117-16 From One Lock Switch
120 Pow er W in d o w s ................................... 8A-120-0 (2 Door P ickup).............................. 8A-130-9
Component Location Table...................... 8A-120-3 Cargo Door Lock Motor Does Not
Diagnosis - Power W indow................ 8A-120-4 Lock /Unlock (Suburban/Utility)..... 8A-130-9
Troubleshooting H ints:.......................... 8A-120-4 Circuit O peration................................... 8A-130-10
Diagnosis - Power Windows Rear Cargo Doors...............................8A-130-10
(2 D oor).................................................8A-120-5 132 R em ote K eyless E n try ....................... 8A-132-0
Both Power Windows Inoperative........8A-120-5 Component Location Table...................... 8A-132-5
LH Window Inoperative; RH Diagnosis - Remote Keyless E ntry....... 8A-132-8
Window Operates Normally.............8A-120-5 Troubleshooting H ints:...........................8A-132-8
RH Window Is Inoperative From Remote Keyless Entry Does Not
Individual Window Switch, But O perate........................................... 8A-132-9
Operates Normally From The LH All Power Doors Do Not Lock
Window Switch..................................8A-120-6 Using Transmitter............................8A-132-10
RH Window Is Inoperative From LF Power Door Does Not Unlock
Both The LH Window Switch And Using Transmitter............................8A-132-10
RH Window Switch; LH Window RF and RR Power Doors Do Not
Operates Normally........................... 8A-120-6 Unlock Using Transm itter.............. 8A-132-11
Diagnosis - Power Windows (4 Door).... 8A-120-7 Cargo Power Door Inoperative
All Power Windows Inoperative...........8A-120-7 Using Transmitter............................8A-132-11
LF Window Inoperative; All Others Liftgate Window Release Inoperative
Operate Normally..............................8A-120-7 Using Transmitter............................8A-132-12
RF, LR, Or RR Window Is Inoperative One Door Lock Inoperative. Using
From Individual Window Switch, Transmitter (Excluding LF Door).. 8A-132-13
But Operates Normally From Both Horn Chirp Function Inoperative
The LF Window Sw itch................... 8A-120-8 Using Transmitter............................8A-132-13
One Window (Other Than LF) Is Courtesy Lamps Inoperative Using
Inoperative From The LF Window Transm itter.....................................8A-132-13
Switch And The Individual Window Transmitter Functions Do Not
Switch; All Other Windows Operate O perate........................................... 8A-132-14
Norm ally............................................ 8A-120-8 Circuit O peration..................................... 8A-132-14
Circuit Operation........................................ 8A-120-9 Power Door Locks/Remote Keyless
Master Window Switch Operation........8A-120-9 Entry.................................................8A-132-14
Individual Window Switch Operation... 8A-120-9 Door Lock Operation - Switches...... 8A-132-14
130 Pow er D oor L o cks ...............................8A-130-0 Door Lock Operation - Remote
Component Location Table...................... 8A-130-4 Keyless Entry.................................. 8A-132-14
Diagnosis - Power Door Locks................8A-130-7 Rear Window Release.........................8A-132-15
Troubleshooting H ints:.......................... 8A-130-7 134 L iftg ate W indow R e le a s e ................... 8A-134-0
Power Door Locks Inoperative From Component Location Table...................... 8A-134-2
Either Switch (P ickup)..................... 8A-130-8 Diagnosis - Liftgate Window Release.... 8A-134-2
Both Power Door Lock Switches Troubleshooting Hints:...........................8A-134-2
Open Only One Power Door Liftgate Window Release
Lock (Pickup)....................................8A-130-8 Inoperative........................................ 8A-134-3
Both Power Lock Motors Circuit O peration....................................... 8A-134-3
Inoperative (Suburban/Utility)..........8A-130-8 138 B rake Tran saxle/T ran sm issio n
Both Power Door Lock Switches S h ift In te rlo ck (B T S I) ..................... 8A-138-0
Only Open One Power Door Lock Component Location Table...................... 8A-138-1
(Suburban/Utility)...............................8A-130-9 Diagnosis - Brake Transmission
Power Door Locks Only Work From Shift Interlock (BTSI)............................8A-138-1
One Power Door Lock Switch Troubleshooting Hints:...........................8A-138-1
(Suburban/Utility)...............................8A-130-9
8 Table of Contents Chassia/Body Electrical
Transmission May Be Shifted From Diagnosis - Electrochromatic And

Park Without Actuation Of The Day-Night M irrors................................. 8A-148-2
Brake Pedal And With Ignition Troubleshooting H ints:...........................8A-148-2
In R un............................................... 8A-138-2 System Check........................................ 8A-148-2
Transmission W ill Not Shift From Electrochromatic And Automatic
Park With The Brake Pedal Day-Night Mirrors Inoperative....... 8A-148-3
Actuated And Ignition Switch LH/RH Outside Automatic Day-Night
In R un............................................... 8A-138-3 Mirror Does Not Operate
Circuit Operation........................................ 8A-138-3 Properly............................................. 8A-148-3
140 Power S e a ts......................................... 8A-140-0 Automatic Day-Night Mirrors
Component Location Table...................... 8A-140-1 Inoperative......... .............................. 8A-148-3
Diagnosis - Power S eats......................... 8A-140-2 Automatic Day-Night Mirrors
Troubleshooting H ints:.......................... 8A-140-2 Inoperative In Reverse.................... 8A-148-4
Power Seat Inoperative........................ 8A-140-2 150 Radio And Power A m p lifie r..............8A-150-0
Power Seat Front Tilt Motor Component Location Table...................... 8A-150-4
Inoperative......................................... 8A-140-2 Diagnosis - Radio And Power
Power Seat Rear Tilt Motor Am plifier............................. 8A-150-6
Inoperative........................................ 8A-140-3 Troubleshooting H ints:...........................8A-150-6
Power Seat Forward/Rearward Audio System Diagnostic Overview....... 8A-150-6
Motor Inoperative.............................8A-140-3 Identifying Concerns..... ........................8A-150-6
Circuit Operation....................................... 8A-140-4 Corrective A ction ................................... 8A-150-7
41 Lum bar S up p orts...... ...........................8A-141-0 Generator Whine Concerns,................. 8A-150-8
Component Location Table..................... 8A-141-3 Radio Does Not Retain Stations
Diagnosis - Lumbar Supports................. 8A-141 -4 In Memory Or Clock Is
Troubleshooting H ints:..........................8A-141-4 Inoperative........................................ 8A-150-8
Lumbar Supports - Power Lumbar Radio Illumination Lamps Do
Inoperative........................................ 8A-141 -4 Not Come O n ................................... 8A-150-8
Circuit Operation....................................... 8A-141-5 Display Dimming Function Is
143 Heated S ea ts....................................... 8A-143-0 Inoperative........................................ 8A-150-9
Diagnosis - Heated Seats....................... 8A-143-3 Display Is Inoperative, No Sound
Troubleshooting H ints:..........................8A-143-3 From Any Speaker...........................8A-150-9
Heated Seats Inoperative.................... 8A-143-3 No Sound From One Speaker............. 8A-150-9
Power Seat Heater Switch Tape Player Is Inoperative................. 8A-150-10
Operative.......................................... 8A-143-4 Tape Plays Weak, Slow Or
Heated Seat Inoperative When Garbled............................................ 8A-150-10
Seat Belt Is Connected Compact Disc Player Does Not
(RF O n ly)......................................... 8A-143-4 Operate Properly............................8A-150-10
Circuit Operation....................................... 8A-143-5 Noise/Poor Reception..........................8A-150-11
147 Power M irro rs...................................... 8A-147-0 Power Amplifier Is Inoperative........... 8A-150-12
Diagnosis - Power M irrors...................... 8A-147-2 No Sound Or Distorted Sound
Troubleshooting H ints:....................... 8A-147-2 From Rear Speakers..................... 8A-150-12
LH Mirror Will Not Adjust Up Antenna System Test..........................8A-150-13
And D ow n........................................ 8A-147-2 Use And Construction Of A
RH Mirror W ill Not Adjust Up Noise “Sniffer” ................................ 8A-150-14
And D ow n........................................ 8A-147-2 Customer’s T IP s.................................. 8A-150-14
LH Mirror Will Not Adjust Left How To Enjoy Fm Stereo............... 8A-150-14
And R ight........................... ............. 8A-147-3 How To Enjoy A m ............................8A-150-14
RH Mirror W ill Not Adjust Left Ways To Reduce N oise.................. 8A-150-14
And R ight......................................... 8A-147-3 Circuit O peration.......................... 8A-150-14
Neither Mirror Is Operational............... 8A-147-3 Radio.....................................................8A-150-14
Circuit Operation....................................... 8A-147-3 Power Amplifier (Suburban O nly).... 8A-150-15
Power M irrors........................................8A-147-3 Remote Cassette Tape Player
148 A utom atic Day-Night M irro rs ...........8A-148-0 (Optional)......................................... 8A-150-15
Auxiliary Speaker - Z56...................... 8A-150-15 Dome Lamp Replacement.............................8B-15

200 M aster Com ponent Table................... 8A-200-0 Door Jamb Switch Replacement.................. 8B-16
Component Location Table...................... 8A-200-0 Liftgate Jamb Switch Replacement.............. 8B-16
Diodes.......................................................8A-200-15 Selectable Four-Wheel Drive Indicator
Grommets.................................................8A-200-15 Lamp Replacement................................... 8B-16
G rounds....................................................8A-200-15 Headlamp Switch Replacement.................... 8B-17
S plices................ 8A-200-16 Emergency Roof Lamp Switch.................. ...8B-17
201 Com ponent Location V ie w s..............8A-201-0 Instrument Panel Storage Compartment
202 Harness C onnector Faces................. 8A-202-0 Lamp and Switch Replacement............... 8B-18
Lighting Systems.............................................. 8B-1 Overhead Console Lamp Replacement.......8B-18
On-Vehicle S ervice o f E xterior L ig h tin g ....... 8B-1 Sunshade Vanity Mirror Lamp
Cargo/Stoplamp Replacement.........................8B-1 Replacement...............................................8B-19
Pickup and Cab/Chassis M odels.................8B-1 S p e c ific a tio n s .................................................... 8B-20
Center High-Mounted Stoplamp (CHMSL) Bulb Specifications......................................... 8B-20
Replacement.................................................8B-2 Fastener Tightening Specifications............... 8B-21
Suburban and Utility M odels..... ..................8B-2 S p ecial T o o ls ..................................................... 8B-21
Composite Headlamp Bulb Replacement...... 8B-2 Instrument Panel and Gauges ................... 8C-1
Composite Headlamp Adjustm ent.................. 8B-3 G en eral D e s c rip tio n ........................................... 8C-1
Visual Headlamp Aiming Procedure Electrostatic Discharge (ESD) Notice............. 8C-1
(Preferred)...................................... 8B-3 Instrument Panel.................................. 8C-1
Headlamp Aiming by the Screen Instrument Panel H arness.... ...................... 8C-1
M ethod......................................................8B-4 Heater and Air Conditioning Harness............8C-1
Location......................................................8B-4 Seat Belt Alarm ................................................ 8C-3
Aiming Screen........................................... 8B-4 Fuse Block and Convenience C enter............ 8C-3
Headlamp Aiming Procedure...................... 8B-5 Engine Control Switch (Ignition Switch).........8C-3
Headlamp Aiming Alternative Procedure....8B-5 Electric Speedometer....................................... 8C-4
Sealed Beam Headlamp Replacement..........8B-6 Vehicle Speed Sensor...................................... 8C-4
Sealed Beam Headlamp Adjustment.............. 8B-6 Vehicle Speed Sensor Calibrator M odule..... 8C-4
Endgate Lamp Replacement...........................8B-6 Fuel Gauge........................................................8C-5
Fog Lamp Adjustment................. 8B-7 Fuel Gauge Sender...................................... 8C-5
Fog Lamp Bulb Replacement...................... ...8B-7 Check Gauges Lam p....................................... 8C-5
Front Parking Lamp Replacement.................. 8B-8 Coolant Temperature G auge...........................8C-5
Front Side Marker and Reflector Low Coolant Lamp.................................... 8C-6
Replacement.................................................8B-8 Oil Pressure G auge......................................... 8C-6
Spotlamp (Police Package)..............................8B-8 Voltmeter............................................................ 8C-6
Spotlamp Bulb................................................8B-9 Charging System Warning System................. 8C-6
Spotlamp Travel Adjustm ent..................... 8B-10 Malfunction Indicator Lamp (M IL)................... 8C-6
License Lamp Replacem ent..........................8B-10 Brake Warning System .................................... 8C-6
Rear Fender Marker Lamp Replacement.... 8B-11 Electronic PRNDL............................................ 8C-6
Roof Marker Lamp Replacement.................. 8B-12 O n-V ehicle S e rv ic e ............................................. 8C-7
Tail/Stop/Turnlamp Replacem ent.................. 8B-12 E lectro static D isch arg e (E S D ) N o tic e ............8C-7
Cab/Chassis.................................................8B-12 Instrument Cluster Replacement...................8C-11
Pickup, Suburban, and Utility Models.......8B-13 Instrument Cluster BulbReplacement............8C-12
Underhood Stationary Lamp Transmission Indicator (PRNDL)
Replacement.............................................. 8B-13 Replacement.............................................. 8C-12
O n-Vehicle Service o f In te rio r Lighting Instrument Panel Fuse Block
and S w itch e s............................................... 8B-13 Replacement.............................................. 8C-12
Ashtray Lamp Replacement...........................8B-13 Convenience Center Replacement............... 8C-13
Accessory/Dome Lamp and Hatch 12-Volt Power Supply..................................... 8C-13
Release Switch Replacement.................. 8B-14 Ashtray Replacement..................................... 8C-13
Daytime Running Lights (DRL) Module Cupholder Replacement.................................8C-13
and Relay Replacement............................8B-14 Rolling Instrument Panel................................8C-14
DRL Module.................................................8B-14 Instrument Panel C om partm ent A ss em b ly...8C -14
DRL Relay....................................................8B-15
Inflatable Restraint IP Module O n-V ehicle S e rv ic e ....................................... ..8E1-14

Replacement.............................................. 8C-15 Wiper Arm Assembly Replacement............ 8E1-14
Instrument Panel Assembly Wiper Blade Assembly and Insert
Replacement.............................................. 8C-16 Replacement...................... 8E1 -14
Vehicle Speed Sensor Replacement......... . 8C-18 Circuit board and Terminal Assembly
Vehicle Speed Sensor Calibrator Replacement.............................................8E1-15
Module Replacement..... ..........................8C-18 Wiper Transmission Assembly
Inflatable Restraint IP Module S w itch..........8C-18 Replacement.............................................8E1 -15
Coolant Temperature Sender Wiper Motor Assembly Replacement......... 8E1-15
Replacement.............................................. 8C-19 Wiper/Washer Switch Assembly
Oil Pressure Sender Replacement..... ......... 8C-19 Replacement:......................................... ..8E1-16
Low Coolant Module Replacement............... 8C-20 Washer Solvent Container and Pump
Engine Control Switch (Ignition Switch) Replacement.............................................8E1-17
Replacement.............................................. 8C-20 S p e c ific a tio n s ..................................................8E1 -18
Accessory Switch Replacement.................... 8C-20 Fastener Tightening Specifications............. 8E1-18
S p ecial T o o ls .....................................................8C-23 Rear Window Wiper/Washer System .... 8E2-1
Chassis Electrical.................... 8D-1 G en eral D e s c rip tio n ......................................... 8E2-1
G en eral D e s c rip tio n ........................................... 8D-1 Rear Window Wiper/Washer System ........... 8E2-1
Horn System...................................................... 8D-1 System O peration....................................... 8E2-1
Camper and Trailer W iring...............................8D-1 Container-Mounted Washer System ..... ....... 8E2-1
O n -V eh icle S e rv ic e ................................ 8D-2 D iagnosis o f th e R ear W indow
Horn Replacement............................................ 8D-2 W iper/W asher S y s te m ................................ 8E2-2
S p e c ific a tio n s ...................................................... 8D-3 S ystem C h e c k ................................................... 8E2-3
Fastener Tightening Specifications................. 8D-3 Wiper/Washer Switch Test.............................8E2-3
Windshield Wiper/Washer System .......... 8E1-1 O n-V ehicle S e rv ic e ........................... ....8E2-4
G en eral D e s c rip tio n ......................................... 8E1-1 Wiper Arm Assembly Replacement.............. 8E2-4
Wiper/Washer System ....................................8E1 -1 Wiper Blade Assembly Replacement........... 8E2-4
Wiper/Washer O peration................................ 8E1 -1 Wiper Blade Element Replacem ent........... ..8E2-4
Washer Hose Routing.................................... 8E1 -3 Controller Assembly Replacement................ 8E2-4
D iag n o sis o f th e W ip er/W ash er S y s te m ..... 8E1 -3 Wiper Motor Assembly Replacement........... 8E2-6
W iper Arm C hatter......................................... 8E1 -3 Wiper/Washer Switch Assembly
Checking Wiper Arm Pressure..................... 8E1 -3 Replacement..................................... 8E2-6
Blade Insert Set Check.................................. 8E1-3 Washer Pump Replacement..... ....................8E2-6
W iper Motor Assembly Diagnosis................. 8E1-3 S p e c ific a tio n s .................................................... 8E2-6
P ulse W ip er S ystem C h e c k ............................8E1-7 Fastener Tightening Specifications............... 8E2-6
ELECTRICAL DIAGNOSIS 8A
SECTION 8A
ELECTRICAL DIAGNOSIS
1998 C/K TRUCK
8A - 2 - 0 ELECTRICAL DIAGNOSIS
INTRODUCTION
DIAGNOSTIC INFORMATION The System C heck gives a summary of how the

The Electrical D iagnosis section contains the follow ing system should be operated and what should happen. This is
types of diagnostic information (the way in which the especially important when w orking on a new system. The
information is arranged may vary from system to system or System C heck w ill help identify sym ptom s, lead to
vehicle to vehicle): diagnosis and confirm normal operation of the system after
• Electrical Schematics. repair.
• Component Location Lists. The System D iagn osis provides a procedure to follow
• Harness Connector Faces. that w ill locate the condition in a circuit causing a
• Troubleshooting Hints. malfunction. If your own knowledge of the system and the
• System Checks. Troubleshooting Hints have not produced a quick fix,
• System Diagnosis. follow the System Diagnosis. A ll procedures are based on
• Circuit Operation Descriptions. symptoms to assist in locating the condition as fast as
• Harness Routing Views. possible.
U sin g these elements together w ill make electrical The C ircu it O peration describes the components and
troubleshooting faster and easier. Each element is described how the circuit works.
below.
The C ircu it Schem atic shows the electrical current SECTION/PAGE NUMBER
paths when a circuit is operating properly. It is essential to
Sections are organized by subsystem s w ith m ost
understand how a circuit should w ork before trying to
containing a circuit schematic and the associated text. This
diagnose a failure.
makes the section easy to use, since the page number w ill
The Com ponent Location L ist helps to rind where the
stay the same year after year. F o r exam ple, the cruise
components o f a system can be located. A brief statement
control schematic w ill always begin on page 8A-34-0. The
of the location is given and also a reference to a drawing
other information for cruise control follow s and is paged
that shows the component and its connecting wires. These
8A-34-1, 8A-34-2, etc.
Com ponent Location M e w s are in S E C T IO N 8A-201.
Som e sections m ay have m ore than one circuit
The H a rn ess Connector Faces show the cavity or
schematic, such as Power Distribution, Interior Lights and
terminal locations in all the 4 pin or larger connectors
A ir Conditioning. The circuit of interest can either be
shown in the schematic. Together with the wire colors and
terminals given in the schematic, they help locate test located by using the Index or by a quick look through the
points. The drawings show the connector faces as seen after related section.
the harness connector has been disconnected from a A ll the engine circuits for a particular engine V IN type
component or mating connector. are in the same section. This makes that section easy to
The Troubleshooting H in ts offer shortcuts or checks use, since schematics for other engines are not in your way.
to help determine the cause o f a complaint. They are not The Instrument Panel schematics are organized similarly. If
intended to be a rigid procedure for solving an electrical you are w orking on a vehicle with a D igital Cluster, only
situation. Rather, T roubleshooting H in ts represent a the schematics that apply to that vehicle’s Digital Cluster
common sense approach, based on an understanding of the w ill be in the section you use. Inform ation on the
circuit. Indicators and Gauges Clusters w ill be in other sections.
ELECTRICAL DIAGNOSIS 8A - 2 -1
IHotAtAITlmwl
Steering
Wheel
Figure 1— Typical Horn Schematic
SCHEMATICS The number of cavities for each connector is listed in

Schematics break the entire electrical system down into the Component Location List. Sim ilarly, switches and
individual circuits. W iring w hich is not part of the circuit other components are shown as sim ply as possible,
o f interest is referenced to another page, where the circuit with regard to function only.
is shown complete.
W hen diagnosing a H orn problem, the technician
w ould reference the H orn section. The schem atic in
Important: Figure 1 is a typical example of what would be found in a
H o rn se c tio n o f S E C T IO N 8 A , a lo n g w ith the
• It is important to realize that no attempt is made on follow ing text.
the schematic to represent components and w iring as Voltage is applied to the H orn Relay at all times.
they physically appear on the vehicle. For example, a W hen the relay coil is grounded by closing the Horn
4-foot length o f wire is treated no differently in a Switch, the relay contacts close. W hen the relay contacts
schematic from one which is only a few inches long. are closed, both the L H and R H H om s are energized.
8A-2-2 ELECTRICAL DIAGNOSIS
INTRODUCTION
COMPONENT LOCATIONS Where connectors are listed, the number of cavities is
To locate the schematic components on the vehicle, use provided. This represents the total number of cavities in the
the Component Location List. Refer to “Typical Entries in connector, regardless of how many are actually used. This
the Component Location List.” information is provided to help identify connectors on the
Listed in the left hand column are the components, vehicle. In the far right colum n is a page reference where a
connectors, grounds and splices shown on the schematic. view of the connector face may be found. Connectors with
To the right of the component is the location, “Under R H 3 cavities or less are not included in S E C T IO N 8A-202,
side o f I/P.” Reference to L H and R H is made as though “Harness Connector Faces.”
the technician was sitting in the driver’s seat. O n the same Grounds are listed next in the table. The location
line, in the next tw o colum ns, are page and figure description for G 101 reads, “ B e h in d L H com posite
references for S E C T IO N 8A-201, “Component Location headlamp.” You are directed to page 8A-201-8, Figure 14.
View s.” In this case, you are directed to Figure 4 on Nearly every component, connector, ground or splice
page 8A-201-1. shown on a schematic can be pinpointed visually by using
the Component Location View figures.
Typical Entries in the Component Location List

COMPONENT LOCATION 201-PG FIG. CONN
Convenience Center Under R H side of I/ P .................................................. 1 .... .. 4
Fuse B lo c k ........... Behind I/P compartment door........................................ 0 .... .. 2
C l 00 (34 cavities)... Mounted to L H hood h in g e ........................................... 7 .... .. 11... . 202-0
C 210 (15 cavities)... Above convenience center, behind I/P compartment............ 1 8 ..... 23 ... . 202-2
G 101................... Behind L H composite headlamp................... ......... ........ 8 ...... .. 14
S 1 3 9 ................... Forward lamp w iring ham, behind R H composite headlamp.. 8 .... .. 15
S 2 1 2 ................... I/P w iring ham, behind I/P, above steering colum n............. 6 .... .. 8
ELECTRICAL DIAGNOSIS 8A - 2 - 3
C201
g^ S S^S H ^E SSB^
m m
r o )BSS^ P
m h
C209
m
oa ec
E ar*
s F3CA
12059472 12064752
6 - WAY F METRI - PACK 280 SERIES
7 -W A Y F M E T R I-P A C K MIXED SERIES
■LK
■LK
C406
E 3
a
KtBpKcE, EAu
12034297
4 - WAY M /F WEATHER PACKSHD 12065666
■LK
12-W A Y PC EDQEBOARD- ECM
■LK
CRUISE CONTROL MODULE
6 -1 -9 4
MHHHl/Va
Figure 2— Typical Harness Connector Faces
HARNESS CONNECTOR FACES OTHER INFORMATION

The connectors (see Figure 2) are labeled with the
component they are connected to, or the connector number. VIN REFER EN C ES
In addition the color of the connector is given along with If schematics for more than one variation of an engine
the family/series name. type (V6, for example) are shown, then the schematics w ill
If you need to backprobe a connector while it is on the be labeled w ith V IN designation to d istin gu ish the
component (refer to page 8A-4-3 for probing procedures), variations.
the order of the terminals must be mentally reversed. The
wire color is a help in this situation. If there is more than
SER VIC E PARTS ID E N TIFIC A TIO N LABEL
one wire of the same color, you may need to locate a test
To aid service and parts personnel in identifying
point from its terminal number. A useful trick is to imagine
options and parts originally installed, a Service Parts
that you are probing a terminal from behind the page you
Identification Label has been placed in the vehicle. Refer to
are looking at. Then mentally locate that terminal with
General Information, S E C T IO N OA, for the location of the
respect to the keyway or other reference mark.
label and the definition of the option codes.
8A - 2 ■ 4 ELECTRICAL DIAGNOSIS
INTRODUCTION
A B B R EVIA TIO N S component after a Fusible L in k is also shown. In certain
instances, the first component after a Fuse Block fuse and
A/C A ir Conditioning
Light Switch is also shown.
CKT Circuit
The Power Distribution schematic refers to Fuse Block
CONN Connector
Details or the appropriate section schematics. B y using
EBCM Electronic Brake Control M odule these schematics, power distribution w iring can be followed
EBTCM Electronic Brake and Traction Control M odule from the Battery and Generator to the first component after
ECM Engine Control M odule a Fusible Link, Fuse or Light Switch. The ability to follow
HARN Harness the power distribution w iring to the first component in each
I/P Instrument Panel circuit is extremely helpful in locating short circuits which
IP C Instrument Panel Cluster cause fusible links and fuses to open.
LH Left Hand Figure 3 is a sample Power Distribution schematic. It
PCM Powertrain Control M odule shows how voltage is applied from the positive battery
RH R ight Hand terminal to the various circuits on the vehicle. For example,
TERM Terminal battery voltage is applied to the Starter Solenoid, Fusible
L in k D , Fuses 1 and 2 in the Fuse Block and the Light
F o r a list o f additional abbreviations, refer to
Switch in the L H Pod. These fuses are said to be “Hot A t
S E C T IO N OA.
A ll Tim es” , since battery voltage is always applied to
them.
PO W ER D IS TR IB U TIO N Notice that battery voltage is also applied to “Fusible
The Power Distribution schematic shows the w iring L in k F ” and “Coolant Fan Relay.”
from the Battery and Generator to the Starter Solenoid,
Fuse Block, Ignition Switch and Light Switch. The first
Figure 3—Typical Power Distribution Schematic

INTRODUCTION
[HotAtAITjmj*]
Figure 4— Typical Fuse Block Details Schematic

FUSE BLO C K DETAILS
The Fuse B lo ck Details schematic (see Figure 4)
shows all of the w iring between a fuse and the components
connected to the fuse. The Fuse Block Details schematic is
extremely helpful in locating a short circuit that causes a
fuse to open.
LH Front LH LH D ual RH Front RH RH Dual

Park/Tum H igh Beam Beam Park/Tum H igh Beam Beam
Lam p H eadlam p H eadlam p Lam p H eadlam p H eadlam p
✓ “ —\ + ■*» /■ " — \
i i i ' i i i i i \ i i
\ _ _✓ \_ _ /
Y N
j y Y s
j Y
0 .8 BLK 150 0 .8 BLK 150 0 .8 BLK/W HT 151 0 .8 BLK/ 151

W HT
0 .8 BLK 150 0 .8 BLK/ 151

W HT
.S I 05
S100 . / __________
0 .8 BLK 150 0 .8 BLK/W HT 151
#0101 #0102
Figure 5— Typical Ground Distribution Schematic
G R O U N D D ISTR IB U TIO N common ground wire or the ground connection itself. On

Figure 5 is a sample Ground Distribution schematic for the other hand, if one of the lamps work, the ground and
the Headlamps. It shows exactly which components share the wire up to the splice are good. You have learned this
each ground. This information can often be a timesaver just by inspecting the schematic and knowing the vehicle’s
when troubleshooting ground circuits. symptoms. N o actual work on the lighting system was
For example, if both Headlamps and the Park/Tum needed.
Lam p on one side are out, suspect an open in their
SYMBOLS
ELECTROSTATIC DISCHARGE (ESD) SUPPLEMENTAL INFLATABLE RESTRAINT

SENSITIVE DEVICES (SIR) SYSTEM
A ll E S D sensitive components are Solid State and the The S IR sym bol (Figure 3) is used on schematics to
follow ing information applies to them. alert the technician to the follow ing important caution:
The E S D sym bol (Figure 1) is used on schematics
(Figure 2) to indicate which components are E S D sensitive. CAUTION: This vehicle is equipped with
W hen handling any electronic part, the service technician S u p p lem en tal In fla ta b le R estrain t (S IR ).
should follow the guidelines below to reduce any possible Refer to CAUTIONS in SECTION 9J under
electrostatic charge build-up on the service technician’s “ O N -V E H IC L E S E R V IC E ” an d th e SIR
body and inadvertent discharge to the electronic part. If it Com ponent and W iring Location view in
is not known whether or not a component is E S D sensitive, SECTION 9J before performing service on
assume it is susceptible. o r a ro u n d S IR c o m p o n e n ts o r w irin g .
Failure to follow CAUTIONS could result in
H A N D LIN G PR O C ED U R ES p o s sib le a ir bag d e p lo y m e n t, p erso n al
1. A lw ays touch a known good ground before handling injury, or otherwise unneeded SIR system
the part. This should be repeated while handling the repairs.
part and more frequently after sliding across a seat,
sitting down from a standing position or w alking a
distance.
2. A void touching electrical terminals of the part, unless
so instructed by a written diagnostic procedure.
3. W hen using a voltmeter, be sure to connect the ground
lead first.
4. D o not remove a part from its protective package until
it is time to install the part.
0.8 PNK/BLK 439 H S C 205
5. Before removing the part from its package, ground the
package to a known good ground on the vehicle. 0.8 BRN/WHT 419
A6_X_................ A& C2
____
M EA SU R IN G PR O C ED U R ES
I Ignition
The circuits show n w ithin the boxes are greatly I Control
simplified. D o not troubleshoot by measuring resistance at
I L>mp I Module (ECM)
any terminal of these devices unless so instructed by a I Ground I
- - - - - - J
A
written diagnostic procedure. Due to the sim plification of A12YC2
the sch e m atics, re sistan ce m easurem ents co u ld be 1 BLK/WHT 450
misleading, or could lead to electrostatic discharge.
Figure 2 - Typical Schematic
Figure 3 - SIR Symbol

Figure 1 - ESD Symbol
ON-BOARD DIAGNOSTICS II (OBD II)

SYMBOL
The O B D II sym bol (Figure 4) is used on circuit
diagrams to alert the technician that the circuit is essential
for proper O B D II em ission control circuit operation. A n y
circuit which, if it fails, causes the S E R V IC E E N G IN E
S O O N indicator to turn on, is identified as an O B D II
circuit. Refer to page 8A-5-12 for O B D I I Circuit Service
procedures.
Figure 4 - OBD II Symbol

SYMBOLS
ENTIRE
CO M PO NENT 2 RED/YEL WIRE INSULATION
SHOW N IS RED WITH A
79 YELLO W STRIPE.
r —>i PART OF A WIRE C A G E A N D INSULATION

CO M PO NENT COLOR ARE LABELED.
I I SHOW N
SPLICES ARE SHOW N
I I A N D NUMBERED.
CIRCUIT NU M BER IS
SHOW N TO HELP IN
0
PA R K „ ^ N A M E OF .5 RED ■ 2 TRACING CIRCUITS.
BRAKE CO M PO N EN T
SWITCH
CLOSED WITH DETAILS A BO UT
PARKING CO M PO N EN T OR
BRAKE ON ITS OPERATION
PASSTH RO UGH
□1
GRO M M ET. NUMBERED
FOR REFERENCE.
CO M PO NENT CASE
IS DIRECTLY
.5 R E D ! 2 A W A V Y LINE
ATTACHED TO
M EA N S A WIRE IS
M ETA L PART
TO BE CONTINUED.
OF VEHICLE
(GROUNDED).
WIRE IS ATTACHED TO
M ET A L PART OF VEHICLE
(GROUNDED). FUSIBLE LINK SIZE A N D
INSULATION COLOR
GRO UND IS NUMBERED ARE LABELED.
G103 FOR REFERENCE ON
CO M PO NENT LOCATION LIST.
WIRE IS INDIRECTLY
I SEE GROUND
CONNECTED TO GROUND.
CURRENT PATH
IS CONTINUED
DISTRIBUTION A S LABELED.
I PAGE SA-14-0
WIRE M A Y H AVE ONE OR
THE ARRO W SHOW S
M ORE SPLICES OR CONNECTORS
THE DIRECTION OF
I BEFORE IT IS GROUNDED.
CURRENT FLO W
G101
A N D IS REPEATED
WHERE CURRENT
TO GENERATOR PATH CONTINUES.
PAGE8A-30-0
FEM ALE TERM INAL

CONNECTOR REFERENCE
NU M BER FOR CO M PO N EN T
LOCATION LIST A WIRE WHICH
CONNECTS TO
LIST A LSO SHOW S TOTAL ANOTHER CIRCUIT.
N U M BER OF TERMINALS
\
THE WIRE IS
POSSIBLE. C1B3(S CAVITIES) SHOW N AGA IN
ON TH AT CIRCUIT.
M A LE TERMINAL
TO INSTRUMENT CLUSTER
PAGE 8A-S1-3
A
□
CONNECTOR
ATTACHED TO
CO M PO NENT
CIRCUIT
BREAKER
.5 G R Y l
SWITCH CONTACTS THAT

M O V E TOGETHER
CONNECTOR ON
CO M PO N EN T
T t t *- DASHED LINE SHOW S
A M ECHANICAL
LEAD (PIGTAIL) CONNECTION BETWEEN
SWITCH CONTACTS.
TW O TERMINALS INDICATES THIS CIRCUIT

IN THE SA M E
CONTINUES WITHIN DEVICE;
CONNECTOR
I.E., OTHER BULBS
DASHED LINE SHOW S
A PHYSICAL A N INDICATOR
CONNECTION WHICH DISPLAYS
RETWEEN PARTS THE LIGHTED
(SAM E CONNECTOR). W O RD 'B R A K E '
PCM CONNECTOR IDENTIFICATION

C1 • H A C K • 32 W A Y
a • HACK • 24 W A Y
- I p o w c t t iu u n
INDICATES THAT
■ (.BWfROC
THE CIRCUITRY IS
I M O DULE (PCM)
NO T SHOW N M
SEE GROUND COMPLETE DETAIL
DISTRIBUTION BUT IS COMPLETE ON
PAGE BA-14-0
I THE INDICATED PAGE
ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE DEVICES
ARE IDENTIFIED. REFER TO
PAGE 4A-3-0 FOR HANDLING
A N D M EASURING PROCEDURES.
WIRE CHOICES
FOR OPTIONS
OR DIFFERENT
M O DELS ARE
SHOW N A N D
LABELED.
LABEL OF
H O T IN A C C Y O R R U N FUSE H O C K
UNLESS NOTED. INDICATES THAT — — — I FUSE

] CONNECTOR
CAVITY
THE RELAY WILL POW ER IS

BE SHOW N IN A
DE-ENERGIZED STATE
SUPPLIED WITH
RADIO
EU$E
/
IGNITION SWITCH 10 A M P I
WITH NO CURRENT I N 'A C C Y 'A N D
FLOWING THROUGH
THE CO IL
'R U N ' POSITIONS I
N O R M A LLY
aO SED
CONTACT
N O R M A LLY
OPEN
CONTACT
DIODE
ALLO W S CURRENT
TO FLO W IN ONE
DIRECTION ONLY
FUSIBLE U N K
3 CONNECTORS ARE
SHOW N CONNECTED
TOGETHER A T A
JUNCTION BLOCK.
FOURTH WIRE IS
SOLDERED TO CO M M O N
CONNECTION ON
HOCK.
FU S IH E U N K
NUM BER FOR TOTAL
CONNECTS TO
SCREW TE R M IN A L CONNECTOR
SHOW N SEPARATED
LETTERS FOR EACH
CONNECTOR TERMINAL
12*10*06
B80018A3
SYMBOLS
EASY FLO W DIRECTION

HOSE COLOR VACUUM-
TANK
VACUUM
CHECK
VALVE
IN T H E 'A T R E S T
VAi POSITION SH O W N , N O FLO W DIRECTION
THE VALVE DOES
THE FOLLOWING:
P O R TA IS SEALED.
PORT I IS VENTED
TO THE ATMOSPHERE.
DOUBLE DIAPHRAGM M OTOR

NO VACUUM
W H EN THE VALVE IS
VACUUM M O V ED TO THE
'O PERATED* POSITION,
V A C U U M FROM P O R TA
IS CONNECTED TO
PORTB.
THE SOLENOID VA C U U M
VALVE USES THE
SOLENOID TO M O VE
THE VALVE.
SINGLE DIAPHRAGM M OTOR

M
NO VACUUM
NO VACUUM VACUUM
SERVO MO TO R
6 -1 -9 4
BtKMHflAI
VACUUM MOTORS AND DEVICES Some Vacuum M otors such as the Servo M otor in the
Vacuum M otors operate like electrical solenoids, Cruise Control can position the actuating arm at any
mechanically pushing or pulling a shaft between two fixed position between fully extended and fully retracted. The
positions. W hen vacuum is applied, the shaft is pulled in. servo is operated by a control valve that applies varying
W hen no vacuum is applied, the shaft is pushed all the way amounts of vacuum to the motor. The higher the vacuum
out by a spring. level, the greater the retraction o f the motor arm. Servo
Double Diaphragm M otors can be operated by vacuum M otors w ork like the two position motors; the only
in two directions. W hen there is no vacuum, the motor is difference is in the w ay the vacuum is applied. Servo
in the center “A T R E S T ” position. M otors are generally larger and provide a calibrated
control.
TROUBLESHOOTING PROCEDURES
Exam ple:
BASIC KNOWLEDGE REQUIRED A customer brings in a vehicle and says that the H igh
W ithout a basic knowledge of electricity, it w ill be beams do not work.
difficult to use the diagnostic procedures contained in this
section. You should understand the basic theory of S tep 1: Perform a S ystem C heck on th e
electricity and know the meaning of voltage, current (amps) H eadlam p C ircu it
and resistance (ohm s). You should understand what You may discover that both Low beams operate. In
happens in a circuit with an open or a shorted wire. You “H igh,” you may notice that the H igh Beam Indicator
should be able to read and understand a w iring diagram. comes on, but neither H igh beam operates.
The follow ing four-step troubleshooting procedure is
recommended:
S tep 2: Read th e H eadlam ps E lectrical
S ch em atic (F ig u re 1).
S tep 1: C heck th e Problem T h is is the step that w ill save time and labor.
Perform a System Check to determine a symptom. Remember, it is essential to understand how a circuit
D o n ’t waste time fixing part of the problem! D o not begin should work before trying to figure out why it doesn’t.
disassembly or testing until you have narrowed down the After you understand how the circuit should operate,
possible causes. read the schematic again, this time keeping in mind what
you have learned by operating the circuit.
Since both Low beams work, you know that the
S tep 2: Read th e E lectrical S chem atic Headlamp Switch, the Y E L wire, the Low contacts of the
Study the schematic. Read the Circuit Operation text if Headlamp Dim m er Switch, terminal “ I E ” of C100, the
you do not understand how the circuit should work. Check T A N wires, and grounds G105 and G 109 are all good.
circuits that share w iring with the problem circuit. (Shared Furtherm ore, since you saw that the H igh Beam
c ircu its are show n on P ow er D istrib u tio n , G rou n d Indicator came on when the Headlamp Dim m er Switch was
Distribution, Fuse Block Details, and Light Switch Details moved to “H igh,” you know that the H igh contacts of the
pages.) Try to operate the shared circuits. If the shared Headlamp Dim m er Switch and the L T G R N wire between
circuits work, then the shared w iring is O K . The cause the Headlamp Dim m er Switch and C100 are good.
must be within the w iring used only by the problem circuit. A t this point, you could test for voltage at the R H
If several circuits fail at the same time, chances are the Headlamp with the Headlamp Dim m er Switch in “H igh.”
power (fuse) or ground circuit is faulty. However, it is extremely unlikely that the H igh beam
filaments have burned out in both headlamps, or that both
S tep 3: Find th e F au lt and R epair headlamp connections are bad. The cause must be a bad
connection at C l 00, or a break in the L T G R N wire
• Narrow down the possible causes.
between C l 00 and the R H Headlamp.
• Use the Troubleshooting Hints.
You have quickly narrowed the possible causes down
• M ake the necessary measurements or checks as given
to one specific area, and have done absolutely no work on
in the System Diagnosis.
the vehicle itself.
• Before replacing a component, check power, signal
and ground wires at the component harness connector.
S tep 3: Find th e Fault and R ep air it
If the checks and connections are O K , the most
U s in g the C om p onent L o c a tio n Table and the
probable cause is component failure.
corresponding figure, you can quickly find C l 00 and the
L T G R N wire, locate the exact trouble point and make the
S tep 4: Test th e R epair
repair.
Repeat the System Check to verify that the fault has
been corrected and that no other faults were induced during
the repair.
System Check on the Headlamps C ircuit test light. W hile a test light shows whether or not voltage
This, of course, means m aking sure that both H igh is present, a D M M indicates how much voltage is present.
beams, both Low beams, and the H igh Beam Indicator are A n increasing number of circuits include solid state
all working. control modules. One example is the Powertrain Control
N ow suppose that the symptoms were different. You M odule (PC M ). Voltages in these circuits should be tested
may have operated the Headlamps and found that the Low only with a 10-megohm or higher impedance D M M or
beams were working, but neither the H igh beams nor the J 3920 0 m ultim eter. U n le ss directed to w ith in the
H ig h Beam Ind icator were w orking. L o o k in g at the diagnostics, never use a test light on circuits that contain
schematic, you might conclude that it is unlikely that both solid state components, since damage to these components
H igh beam filaments and the H igh Beam Indicator have all may result.
burned out at once. The cause is probably the Headlamp W h en te stin g fo r vo lta g e or c o n tin u ity at the
Dim m er Switch or its connector. connection, it is not necessary to separate the two halves of
the connector. Unless testing a Weather Pack® or a Metri
TROUBLESHOOTING TOOLS Pack® connector 150 series and below, always probe the
Electrical troubleshooting requires the use of common connector from the back. Alw ays check both sides of the
electrical test equipment. connector. A n accumulation of dirt and corrosion between
contact surfaces is som etim es a cause o f electrical
TEST LIGHT/DIGITAL MULTIMETER problems. A terminal contact checking procedure can be
Use a test light to check for voltage. A J 34142-B Test found on page 8A-4-6.
Light is made up of a 12 volt light bulb with a pair of
leads attached. After grounding one lead, touch the other
lead to various points along the circuit where voltage
should be present. W hen the bulb goes on, there is voltage
at the point being tested.
CO N N EC TO R T E S T A D A PTER S S H O R T FINDER
Connector Test Adapter K it (J 35616-A ) is available J 8681 short finders are available to locate hidden
for m aking tests and measurements at separated connectors. shorts to ground. The short finder creates a pulsing
This kit contains an assortment of probes which mate with magnetic field in the shorted circuit and shows you the
many of the types of terminals you w ill see. Avoid using location of the short through body trim or sheet metal.
paper clips and other substitutes since they can damage
terminals and cause incorrect measurements. TROUBLESHOOTING TESTS
SELF-P O W ER ED TE S T LIG H T A FTER M A R K ET A C C ESSO R IES

A self-powered test light (J 21008-A ) can be used to D o not connect aftermarket accessories into S IR
check for continuity. This tool is made up of a light bulb, circuits. A ll such circuits are indicated on circuit diagrams
battery and two leads. If the leads are touched together, the with the S IR symbol. Refer to Sym bols, S E C T IO N 8A-3.
bulb w ill go on. D o not connect aftermarket accessories into O B D II
A self-powered test light is used only on an unpowered circuits. A ll such circuits are indicated on circuit diagrams
circuit. First remove the fuse which feeds the circuit you’re w ith the O B D II s y m b o l. R e f e r to S y m b o ls ,
working on. Select two specific points along the circuit S E C T IO N 8A-3.
through which there should be continuity. Connect one lead Alw ays check for aftermarket accessories (non-O EM )
of the self-powered test light to each point. If there is as the first step in diagnosing electrical problems. If the
continuity, the test light circuit w ill be completed and the vehicle is so equipped, disconnect the system to verify that
bulb w ill go on. these add-on accessories are not the cause of the problems.
Never use a self-powered test light on circuits that Some possible causes o f vehicle problems related to
contain solid state components, since damage to these aftermarket accessories include:
components may result.
1. Pow er feeds connected to points other than the
Battery.
O HM M ETER 2. Antenna location.
The ohmmeter function on a D M M can be used instead 3. T ransceiver w irin g located too close to vehicle
of a self-powered test light. A n ohmmeter shows how electronic modules or wiring.
much resistance there is between two points along a circuit. 4. Poor shielding or poor connectors on antenna feed
Low resistance means good continuity. line.
Circuits which include any solid state control modules,
Check for recent service bulletins detailing installation
such as the P C M , should be tested only with a 10-megohm
guidelines for aftermarket accessories.
or higher impedance J 39200 digital multimeter.
Before measuring resistance with a D M M , disconnect
PRO BING
the vehicle’s battery. This w ill prevent incorrect readings.
A fter probing, w hen reconnecting connectors or
D M M s apply such a small voltage to measure resistance
replacing terminals, always be sure to reinstall Connector
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can Position Assurance (C PA ) and Terminal Position Assurance
cause an ohmmeter to give a false reading. To find out if a (TPA).

component is affecting a measurement, take a reading once,
reverse the leads and take a second reading. If the readings Frontprobe
differ, the so lid state com ponent is affe ctin g the W hen ffontprobing of connectors is required, always
measurement. use a mating terminal adapter from Connector Test Adapter
K it (J 35616-A). The use o f proper adapters w ill ensure
FU SED JU M PER W IR E that proper terminal contact integrity is maintained. For a
A J 36169 fused jumper is available with small clamp terminal contact checking procedure, refer to page 8A-4-5.
connectors providing adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20 A B ackprobe
fuse which may not be suitable for some circuits. D o not O nly backprobe connector terminals when specifically
use a fuse with a higher rating than the fuse that protects called for in diagnostic procedures. Since backprobing can
the circuit being tested. be a source of damage to connector terminals, extra care
must be taken to avoid deforming the terminal, either by
N O T IC E : A fused jumper may not protect solid forcing the test probe too far into the cavity or by using too
state components from being damaged. large a test probe.
After backprobing any connector, always check for 2. Connect the negative lead to the other end of the wire
terminal damage. If terminal damage is suspected, check (or the other side of the connection or switch).
for proper terminal contact (refer to “Checking Terminal 3. Operate the circuit.
Contact,” page 8A-4-5). 4. The D M M w ill show the difference in voltage
between the two points.
TESTIN G FOR VOLTAGE (F ig u re 2)
1. Connect one lead of a test light to a known good
ground. W hen using a D M M , be sure the voltmeter’s
negative lead is connected to ground.
2. Connect the other lead of the test light or voltmeter to
a selected test point (connector or terminal).
3. If the test light illuminates, there is voltage present.
W hen using a D M M , note the voltage reading.
TE S TIN G FOR C O N TIN U ITY (F ig u re 3)

1. Rem ove the fuse to the circuit involved.
2. Connect one lead o f a self-powered test light or
ohmmeter to one end of the part of the circuit you
w ish to test.
3. Connect the other lead to the other end of the circuit.
4. If the self-powered test light glows, there is continuity.
W hen using an ohmmeter, low or no resistance means
good continuity.
6 -3 - 9 4
M0029M
TE S TIN G FOR VOLTAGE DRO P (F ig u re 4)
Figure 3—Continuity Check through a Switch
This test checks for voltage being lost along a wire, or
through a connection or switch.
1. Connect the positive lead of a D M M to the end of the
wire (or to one side of the connection or switch)
which is closer to the Battery.
6 -3 - 9 4
6 -3 - 9 4
B8001SA4
Figure 2—Voltage Check Figure 4—Voltage Drop Test

8A ■ 4 - 4 ELECTRICAL DIAGNOSIS
TE S TIN G FOR S H O R T TO G RO UND
W ith a Test Light or DMM (Figure 5)
1. Remove the blown fuse and disconnect the load.
2. Connect a test light or voltmeter across the fuse
terminals (be sure that the fuse is powered). HOT A T ALL TIM ES
3. Beginning near the Fuse Block, wiggle the harness

from side to side. Continue this at convenient points
(about 6 inches apart) while watching the test light or
DMM.
4. W hen the test light glows, or the D M M registers,
there is a short to ground in the w iring near that point.
W ith a S elf-P ow ered Test Light or O hm m eter

(Figure 6)
1. Remove the blown fuse and disconnect the Battery
and load.
2. Connect one lead o f a self-powered test light or
ohmmeter to the fuse terminal on the load side.
3. Connect the other lead to a known good ground.
4. Beginning near the Fuse Block, wiggle the harness
from side to side. Continue this at convenient points
(about 6 inches apart) while watching the self-powered
test light or ohmmeter.
•-3 -9 4
5. W hen the self-pow ered test ligh t glow s, or the
ohmmeter registers, there is a short to ground in the
w iring near that point. Figure 5 - Testing for Short with Test Light or DMM
Fuses Pow ering Several Loads

1. F in d the schem atic in “ Fu se B lo c k D e ta ils,”
page 8A-11-0, for the fuse that has blown.
BATTERY DISCONNECTED
2. Open the first connector or switch leading from the
fuse to each load.
3. Replace the fuse.
• If the fuse blows, the short is in the w iring leading

to the first connector or switch. Use a test light or
D M M as described on previous page.
• If fuse does not blow, refer to next step.
4. Close each connector or switch until the fuse blows in

order to find which circuit has the short. Connect test
light or D M M at the connector to the suspect circuit
(disconnected) rather than at the fuse terminals.
INTERMITTENT AND POOR CONNECTIONS

M o st intermittents are caused by faulty electrical
connections or w iring, although occasionally a sticking
relay or solenoid can be a problem. Some items to check
are:
• Poor mating of connector halves, or terminals not fully

8 -3 -3 4
seated in the connector body (backed out).
• D irt or corrosion on the terminals. The terminals must
be clean and free o f any foreign material which could Figure 6 - Testing for Short with Self-Powered Test Light or
impede proper terminal contact.
Digital Multimeter
• Damaged connector body, exposing the terminals to Contamination is caused by the connector halves being
moisture and dirt, as well as not maintaining proper improperly connected, a m issing or damaged connector
terminal orientation with the component or mating seal, or damage to the connector itself, exposing the
connector. terminals to moisture and dirt. Contamination, usually in
• Im p ro p e rly form ed or dam aged term inals. A ll underhood or underbody connectors, leads to terminal
connector terminals in problem circuits should be corrosion, causing an open circuit or intermittently open
checked carefully to ensure good contact tension. Use circuit.
a corresponding mating terminal to check for proper Deformation is caused by probing the mating side of a
tension. Refer to “Checking Terminal Contact” in this connector terminal without the proper adapter, improperly
section for the specific procedure. joining the connector halves or repeatedly separating and
• The J 35616-A Connector Test Adapter K it must be joining the connector halves. Deformation, usually to the
used w henever a d iagn ostic procedure requests female terminal contact tang, can result in poor terminal
checking or probing a terminal. U sing the adapter w ill contact (R e fe r to F ig u re 7), c a u sin g an open or
ensure that no damage to the terminal w ill occur, as intermittently open circuit.
well as giving an idea of whether contact tension is Follow the procedure below to check terminal contact.
sufficient. If contact tension seems incorrect, refer to 1. Separate the connector halves. Refer to J 38125-A
“ C hecking Term inal Contact” in this section for Terminal Repair K it or J 38125-4 Instruction Manual.
specifics. 2. Inspect the connector halves for contam ination.
• Poor terminal to wire connection. Some conditions Contamination w ill result in a white or green build-up
which fall under this description are poor crimps, poor w ithin the connector body or between terminals,
solder joints, crim ping over wire insulation rather than causing high terminal resistance, intermittent contact,
the wire itself, corrosion in the wire to terminal or an open circuit. A n underhood or underbody
contact area, etc. connector that shows signs of contamination should be
• W ire insulation which is rubbed through, causing an replaced in its entirety: terminals, seals, and connector
intermittent short as the bare area touches other w iring
or parts of the vehicle.
• W iring broken inside the insulation. This condition
could cause a continuity check to show a good circuit,
but if only one or two strands of a multi-strand type
wire are intact, resistance could be far too high.
To avoid any of the above problems when making

w iring or terminal repairs, always follow the instructions
fo r w irin g and term inal rep air outlined in R e p a ir
Procedures, S E C T IO N 8A-5.
CHECKING TERMINAL CONTACT

W hen diagnosing an electrical system that utilizes
M e tri-P a c k 150/280/480/630 series term inals, it is
important to check terminal contact between a connector
and component, or between in-line connectors, before
re placing a suspect com ponent. Refer to J 3 8 1 2 5 -A
Terminal Repair K it or J 38125-4 Instruction M anual for
terminal identification.
Frequently, diagnostics lead to a step that reads:
“Check for poor connection.” M ating terminals must be
inspected to assure good term inal contact. A poor
connection between the male and female terminal at a
con n e cto r m ay be the re su lt o f con tam ination or
deformation.
Figure 7 - Deformation of a Typical Metri-Pack
150/280/480/630 Series Female Terminal
3. U sing an equivalent male terminal from the J 38125-A 3. Press the “M IN M A X ” button. The D M M should
Terminal Repair Kit, check the retention force of the read “ 100 ms R E C O R D ” (100 millisecond record)
female terminal in question by inserting and removing and emit a 1/4 second beep. The D M M is now ready
the male term inal to the female term inal in the to record and w ill generate an audible tone for any
connector body. Good terminal contact w ill require a change in voltage. A t this point, you may w ish to
certain amount of force to separate the terminals. press the “P E A K M IN M A X ” button, which w ill
4. U s in g an e qu ivalen t fem ale term inal from the record any voltage variations that occur for at least
J 38125-A Terminal Repair Kit, compare the retention 1 millisecond.
force o f this term inal to the female term inal in 4. Try to sim ulate the condition that is potentially
question by joining and separating the male terminal causing an intermittent connection, either by w iggling
to the good female terminal, and then joining and connections or wiring, test driving or performing other
separating the male terminal to the female terminal in operations. If an open or resistance is created, a
question. If the retention force is significantly different voltage w ill be present and the D M M w ill emit a tone
between the two female terminals, replace the female for as long as the open or resistance exists. A ny
terminal in question. Refer to J 38125-A Terminal change in voltage w ill cause the D M M to emit a tone
Repair Kit. for no less than 1/4 second. (Listening for a tone
If a visual (physical) check does not reveal the cause w hile m an ip ulatin g w irin g is ve ry h e lp fu l for
of the problem, the vehicle may be able to be driven with a narrowing down an intermittent connection.)
DMM connected to the suspected circuit. A n abnormal Use the M EM and M A X values when the D M M is
voltage reading when the problem occurs indicates the out of sight or sound range, in noisy areas or for test
problem may be in that circuit. driving when it may not be possible to monitor the
DMM.
DETECTING ELECTRICAL INTERMITTENTS To check the M IN and M A X recorded voltages
U se the follow ing procedure to detect intermittent press “M IN M A X ” once for M A X and twice for
terminal contact or a broken wire with an intermittent M IN . A variation between M IN and M A X recorded
connection inside the insulation. v o lta g e s (u n le ss n e a rly 0 v o lts) su g g e sts an
The J 39200 D igital Multimeter (D M M ) has the ability intermittent open or that resistance exists and should
to monitor current, resistance, or voltage while recording be repaired as necessary. Refer to Repair Procedures,
the m inim um ( M IN ) and m axim um ( M A X ) valu es S E C T IO N 8 A -5 fo r a p p ro ve d c irc u it re p a ir
measured. The D M M can also be set to display the average procedures.
(A V G ) value measured.
W hen diagnosing circuits that have voltage applied, Important:
use the voltage setting to monitor a connector (or length of
a circuit) which is suspected of having an intermittent
• The “ 100 ms R E C O R D ” (100 m illisecond record)
connection but is currently operating normally.
mode is N O T the amount of time allowed to perform
1. Connect the J 39200 D igital Multimeter to both sides
a specific procedure. It is the amount of time used to
o f a suspect connector (still connected) or from one
record each sn ap sho t o f in fo rm a tio n used for
end o f a suspect circuit to the other. T h is w ill
calculating “A V G ” when in the “M IN M A X ” mode.
continuously monitor the terminal contacts or length
of wire being checked. Refer to “Digital Multimeter DIGITAL MULTIMETER (DMM)
(D M M ) Connections” in this section for examples of CONNECTIONS
the various methods for connecting the D M M to the
The previous diagnostic procedure w as written to
circuit.
detect intermittents using the D M M set to voltage. Whether
2. Set the D M M for voltage. Since the “M IN M A X ”
using the current, voltage, or resistance setting to detect
mode does not use auto ranging, manually select the
intermittents, it is necessary to properly connect the D M M
voltage range necessary before proceeding.
to the circuit.
Follow ing are examples o f the various methods of ADDITIONAL INFORMATION

connecting the D M M to the circuit to be checked:
N O T IC E : 'R im off power to the test circuit before
• Backprobe both ends of the connector and either hold
attempting in -circu it resistance m easurem ents to
the leads in place while manipulating the connector or
prevent false readings or damage to the D M M . D o not
tape the leads to the harness for continuous monitoring use the D M M to measure resistance through a solid
while performing other operations or test driving. (D o state module.
not backprobe “Weather Pack® ” type connectors.)
• Disconnect the harness at both ends of the suspect C o n tin u ity tests that w o rk w e ll fo r detecting
circuit where it connects either to a component or to intermittent shorts to ground can be performed by setting
other harnesses. the D M M to “ohms,” then pressing the “P E A K M IN
• Use J 35616-A Connector Test Adapter K it to connect M A X ” button. A n audible tone w ill be heard whenever the
the D M M to the circuit. D M M detects continuity for at least 1 millisecond.
• If the system being diagnosed has a specified pinout The J 39200 Instruction M anual is a good source of
or breakout box, it may be used to sim plify connecting information and should be read thoroughly upon receipt of
the D M M to the circuit or for checking multiple the D M M as well as kept on hand for reference during new
circuits quickly. procedures.
REPAIR PROCEDURES
Repair o f circuits w hich are part o f the O B D II
ELECTRICAL REPAIRS (On-Board Diagnostics II) em issions control system have
T his section provides instruction in the follow ing several special requirements which must be followed to
repairs: ensure proper system operation. These requirements are
listed on page 8A-5-12 under “ O B D II circuit repairs.”
• Circuit protection.
• Typical electrical repairs.
CIRCUIT PROTECTION
• Splicing copper wire.
The purpose of circuit protection is to protect the
• Splicing twisted/shielded cable.
w iring assembly during normal and overload conditions.
• Repairing connectors (except Weather Pack®).
A n overload is defined as a current requirement that is
• Repairing Weather Pack® (environmental) connectors.
higher than normal. This overload could be caused by a
• Terminal repair.
short circuit or system malfunction. The short circuit could
• Diode replacement.
be the result of a pinched or cut wire or an internal device
• Heated Oxygen Sensor (H 0 2 S ) repair.
short circuit, such as an electronic module failure.
• O B D I I circuit repair.
The circuit protection device is only applied to protect
• G M S P O service parts ordering.
the w iring assembly, and not the electrical load at the end
After any electrical repair is made, always test the of the assembly. For example, if an electronic component
circuit by operating the devices in the circuit This confirms short circuits, the circuit protection device w ill assure a
not only that the repair is correct but, also, that it was the source is removed.
cause of the complaint. The other type is solid state, called out in this section
m inim al am ount o f damage to the w irin g assem bly. as Electronic Circuit Breaker (EC B). This device has a
However, it w ill not necessarily prevent damage to the positive temperature coefficient. It increases its resistance
component. greatly when excessive current passes through it. The
There are three basic types o f circuit protection excessive current heats the E C B . A s it heats, its resistance
devices: circuit breakers, fuses and fusible links. increases, therefore h a v in g a p o sitiv e tem perature
coefficient. Eventually the resistance gets so high that the
CIRCUIT BREAKERS circuit is effectively open. The E C B w ill not reset until the
A circuit breaker is a protective device designed to circuit is opened, removing voltage from its terminals.
open the circuit when a current load is in excess of rated
Once voltage is removed, the circuit breaker w ill reclose
breaker capacity. If there is a short or other type of
within a second or two.
overload condition in the circuit, the excessive current w ill
open the circuit between the circuit breaker terminals. FUSES
There are two basic types of circuit breakers used in G M The most common method of automotive w iring circuit
vehicles: cycling and non cycling.
protection is the fuse (Figure 1). A fuse is a device that, by
the melting of its element, opens an electrical circuit when
C YC LIN G C IR C U IT BREAK ER the current exceeds a given level for a sufficient time. The
The cycling circuit breaker w ill open due to heat action is non reversible and the fuse must be replaced each
generated when excessive current passes through it for a time a circuit is overloaded or after a malfunction is
period of time. Once the circuit breaker cools, it w ill close repaired.
again after a few seconds. If the cause of the high current F u se s are c o lo r coded. The standardized co lo r
is still present it w ill open again. It w ill continue to cycle identification and ratings are show n in Figure 2. For
open and closed until the condition causing the high service replacement, non color-coded fuses of the same
current is removed. respective current rating can be used.
Exam ine a suspect fuse for a break in the element. If
NON C Y C LIN G C IR C U IT BREAK ER the element is broken or melted, replace the fuse with one
There are two types of non cycling circuit breakers. of equal current rating.
One type is mechanical and is nearly the same as a cycling There are additional specific circuits with in-line fuses.
circuit breaker. The difference is a small heater wire within These fuses are located within the individual wiring harness
the non cycling circuit breaker. This wire provides enough and w ill appear to be an open circuit if blown.
heat to keep the bimetallic element open until the current
AUTOFUSE
CURRENT RATING COLOR
3 VIOLET
5 TAN
7.5 BROWN
10 RED
15 BLUE
20 YELLOW
25 NATURAL
30 GREEN
Fuse Elem ent M axifuse
MAXIFUSE
20 YELLOW
30 GREEN
40 AMBER
50 RED
60 BLUE
70 BROWN
80 NATURAL
•-7 -9 4
B80009AS
Figure 1 - Fuse Devices

A U TO FU SE
The Autofuse, normally referred to sim ply as “Fuse,”
is the most common circuit protection device in today’s
MINIFUSE
vehicle. The Autofuse is most often used to protect the
w iring assembly between the fuse block and the system
components. 2 GRAY
5 TAN
7.5 BROWN
M A X IFU S E ® 10 RED
15 BLUE
The M axiFuse® was designed to replace the fusible 20 YELLOW
lin k and P acific Fuse elements. The M a x iF u se ® is 25 NATURAL
30 GREEN
designed to protect cables, normally between the battery
and fuse block, from both direct short circuits and resistive
short circuits.
Compared to a fusible link or a Pacific Fuse element,
the M axiFuse® performs much more like an Autofuse,
although the average opening time is slightly longer. This
is because the M axiFuse® was designed to be a slower PACIFIC FUSE ELEMENT
blow ing fuse, with less chance of nuisance blows. CURRENT RATING COLOR
30 PINK
M IN IF U S E ® 40 GREEN
The M iniFuse® is a smaller version of the Autofuse 50 RED
60 YELLOW
and has a sim ilar performance. A s with the Autofuse, the
M in iF u se ® is usually used to protect the w iring assembly 12-10-99
B80018A5
between a fuse block and system components.
Figure 2 - Fuse Rating and Color
REPAIR PROCEDURES
PACIFIC FUSE ELEMENT
The Pacific Fuse Element was developed to be a
replacement for the fusible link. Like a fusible link, the CONNECTOR COVERING
fuses are designed to protect w iring from a direct short to
ground. These elements are easier to service and inspect
than a fusible link.
FUSIBLE LINKS
In addition to circuit breakers and fuses, some circuits
use fusible links to protect the wiring. Like fuses, fusible
links are “one-time” protection devices that w ill melt and
create an open circuit (refer to Figure 3).
Not all fusible link open circuits can be detected by
observation. Alw ays inspect that there is battery voltage
past the fusible link to verify continuity.
Fusible links are used instead of a fuse in w iring
circuits that are not norm ally fused, such as the ignition
circuit. For A W G sizes, each fusible link is four wire gauge
sizes smaller than the wire it is designed to protect. For
example: to protect a 10 gauge wire, use a 14 gauge link or
for metric, to protect a 5 mm2 wire, use a 2 mm2 link
(refer to Figure 6). Links are marked on the insulation with
wire-gauge size because the heavy insulation makes the C -2 9 -M
link appear to be a heavier gauge than it actually is. The

same wire size fusible link must be used when replacing a Figure 3 - Good and Damaged Fusible Links
blown fusible link. CAUTION: Fusible links cut longer than
F u sib le lin k s are available w ith three types o f 225 mm (approx. 9 inches.) will not provide
insulation: H yp alon ® , S ilic o n e / G X L (S IL / G X L ) and sufficient overload protection.
Expanded Duty. A ll future vehicles that use fusible links
w ill utilize the Expanded Duty type of fusible link. W hen To replace a damaged fusible link (Figure 4), cut it off
servicing fusible links, all fusible links can be replaced beyond the splice. Replace with a repair link. W hen
with the Expanded Duty type. S IL / G X L fusible links can connecting the repair link, strip wire and use staking-type
be used to replace either S IL / G X L or Hypalon® fusible pliers to crimp the splice securely in two places. For more
links. Hypalon® fusible links can only be used to replace details on splicing procedures, refer to “ Splicing Copper
Hypalon® fusible links. W ire using Splice C lips,” “ Splicing Copper W ire using
Determining characteristics of the types of fusible links C rim p and S e a l S p lic e S le e v e s,” and “ S p lic in g
Twisted/Shielded Cable” later in this section.
are:
To replace a damaged fusible link which feeds two
— H ypalon® (limited use): only available in 0.35 mm2 harness wires, cut them both off beyond the splice. Use
or smaller and its insulation is one color all the way two repair links, one spliced to each harness wire (refer to
through. Figure 5).
— S IL / G X L (widely used): available in all sizes and has
a white inner core under the outer color o f insulation. REPAIRING SHORT CIRCUITS CAUSED BY
— Exp an d e d D u ty: availab le in all size s, has an DAMAGED WIRE INSULATION
insulation that is one color all the way through and • Locate the damaged wire.
has three dots follow ing the writing on the insulation. • Find and correct the cause o f the wire insulation
damage.
Service fusible links are available in many lengths.
• For m inor damage, tape over the wire. If damage is
Choose the shortest length that is suitable. If the fusible
more extensive, replace the faulty segment of the wire
link is to be cut from a spool, it should be cut 150-225 mm
(refer to the appropriate splicing instructions in this
(approx. 6-9 inches.) long. N E V E R make a fusible link
section for copper or shielded cable for the correct
longer than 225 mm (approx. 9 inches.).
splicing procedure).
DAMAGED
FUSIBLE
DAM AGED
FUSIBLE L IN K C U T HERE
REPAIR L IN K O N E H A RN ESS
W IR E (R E D )
s-at-M •-29-94
Figure 4 - Single Wire Feed Fusible Link Figure 5 - Double Wire Feed Fusible Link
SPLICING COPPER WIRE USING SPLICE you decide to cut more wire off to change the location of a
CLIPS splice. You may have to adjust splice locations to make
Splice clips are included in the J 38125-A Terminal certain that each splice is at least 40 mm (1.5 inches) away
Repair Kit. The splice clip is a general purpose wire repair from other splices, harness branches, or connectors.
device. It may not be acceptable for applications having
special requirements such as moisture sealing. Refer to the S tep 3: S trip th e In su latio n
appropriate Service M anual section to determine if there W hen replacing a wire, use a wire of the same size as
are any special requirements. the original wire or larger. The schematics list wire size in
metric units. The follow ing table (Figure 6) shows the
S tep 1: O pen th e H arness commercial (A W G ) wire sizes that can be used to replace
If the harness is taped, remove the tape. To avoid wire each metric wire size. Each A W G size is either equal to or
insulation damage, use a sewing “ seam ripper” to cut open larger than the equivalent metric size.
the harness (available from sewing supply stores). If the To find the correct wire size either find the wire on the
harness has a black plastic conduit, sim ply pull out the schematic page and convert the metric size to the A W G
desired wire. size, or use an A W G wire gauge.
If you aren’t sure o f the wire size, start with the largest
S tep 2: C u t th e W ire opening in the wire stripper and work down until a clean
Be gin by cutting as little wire off the harness as strip of the insulation is removed. Be careful to avoid
possible. You may need the extra length o f the wire later if nicking or cutting any of the wires.
REPAIR PROCEDURES
M ETRIC W IRE SIZES AWG SIZES large anvil.) Overlap the stripped wire ends and hold them
(mm2) between your thumb and forefinger as shown in Figure 7.
0.22 24 Then, center the splice clip under the stripped wires and
0.35 22 hold it in place.
0.5 20 • Open the crimping tool to its full width and rest one
0.8 18 handle on a firm flat surface.
1.0 16 • Center the back of the splice clip on the proper anvil
2.0 14 and close the crimping tool to the point where the
former touches the w ings of the clip.
3.0 12
• M ake sure that the clip and wires are still in the
5.0 10
correct position. Then, apply steady pressure until the
8.0 8
crim ping tool closes (refer to Figure 8).
13.0 6 • Before crimping the ends of the clip, be sure that:
19.0 4
— The wires extend beyond the clip in each direction.
32.0 2
— N o strands of wire are cut loose.
— N o insulation is caught under the clip.
Figure 6 - W ire Size Conversion Table
Crim p the splice again, once on each end. D o not let
S tep 4: C rim p th e W ires the crim ping tool extend beyond the edge of the clip or you
Select the proper clip to secure the splice. To may damage or nick the wires (refer to Figure 9).
determine the proper clip size for the wire being spliced,
follow the directions included in the J 38125-A Terminal S tep 5: S o ld er
Repair Kit. Select the correct anvil on the crimper. (On A pply 60/40 rosin core solder to the opening in the
most crimpers your choice is limited to either a small or back o f the clip (refer to F ig u re 10). F o llo w the
manufacturer’s instructions for the solder equipment you
B -2 8 -9 4
BSOOMAS
Figure 7 - Centering the Splice Clip Figure 8 * Crimping the Splice Clip
A L IG N T O O L W IT H ED G E O F C LIP
T O C R IM P E N D S O F SPLICE
G O O D (R O L L E D )
Figure 9 • Completing the Crimp
B A D (F L A G G E D )
8 -2 8 -9 4
S80KMA5
Figure 11 - Proper First Taping
SPLICING COPPER WIRE USING CRIMP

AND SEAL SPLICE SLEEVES
Crim p and seal splice sleeves may be used on all types
of insulation except Tefzel® and coaxial to form a one to
S tep 6: Tape th e S p lice one splice. They are to be used where there are special
Center and roll the splicing tape. The tape should requirem ents such as m oisture sealing. Refer to the
cover the entire splice. R o ll on enough tape to duplicate the appropriate section of the Service M anual to determine if
thickness of the insulation on the existing wires. D o not the crimp and seal is necessary. Crim p and seal splice
flag the tape. Flagged tape m ay not provide enough sleeves are included in the J 38125-A Terminal Repair Kit.
insulation, and the flagged ends w ill tangle with the other
wires in the harness (refer to Figure 11).
S tep 1: O pen th e H arness
If the wire does not belong in a conduit or other
If the harness is taped, remove the tape. To avoid wire
harness covering, tape the wire again. Use a w inding
insulation damage, use a sewing “ seam ripper” to cut open
motion to cover the first piece of tape (Figure 12).
the harness (available from sewing supply stores). The
crimp and seal splice sleeves may be used on all types of
insulation except Tefzel® and coaxial and may only be
used to form a one to one splice.
REPAIR PROCEDURES
for nicks or cut strands. If the wire is damaged, repeat this
procedure after rem oving the damaged section.
S tep 4: S elect and P oeition th e S p lice S leeve

Select the proper splice sleeve according to wire size.
The splice sleeves and tool nests are color-coded (refer to
the Crim p and Seal Splice Sleeve Chart).
CRIMP AND SEAL SPLICE SLEEVE

CHART
Color Splice Crimp Tool Wire Gauge

Sleeve Nest Color AWG/(metric)
S tep 2: C ut th e W ire Salm on Red 20, 18/(0.5, 0.8)
(yellow ish-pink)
B egin by cutting as little wire off the harness as
Blue Blue 16, 14/(1.0, 2.0)
possible. You may need the extra length of wire later if you
decide to cut more wire to change the location of a splice. Yellow Yellow 12, 10/(3.0, 5.0)
You may have to adjust splice locations to make certain
that each splice is at least 40 mm (1.5 inches) away from
other splices, harness branches or connectors. This w ill U sing the J 38125-8 Splice Crim p Tool (Figure 13),
help prevent moisture from bridging adjacent splices and position the splice sleeve in the proper color nest of the
hand crimp tool. Place the splice sleeve in the nest so that
causing damage.
the crimp falls midway between the end of the barrel and
the stop.
S tep 3: S trip th e In su latio n
The sleeve has a stop in the middle o f the barrel to
If it is necessary to add a length of wire to the existing
prevent the wire from going further (refer to Figure 14).
harness, be certain to use the same size as the original wire
Close the hand crimper handles slightly to hold the splice
(refer to Figure 6, “W ire Size Conversion Table”).
sleeve firm ly in the proper nest.
To find the correct wire size either find the wire on the
schematic and convert the metric size to the equivalent
S tep 5: In sert W ires into S p lice S leeve and C rim p
A W G size or use an A W G wire gauge. If unsure about the
Insert the wire into the splice sleeve until it hits the
wire size, begin with the largest opening in the wire
barrel stop and close the handles of the J 38125-8 Crimper
stripper and work down until a clean strip of the insulation
tightly until the crimper handles open when released. The
is removed. Strip approximately 7.5 mm (5/16 inch) of
crimper handles w ill not open until the proper amount of
insulation from each wire to be spliced. Be careful to avoid
pressure is applied to the splice sleeve. Repeat steps 4 and
nicking or cutting any of the wires. Check the stripped wire 5 for the opposite end of the splice.
.R ED FILL
/
/ I
« n
> \
MFINC L Awa v BLUE FILL
.S -J lad-it
1.0.id
M -M --------YELLOW FILL
T f
1
5 -2 8 -9 4
BS012BA5
Figure 13 - Hand Crimp Tool

Step 6: S h rin k th e In su latio n A round the S p lice

U sin g the J 38125-5 Ultratorch (follow instructions
that accompany Ultratorch), apply heat where the barrel is
crimped. Gradually move the heat barrel to the open end of
the tubing, shrinking the tubing completely as the heat is
&
moved along the insulation. A small amount of sealant w ill
come out of the end of the tubing when sufficient shrinking
is achieved (Figure 14).
SPLICING TWISTED/SHIELDED CABLE s -a -w

Twisted/shielded cable is sometimes used to protect bsoimas
w iring from electrical noise (stray signals). For example, Figure 16 - The Untwisted Conductors
the tw o-conductor cable o f this construction is used
between the E C M and the distributor. Refer to Figure 15 S tep 4: R eassem ble th e C able
for a breakdown of twisted/shielded cable construction. After you have spliced and taped each wire, rewrap the
conductors w ith the m ylar tape. Be careful to avoid
wrapping the drain wire in the tape.
S tep 1: R em ove O u ter Jacket
Next, splice the drain (ground) wire follow ing the
Remove the outer jacket and discard it. Be careful to
splicing instructions for copper wire. Then, wrap the drain
avoid cutting into the drain wire or the mylar tape.
wire around the conductors and mylar tape (Figure 17).
Step 2: U nw rap th e Tape

Step 5: Tape th e C able
Unwrap the m ylar tape, but do not remove it. The tape
Tape over the entire cable using a winding motion
w ill be used to rewrap the twisted conductors after the
(refer to Figure 18). This tape w ill replace the section of
splices have been made.
the jacket you removed to make the repair.
S tep 3: P repare th e S p lice

Untwist the conductors. Then, prepare the splice by
fo llo w in g the sp lic in g in stru ction s for copper w ire
presented earlier. Remember to stagger splices to avoid
shorts (Figure 16).
O U TE R D R A IN W IR E
JAC K ET (U N IN S U L A T E D )
Figure 15 - Twisted/Shielded Cable Figure 18 - Proper Taping

REPAIR PROCEDURES
REPAIRING CONNECTORS N O T IC E : The Terminal Position Assurance (TPA)
• The follow ing general repair procedures can be used must be removed prior to terminal removal and must
to repair m ost types o f connectors. The repair be replaced when the terminal is repaired and reseated.
procedures are divided into three general groups: Push
to Seat, Pull to Seat and Weather Pack®. S tep 1:
• See “Harness Connector Faces,” page 8A-202-0, to
Rem ove any Connector Position Assurance (C P A )
determine which type o f connector is to be serviced.
Locks. C P A s are designed to retain connectors when mated.
• Use the proper pick(s) or tool(s) that applies to the
terminal.
• The J 38125-A Terminal Repair K it contains further S tep 2:
information. Remove any T P A Locks. T PA s are designed to keep
the terminal from backing out of the connector.
PUSH TO SEAT A N D PU LL TO SEAT
C O N N EC TO R REPAIR S tep 3:
F o llo w the steps below to repair P u sh to Seat Open any secondary locks. A secondary lock aids in
(Figure 19) or Pull to Seat (Figure 20) connectors. The terminal retention and is usually molded to the connector,
steps are illustrated with typical connectors. Your connector
Figure 20 - Typical Pull to Seat Connector and Terminal

S tep 5: S tep 4:
Grasp the lead and push the terminal to the forward Insert the Weather Pack® terminal removal tool into
most position. H old the lead at this position. the front (mating end) of the connector cavity until it rests
on the cavity shoulder.
Step 6:
Locate the terminal lock tang in the connector canal. S tep 5:
Gently pull on the lead to remove the terminal through
Step 7: the back of the connector.
Insert the proper size pick (refer to J 38125-A Terminal
Repair K it) straight into the connector canal at the mating N O T IC E : Never use force to remove a terminal
end of the connector. from a connector.
Step 8: Step 6:
Depress the locking tang to unseat the terminal. Inspect the terminal and connector for damage. Repair
as necessary (refer to “Terminal Repair” on the follow ing
• Push to Seat - Gently pull on the lead to remove the
page).
terminal through the back of the connector.
• Pull to Seat - Gently push on the lead to remove the
terminal through the front of the connector. S tep 7:
Reform the lock tang and reseat terminal in connector
body.
N O T IC E : Never use force to remove a terminal
from a connector.
S tep 8:
Close secondary locks and join connector halves.
S tep 9:
Inspect terminal and connector for damage. Repair as
necessary (refer to “Terminal Repair,” page 8A-5-11).
TERMINAL REPAIR
The follow ing repair procedures can be used to repair
Push to Seat, Pull to Seat or Weather Pack® terminals
S tep 10:
(Figure 22). Some terminals do not require all steps shown.
Reform lock tang and reseat terminal in connector
Skip those that don’t apply. The Terminal Repair K it
body. A pply grease if connector was originally equipped
(J 38125-A) contains further information.
with grease.
S tep 11:
Install any C PA s or TPAs, close any secondary locks
CONNECTOR TERMINAL
and join connector halves.
W eath er Pack® C O NNECTO R REPAIR

Follow the steps below to repair Weather Pack®
connectors (Figure 21).
S tep 1:
Separate the connector halves.
S tep 2:
O pen secondary lock. A secondary lock aids in S -2 8 -9 4
terminal retention and is usually molded to the connector. M020SA5
Figure 21 - Typical Weather Pack® Connector and

S tep 3: Terminal
Grasp the lead and push the terminal to the forward

most position. Hold the lead at this position.
REPAIR PROCEDURES
S tep 7:
Hand crimp insulation w ings (non Weather Pack®).
H and crim p insulation w in gs around seal and cable
(Weather Pack®).
S tep 8:
Solder all hand crimped terminals.
DIODE REPLACEMENT
M any vehicle electrical systems use a diode to isolate
circuits and protect the components from voltage spikes.
W hen installing a new diode, use the follow ing procedure:
S tep 1: Open th e H arness

If the diode is taped to the harness, remove all of the
tape.
S tep 2: R em ove In o p erative D iode

Paying attention to current flow direction, remove
inoperative diode from the harness with a suitable soldering
tool. If the diode is located next to a connector terminal,
remove the term inal(s) from the connector to prevent
damage from the soldering tool.
S tep 3: S trip th e Insulation

Carefully strip away a section of insulation next to the
Cut off terminal between core and insulation crimp
old soldered portion of the wire(s). D o not remove any
(minimize wire loss) and remove seal for Weather Pack®
more than is needed to attach the new diode.
terminals.
S tep 4: In stall N ew D iode

S tep 2:
Check current flow direction of the new diode, being
A pply correct seal per gauge size of wire and slide
sure to install the diode with correct bias. Reference the
back along wire to enable insulation removal (Weather
appropriate service manual w iring schematic to obtain the
Pack® terminals only).
correct diode installation position. Reference Figure 23 for
replacement diode sym bols and current flow explanations.
S tep 3:
Attach the new diode to the wire(s) using 60/40 rosin core
Rem ove insulation.
solder. Use a heat sink (aluminum alligator clip) attached
across the diode wire ends to protect the diode from excess
S tep 4: heat. F o llo w the m anufacturer’s instructions for the
A lig n seal w ith end o f cable insulation (Weather soldering equipment you are using.
Pack® terminals only).
S tep 5: In stall T erm in al(s)

S tep 5: Install terminal(s) into the connector body if previously
P o sitio n strip (and seal fo r W eather P a ck ® ) in removed in step 2.
terminal.
S tep 6: Tape D iode to H arness

S tep 6: Tape the diode to the harness or connector using
Hand crimp core wings. electrical tape. To prevent shorts to ground and water
intrusion, com pletely cover all exposed w ire and diode
attachment points.
ACCEPTABLE DIODE REPLACEMENTS • A B S/4 W A L (the A B S Diode on the Delco Moraine is

hidden inside of an electrical connector under the
Diode Brand Rating Num ber Rating carpet at the right panel).
G M SP O 1N4004 1 A , 400 P IV • Wiper.
G M SP O 1N5404 3 A , 400 P IV • Charging system (hidden in wire harness).
G M SP O 1N4001 1 A, 50 P IV • Parking brake (vehicle with A B S).
• Relays.
G M SP O 1N4005 1 A , 600 P IV
• Solenoids.
G M SP O 1N4004 1 A, 400 P IV
• Diesel glow plug circuit.
In the event 1 A, 50 P IV (Peak Inverse rating) diodes

are unavailable, a universal diode with a 1 A, 400 P IV
rating can be used for the follow ing applications:
A/C Compressor Clutch.

REPAIR PROCEDURES
HEATED OXYGEN SENSOR (H02S) • Alw ays replace a relay in an O B D II circuit with the
REPAIR same replacement part. Damaged relays should be
If the heated oxygen sensor pigtail wiring, connector, discarded, not repaired.
or terminal is damaged, the entire oxygen sensor assembly • Refer to S E C T IO N 8A - 11 to identify O B D II circuit
must be replaced. D o not attempt to repair the wiring, fusing.
connector, or terminals. In order for the sensor to function • M ake sure that C P A (Connector Position Assurance)
properly, it must have a clean air reference. This clean air locks and T P A (Terminal Position Assurance) locks
reference is obtained by way of the oxygen sensor signal
are reinstalled on connectors that use them.
and heater w ires. A n y attempt to repair the w ires,
• After repair of connectors or connector terminals,
connectors, or terminals could result in the obstruction of
make sure to achieve proper terminal retention. Refer
the air reference and degraded oxygen sensor performance.
to “ R epairin g C onnectors” on page 8 A -5 -8 for
The fo llo w in g gu id e lin es should be used w hen
procedures.
servicing the heated oxygen sensor:
• Before repairing O B D II heated oxygen sensors and
• D o not apply contact cleaner or other materials to the
sensor or vehicle harness connectors. These materials related w iring, alw ays review the special repair
may get into the sensor, causing poor performance. guidelines provided on page 8A-5-12 under “Heated
Also, the sensor pigtail and harness wires must not be Oxygen Sensor Repair.”
damaged in such a way that the wires inside are • W hen installing an electrical ground fastener, be sure
exposed. T h is could provide a path for foreign to ap p ly the sp e cifie d torque. G ro u n d torque
materials to enter the sensor and cause performance specifications are listed in S E C T IO N 8A-14.
problems. • After repair of connectors, make sure to reinstall
• Neither the sensor or vehicle lead wires should be bent connector seals, where used. Inspect seals for wear
sharply or kinked. Sharp bends, kinks, etc., could and damage. Replace worn or damaged seals.
block the reference air path through the lead wire.
• D o not remove or defeat the oxygen sensor ground GMSPO SERVICE PARTS
wire (where applicable). Vehicles that utilize the
ground wired sensor may rely on this ground as the
GMSPO STANDARD PARTS CATALOG
only ground contact to the sensor. Rem oval of the
Check the G M S P O Standard Parts Catalog, Group
ground wire w ill also cause poor engine performance.
8.965. Fuses, circuit breakers, connectors, term inals,
• To prevent damage due to water intrusion, be sure that
conduit, pigtail kits, and seals are listed in that group.
the peripheral seal rem ains intact on the vehicle
harness connector.
The engine harness may be repaired using Packard’s GMSPO CARLINE PARTS CATALOG
Crim p and Splice Seals Terminal Repair K it J 38125-A. The G M S P O Carline Parts Catalog, G roup 2.535
Under no circumstances should repairs be soldered since contains connector repair kits with terminals and leads.
this could result in the air reference being obstructed.
COMPLETE HARNESS
OBD II CIRCUIT REPAIRS
In many cases repairs can be made by ordering pigtail
R e p a irs fo r O n -B o a rd D ia g n o stic s I I (O B D II)
assemblies (prewired connectors) rather than the entire
em ission control circuits follow the procedures stated in
w iring harness. O nly order complete harnesses when there
S E C T IO N 8A-5. W hen servicing O B D II circuits, the
is major damage to the w iring harness. A lw ays repair
follow ing guidelines are also essential:
• D o not move or alter grounds from their manufactured m inor damage. Com plete harnesses and p igtail part
locations. num bers can be found in the G M S P O Carline Parts
• D o not connect aftermarket accessories into O B D II Catalog.
circuits.
• O nly repair O B D n circuits in accordance with the
manufactured configuration.
ELECTRICAL DIAGNOSIS 8A - 5 -1 3
J 34636
J 35689- A
Solenoid, Relay J 3 5 6 1 6 -A
Micro - Pack Connector
J 36169 and Circuit Tester Connector Test Adapter Kit
Terminal Remover
Jumper Wire
J 34142—B
Unpowered Test Light
J 36400 - 5
Weather Pack II Terminal Remover
J 8681- A
Universal Short Checker
J 22727
Electrical Terminal Remover
J 2 1 0 0 8 -A
Self - Powered Test Light
J 39200
J 33095 Digital Multimeter
Terminal Remover: Micro Pack,
Com - Pack III and ECM Edgeboard
Connectors J 34764
Autofuse Tester
J 3 8 1 2 5 -A
Terminal Repair Kit 1-22-06
BS0238AS
Special Tools
POWER DISTRIBUTION
BASE VEHICLES (W/O ZM9)
LH BATTERY (W /DUAL BATTERY OPTION)
19 RED
D
l|l—
H ' M ' I 1
+
RH BATTERY
— 1| | | | | | | l|l—
- +
5 RED
3
RED
-----(I---------------1 <>-----------------1 * 2 f
" -------------f ------------- -------------f ----- * ----- 1 ------0 -----f ------------ f ------------ f ------------- 1
Kill F9 H91 FAN H7 N8 N6 Nil N41 N3 1 N2 I ___ R7 I Wl
FUSE H i l l I HORN • A /C COMP 11 RR DEFOG • jT |r_ <l BATTERY O LIGHTING<> IGN A • IGN B • ABS • BLOWER • STOP <> SEO • 15^5:
20 A S FUSE S FUSE \ FUSE \ — — S FUSE 7 S FUSE 8 S FUSE 6 S FUSE 5 S FUSE 4 S FUSE 3 \ FUSE 2 S f0 5 S \ FUSE
<> Q 20 A <*10 A (;3 0 A (; < ;5 0 A (; 50A (| 40A ( M A (| 60A ( m a (;3 0 A c 30 a ^ 30 a
In ’440""”' “a""*” I ” T orn' ’il

.8 ORN 740 2 ORN I 1440
▼ t ▼ ▼
03-31-97
4206W0MS
POWER DISTRIBUTION
UPLEVEL FEATURES (W / ZM9)
LH BATTERY (W /OUAL BATTERY OPTION)

19 REO
D
H ' M ' I ' I l | l---
RH BATTERY
—| l | l | l | l | l | K
- +
03-10-97
420SW0M9
8A - 1 0 - 2 ELECTRICAL DIAGNOSIS
POWER DISTRIBUTION
\y
W
FROM IGNmON SWITCH

PAGE 8 A -1 0 -2
01-28-07
4208W0567
POWER DISTRIBUTION
A
FROM PAGE 8 A -1 0 -0 .1
W W W W
5 RED 542
REGULAR/
SUBURBAN/ EXTENDED
UTILITY ONLY AND CREW
CAB ONLY
5 RED 442
• S110
5 RED 542
2 RED 642 3 REO 242
A1 W C l 00 3 RED 542
5 RED I 542
TA i
i ^ C 203
P101
T 1 CONVENIENCE
| I CENTER
I A<> I
I I
J
3 REO 542
5 REO 542
A V 1 /C 4 0 0
5 REO I 5 4 2
I S401
5 RED 542 5 RED 542 5 RED 542
a
p
A £ 3
^
i
r •
A^ 1 A
r — *4
1
r “
A^ A 2 A
r — n
I E 7 A AS A
r — ■»
' P “ 1 BRAKE
1 1 1 1 1 1 1 1 1 1 1 1
1 '
1
L . J
1 1
L .J
1 1
L _ J
1 1
L _ J
1 1
l . j
1
1 1
L - J
1
ELECTROMC ‘ AUXILIARY AUXILIARY AUXILIARY BLOWER MOTOR I SECTION STARTER

BRAKE BLOWER MOTOR BLOWER MOTOR BLOWER MOTOR RELAY .HIGH B A -1 1 0 ENGINE
ELECTRICAL
CONTROL RELAY, LOW RELAY, MEDIUM RELAY, HIGH SECTION B A -6 3
MODULE SECTION B A -6 3 SECTION B A -6 3 SECTION B A -63 UNOERHOOtT — — — —
(EBCM)
A8S CONTROLS
V FUSE-RELAY
CENTER
SUBURBAN
ONLY
03-10-07
4200W0S03
POWER DISTRIBUTION
POLICE PACKAGE (9L4)
343
0 4 -1 * 4 7
POWER DISTRIBUTION
POLICE PACKAGE (6J1)
FUSE BLOCK 3
AUXILIARY
POWER
CENTER
WRAPPED UP UNOERNEATH CENTER IP
03-20-97
4206W0671
ELECTRICAL DIAGNOSIS 8A - 1 0 - 7

A uxiliary Battery.................. L F o f Engine Compartment........................................... . l ...... 4
Auxiliary Blow er M otor Relay,

H ig h ................................ O n top o f Auxiliary H V A C Plenum, near R R
W heelhousing........................................................... 6 6 .... 8 5 .... 202-60

L o w ................................ O n top of Auxiliary H V A C Plenum, near R R
W heelhousing......................................................... . 6 6 .... 8 5 .... 202-60

M e d iu m ........................... O n top o f Auxiliary H V A C Plenum, near R R
W heelhousing........................................................... 6 6 .... 8 5 .... 202-60
A uxiliary Power Center (6 J1)... Center o f IP, below Heater C on trols............................... . 4 2 .... 54
Battery............................... R F o f Engine Compartment.......................................... . 1 .............. 4
Blow er M otor Relay, H ig h ...... Behind IP Compartment Box, on H V A C Plenum .............. . 5 0 .... 6 5 .... 202-60
Brake Lam p R e la y ................ In Underhood Fuse-Relay Center, L R o f Engine

Compartment, on Fender..................................... ...... . 6 ..... 10
Convenience Center.............. Under L H of IP, on Bulkhead....................................... . 3 3 .... 44
Electronic Brake Control

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing............. . 6 ..... 10
Generator............................ L H Front of Engine
Headlamp and Panel Dim m er

Sw itch............................. Low er L H of I P ......................................................... . 3 2 .... 43.... 202-34
Ignition Sw itch.................... O n Steering Column, under Lock C ylin d er...................... . 4 2 .... 57
IP Fuse B lo ck ...................... L H of IP, near L F Door Jamb Sw itch ....................................................................... . 3 2 .... 43
Starter R e la y ........................................................... In Underhood Fuse-Relay Center, L R o f Engine

Compartment, on Fender............................................................................................................ . 1............ 3
Starter M otor Solenoid ............................ O n Starter M o to r ............................................................................................................................................ . 1 6 .... 20
Underhood Fuse-Relay Center... L R o f Engine Compartment, on Fender........................... . 5 ..... 9

C O N N EC T O R S:
C 1 0 0 .................................. Engine Harness to IP Harness, L R of Engine Compartment,

at Bulkhead............................................................ . 4 ....... 8 ........ 202-0
C l 21 (Z56, Police Package).... Auxiliary Power Center Harness to Fused Battery Harness,
L H Engine Compartment, near C l 00............................ . 3 4 .... 45 ........... 202-50
C 2 0 3 ..................................................................................... Behind R H of IP, near Heater Motor, in foam w rap .......................... . 5 0 .......... 65 ........... 202-50
C 2 0 5 ..................................................................................... A t Convenience Center........................................................................................................................ . 3 3 .......... 44........... 202-50
C 2 3 5 ...................................................... ............................. Auxiliary Power Center Harness to Fused Battery Harness,
L H IP, near P100
C 2 6 6 ..................................................................................... IP Harness to Steering Colum n Harness, L H of Steering

Colum n, near Bulkhead ................................................................................................................ . 3 2 .......... 4 3 ........... 202-14
C 4 0 0 ..................................................................................... R R o f vehicle, above Auxiliary Blow er M o to r ............................................ . 6 6 .......... 8 5 ........... 202-56

POWER DISTRIBUTION

G R O M M ETS:
P 1 0 0 .................................. L R o f Engine Compartment, at Bulkhead above C100
P 1 0 1 .................................. R R of Engine Compartment, at Bulkhead........................ 7 ...... 12
S P L IC E S :
S I 10 (5.0L, 5.7L) ................ Engine Harness, approx. 23 cm from E B C M Breakout,
toward Taillamp Harness
S I 10 (7.4L) ........................ Engine Harness, approx. 26 cm from E B C M Breakout, near

Taillamp Harness Breakout
S I 67 (A ll Except Z56,
Police Package)................. Engine Harness, approx. 18 cm from G115
S167 (Z56, Police

Package O nly)................... Battery Harness, approx. 35 cm from C121
5200 (G as).......................... IP Harness, approx. 12 cm from Steering Colum n Harness

Breakout
5201 ................................ IP Harness, approx. 8 cm from Steering Colum n Harness

Breakout, toward P I00
S205 (D iesel)..................... IP Harness, approx. 14 cm from Steering Colum n Harness

Breakout

Breakout


Breakout, toward P I 00
5285 (Z56 - 6 J 1 )................. In A uxiliary Power Center Harness
S401 (w /Auxiliary A / C )......... Auxiliary A/C Harness, approx. 23 cm from Blow er M otor
Relays, toward Blow er M otor
S401 (w /Auxiliary H V A C )...... Auxiliary H V A C Harness, approx. 13 cm from Blow er

M otor Relays Breakout, toward Blow er M otor
BLANK
FUSE BLOCK DETAILS
IP FUSE BLOCK
01-29*97
4208W0626
IP FUSE BLOCK
NAME FUSE SIZE CIRCUIT LOADS
NUMBER
ST O P /H A Z 1 20A FU SE 140 T C C / S T O P L A M P S W IT C H , A U D IO A L A R M M O D U L E ,
FLA SH ER , C H M SL, H A Z A R D LA M P S, ST O P LA M P S
T C A SE 2 20A FU SE 1640 E L E C T R IC T R A N S F E R C A S E F E E D / A T C
C TSY 3 20A FU SE 40 C O U R T E S Y L A M P S , C A R G O L A M P , IP
C O M P A R T M E N T L A M P D O M E / R E A D IN G L A M P S ,
V A N IT Y M IR R O R S , P O W E R M IR R O R S
G AU G ES 4 10A F U S E 39 A U D IO A L A R M M O D U L E , IP C L U S T E R , D R L
M O D U L E A N D RELAY, R E M O T E C O N T R O L D O O R
L O C K R E C E IV E R , H D L P SW , L O W C O O L A N T
M O D U L E , T R A N S F E R C A S E C O N T R O L M O D U L E , VS
M IR R O R , E V O / P A S S L O C K M O D U L E
RR HVAC 5 10A F U S E 341 R R H V A C C O N T R O LS. U T IL IT Y A N D S U B U R B A N O N L Y
C R U IS E 6 10A F U S E 41 C R U IS E C O N T R O L M O D U L E A N D S W IT C H
A U X PW R 7 25A F U SE 840 A U X IL IA R Y P O W E R O U T L E T S , D L C
CRANK 8 10A F U S E 806 IN F L A T A B L E R E S T R A IN T C O N T R O L M O D U L E ,
P C M / V C M , D IE S E L F U E L P U M P
P A R K LPS 9 20A F U SE 240 L IC LP, P A R K LP, T A IL LP, A S H T R A Y LP, R O O F
M A R K E R , T A IL G A T E LP, P A N E L L P S, T R A IL E R T A IL
L P S, F R O N T S ID E M A R K E R S , F O G L P RLY, D O O R
S W IL L U M , F E N D E R LP S, H/L S W IL L U M
A IR B A G 10 10A F U S E 1139 IN F L A T A B L E R E S T R A IN T C O N T R O L M O D U L E (SIR ),
IN F L A T A B L E R E S T R A IN T IP M O D U L E E N A B L E S W
W IP E R 11 25 A F U S E 143 W IP E R M O T O R , W A S H E R P U M P
H T R -A /C 12 25A FU SE 141 L, M l, M 2 B L O W E R , H V A C IN D . LP, A/C C O M P ,
M O D E / T E M P / A IR IN A C T
C IG L T R 13 20A FU SE 640 C IG A R L IG H T E R , P O W E R A M P L IF IE R , R E A R
L IF T G A T E , D O O R L O C K S W A N D R E L A Y , P W R
L U M B A R SEA T
IL L U M 14 10A F U S E 8 H V A C C O N T R O L S , R R H V A C C O N T R O L S , IP
S W IT C H E S , R A D IO IL L U M , A U D IO A L A R M
M O D U L E , 4 W D IN D LP, C L U S T E R
D RL/FO G 15 20A F U SE 340 D R L RELA Y , FO G L A M P S
T U R N -B / U 16 20A F U SE 139A, 139B F R T T U R N , R R T U R N , T R A IL E R T U R N , B/U L P S,
B T S I S O L E N O ID
R A D IO 17 10A F U S E 43 R A D IO (IG N )
BRAKE 18 10A F U S E 441 4W A L/V C M , A B S , C R U IS E , D R A C
R A D IO , B A T T 19 10A F U S E 1140 R A D IO (B A T T )
TRANS 20 10A F U S E 1020 P R N D L , A U T O T R A N S M IS S IO N , S P E E D O , C H E C K
G A U G ES, T E L L T A LE
S E C U R IT Y / S T R G 21 10A F U S E 1740 EV O /PA SSLO C K M O D U L E F E E D
AUX 22 20A FU SE 940 SPO T L A M P
R R W IP E R 23 25 A F U S E 393 R E A R W IP E R , R E A R W A S H E R PU M P. U T IL IT Y A N D
SU B U R B A N O N LY
4W D 24 25 A F U S E 241 F R T A X L E ACT., 4 W D IN D . LP, S P A R E P O W E R
SO U RC E, A U X B A T T ER Y R E L A Y
PW R AC C Y A 30 A C/B 540 P W R D R L K , 6-W A Y P W R ST, K E Y L E S S E N T R Y M D L
P W R W IN D O W S B 3 0 A C/B 343 PW R W DO S
FUSE BLOCK DETAILS
UNDERHOOD FUSE-RELAY CENTER
TO BATTERY
POSITIVE ( + )
01-28-97
4206W0627
UNDERHOOD FUSE-RELAY CENTER

NAME FUSE SIZE CIRCUIT LOADS
NUMBER
H EATED M l- N l 40A 742 H EA T ED SEA T S
SEA T S
ST O P M 2-N 2 30A M A X I 642 ST O P L P S (P IC K U P O N L Y )
FU SE
A JC M 3 -N 3 50A M A X I 542 H I BLO W ER M O TO R R ELA Y A N D R EA R
FU SE B L O W E R R E L A Y (S U B U R B A N )
ABS M 4 -N 4 60A M A X I 442 E L E C T R O N IC B R A K E C O N T R O L M O D U L E
FU SE (E B C M )
IG N -B M 5 -L 5 50A M A X I 342 IG N -B S W IT C H G O T O F U S E B L O C K B U S
FU SE BARS
IG N -A M 6-N 6 40A M A X I 242 IG N -A S W IT C H G O TO F U S E B L O C K B U S
FU SE BAR
BATTERY M 7-N 7 50A M A X I 142 FU SE B LO C K BU S BAR, BATTERY
FU SE
L IG H T IN G M 8-N 8 50A M A X I 42 H D L P & P A N E L D IM M E R SW , F O G A N D
FU SE C T SY FU SES
A JC C O M P K 11-L12 10A F U S E 1240 A/C P R E S S S W T O A/C C L U T C H
HORN H11-J12 20A FU SE 740 H O R N R ELAY, U N D ER H O O D LP S
E C M -B F11-G12 20A F U SE 440 F U E L P U M P, P C M /V C M ,
A U X FA N J10-H9 30A F U SE 1540 A U X FAN
R R DEFO G G 10-F9 30A F U SE 1440 R R DEFO G
E C M -I K 7 -L 8 20A F U SE 539 IG N A S W IT C H T O E N G IN E L O A D S , E G R ,
C A N IS T E R P U R G E , E V R V ID L E C O A S T
S O L E N O ID , H E A T E D 02 S E N S O R S , F U E L
H E A T E R , W A T E R S E N S O R , M A S S A IR F L O W
SEN SO R , V C M
ECM I J8-H7 20A FU SE 439 IN J E C T O R S P C M / V C M , IG N C O IL A N D
M O D U LE
IG N -E G8-F7 10A F U S E 639 A U X F A N R E L A Y C O IL , A/C C O M P R E L A Y ,
FU E L M O D U LE, D U A L TAN K
FU EL SO L F5-G 6 20A FU SE 639, 339 F U E L S O L E N O ID , D IE S E L E N G
G LO W PLU G S G4-F3 10A F U S E 507/503 G LO W PLU G S
D IO D E - I L2-K1 BRAKE 33-680 E L E C T R O N IC B R A K E C O N T R O L M O D U L E
S T U D “A ” R7-P7 30A AUX A
S T U D “B ” R8-P8 30A C A M P E R / T R A IL E R W R G
FUSE BLOCK DETAILS
CONVENIENCE CENTER
REARVIEW 01-28-97
4206W0628
CONVENIENCE CENTER
CAVITY GAUGE/COLOR CIRCUIT # DESCRIPTION
A 5.0 R E D 542 B + R R B L O W E R (S U B U R B A N )
B 1.0 B R N 341 IG N 3 R R H V A C
C4 NO T U SED
C6 .2.0 B L K 150 B U S B A R G R D . E/C M IR R O R S / R O O F M K R / V A N IT Y
Cl .80 O R N 40 V A N IT Y F E E D
C8 .80 B R N 9 ROOF M A R K E R GROUND
C9 NO T U SED
D1 1.0 B L K / W H T 1695 4 W D IN D IC A T O R
D2 .80 O R N 640 PO W ER SEA T S B +
D3 2.0 O R N 540 PO W ER D O O R LO C K S B+
D4 2.0 Y E L 343 P O W E R W IN D O W F E E D
D5 .80 B L K 1576 R R R E L E A S E S W P W R (S U B U R B A N / U T IL IT Y )
D6 2.0 B L K 150 G R N LK /W D O /4W D L P (B U S B A R W IT H C 6)
D7 .35 P N K 39 E L E C T R O C H R O M A T IC M IR R O R
D8 .80 L T G R N 24 E L E C T R O C H R O M A T IC M IR R O R
D9 3.0 P P L 293 R R DEFO G
El .50 D K B L U 1926 B LO W ER LO W
E2 .50 R E D 1925 RR BLO W ER M ED
E3 .50 W H T 1924 RR BLO W ER H I
E4 1.0 L T B L U 97 R R W IP E R M IST /O FF/LO W
E5 1.0 G R Y 391 R R W IP E R
E6 1.0 D K G R N 392 R R W A SH ER
FI .80 B L K 150 GROUND
F2 .80 O R N 40 B+
F3 1.0 B R N 241 IG N 3
F5 NO T U SED
F6 NO T U SED
G1 .80 Y E L 317 F O G L P S R E L A Y C O IL -F E E D
G2 NO T U SED
G3 .80 P P L 34 FO G L A M P S FE E D
G4 .35 P N K 39 D R L R E L A Y C O IL F E E D
G5 1.0 P P L 359 D R L R ELA Y H EA D LA M P FEED
G6 .80 Y E L 634 D RL RELAY B+
G8 .80 B L K 150 H A ZA R D FLA SH E R G RD
HI .80 O R N 340 FO G L A M P P O W ER F E E D
H3 1.0 L T G R N 11 F O G L A M P R E L A Y H. B E A M H D L P F E E D
H4 1.0 T A N 12 D R L R E LA Y LO W B E A M H D LP FEED
H6 .80 L T G R N / B L K 592 D R L R E L A Y O U T P U T -C O IL
H7 1.0 P P L 1697 T U R N S IG N A L F L A S H E R O U T P U T
H8 1.0 G R Y 1696 ABS
H9 1.0 L T B L U 1508 E L E C T R O N IC F L A S H E R F E E D
J1 .35 G R Y 8 IN S T P A N E L L P S
J2 .80 O R N 140 A U D IO A L A R M M O D U L E B +
J3 .80 L T G R N 80 A U D IO A L A R M M O D U L E K E Y -IN W A R N IN G
J4 N O T U SED
K1 .80 B LK / W H T 238 A U D IO A L A R M M O D U L E S A F E T Y B E L T IN P U T
K2 .80 B L K 150 A U D IO A L A R M M O D U L E G R O U N D
K3 .80 Y E L 234 A U D IO A L A R M M O D U L E F A S T E N B E L T S O U T P U T
K4 .35 P N K 39 A U D IO A L A R M M O D U L E
FUSE BLOCK DETAILS
CONVENIENCE CENTER
HOT AT ALL TIMES HOT AT ALL TIMES

HOT AT ALL TIMES
1 1
I
I
F 8 E ------- = > " T O ~ K LPS ~ -
I T CASE F2f"--------- SCTSV
FUSE AND
O R L/FO G FU SE
I FUSE
S SSCURITY/STRG
I S FUSE 2
I C 20 A
C FUSE 21 C 8A-11-10 |
081 G1
20 A
G 7 i 20A I
1 1640 ELECTRIC
.3 5 1740
3 ORN 164 0 AUTOMATIC
ORN
ELECTRIC AUTOMATIC
TRANSFER TRANSFER .8 ORN 40
CASE
J\
CASE 88 /*N
j---------------------- ~\ EVO/PASSLOCK
| j MODULE >
| | SECTION 2 8 5
L _ _ _ J
1 ORN 1640 3 ORN 1640
.8 ORN
S 270 S236
1 ORN 164 0
0.8
ORN 1640 1 ORN 1640
1 ORN 1 64 0 1 ORN 1640
C C131
0.8
ORN F2 / " \ Ar \ C A A B/*V A /" \ A r \
1640
r —i r — •» r — 4i r - i r —n r —t
1 1 1 1 1 1 1 1 1 1 1
• i i 1 1 1 1 1 1 1 1 1 1 1
11 i k _ j k - j
t
U _ J b . j I . . J L . J
C 6 /* V 014 015 A\ C \ 0 Av C2 COURTESY CARGO COURTESY F 1LUM NATE0 UUMMATEO

1 SPARE
r - i P —^ LAMP. LAMP LAMP. COMPARTMENT VANITY VANTTY
I POWER
1 1 1 1 LH IP SWITCH RH IP BOX MIRROR. MIRROR.
1 1
L __ _ -J
1 1 1 1 I SOURCE
SECTION SECTION SECTION LAMP RH LH
1 b .J b .J
1 8 A -1 1 4 8 A -1 1 4 8 A -1 1 4
SECTION SECTION SECTION
AUTOMATIC AUTOMATIC CONVENIENCE
PIC K -U P 8 A -1 1 4 8 A -1 1 4 BA—114
1 1 TRANSFER TRANSFER CENTER
ONLY
L ——— — —- CASE CASE CONTROL SECTION
TRANSFER CASE 8 A -1 1 4
TRANSFER MOOULE
CONTROL MOOULE CASE CONTROLS TRAN5FFR
(TCCM) A CASE CONTROLS
TRANSFER V T A
03-11-97
CASE CONTROLS A l l S S
4208W 0629
8 ORN
.8 ORN
40
.8 ORN .8 ORN 40 .8 ORN 40
.8 ORN .8 ORN 40
B C 498 C ^ C 206 A ^ C207 0 ^ C 2 1 5 C 4 9 6 C > y C 4 I1
.8 ORN 40 .8 ORN 40 .8 ORN 40 .8 ORN 40
.8 ORN 40 .8 ORN 40 .8 ORN 40
S426
.8 ORN I 40
S 4 43 •
.8 ORN 40 8 ORN I 40 .8 ORN I 40 .8 ORN 40
A
r —i
A
r
/*\ H /*\
r —i
A /*\
r - i
A /*\
P"1
a rs
r *“ 1
A /*\
r - i
A / *\
r - i
A / *\
r - i
A /*\
P~T
C
p*“ 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
h . j U .J k_ j U . J k .J k . j k- j k- j k_ j k .J k .J
COURTESY COURTESY POWER DOME READING HOMELINK POME COURTESY COURTESY DOME INTERIOR
LAMP. LAMP. OUTSIOE AND LAMPS. TRANSMITTER ANO LAMP. LAMP. AND LAMP
UR LF REARVIEW READING OVERHEAD READING RF RR READING CONTROL
OOOR DOOR MIRROR LAMPS. CONSOLE LAMPS. DOOR OOOR LAMPS. MODULE
SECTION SECTION SWITCH FRONT SECTION REAR SECTION SECTION FRONT SECTION
8 A -1 1 4 8A-II4 SECTION SECTION 8A-1I4 SECTION 8 A -1 1 4 8 A -1 1 4 SECTION 8 A -1 I4
8 A -1 4 7 8 A -1 1 4 8 A -1 1 4 8A-I14
03-11-97
4208W 0630
FUSE BLOCK DETAILS
OS-11-97
4200W0631
r ““ — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — Tip
MODULE
SECTION
8 A -7 6
04-18-97
4206W 0632
FUSE BLOCK DETAILS
HOT IN RUN
341
I I I I i i I I I I I I I I
I I I I I I I I I I I I
L .J L-J L . J k . J b .J b .J k-J k-J
AUXILIARY AUXILIARY AUXILIARY AUXILIARY AUXILIARY AUXILIARY AUXILIARY AUXILIARY
HVAC HVAC HVAC BLOWER MOPE BLOWER TEMPERATURE BLOWER
CONTROL CONTROL CONTROL MOTOR DOOR MOTOR POOR MOTOR

MODULE, MODULE, LOGIC RELAY. MOTOR RELAY. MOTOR RELAY,
FRONT REAR MODULE LOW SECTION MEDIUM SECTION HIGH
8 A -6 S 8 A -6 3
SECTION SECTION SECTION SECTION SECTION SECTION
8 A -6 5 8 A -6 5 8 A -6 5 8 A -6 3 8 A -6 3 8 A -6 3
A 03-11-87
4200W0634
FUSE BLOCK DETAILS
.3 5 PNK
39
63r \
I I
I I
b —. a
PASSLOCK
.3 5 PNK 39 .3 5 39
PNK
.35 39 .3 5
PNK
39
PN k .3 5 PNK 39
.3 5 PNK 39 .3 5 PNK 39 .3 5 PNK 39
ntwr
.3 5
.n m
39 .3 5 PNK 39 .3 5
PNK
39 .3 5 PNK 39
9
r - 1
I I
I I
MAN
b -j
VEHICLE
TRANS
SPEED
A ONLY
PNK SENSOR
BUFFER
ENGINE
.5 39
PNK CONTROLS
,v
A / \ (M v G4 / \ K4 / \ 22 / \ 7 / \ C / \ A / \ A c s A .
r ™ *i r “ ““ r - i r • * n '• P “ T r — ■»-
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 *
L .J b - j b . j b - J b _ — b _ ji b - J b _ j b _ J J b - 4
j A MTERIOR HEADLAMP DAYTIME AUDIO INSTRUMENT DAYTIME ELECTRO- TRANSFER LOW
r ™ ^ RUNNING CASE COOLANT CASE
LAMP AND RUNNMG ALARM a u s iE R CHROMATIC
I I
CONTROL PANEL LAMPS (D R L) MODULE SECTION 8 A -8 I LAMPS (D R L) REARVIEW SELECT LEVEL CONTROL
I |
b .J MODULE DMMER RELAY (CONVENIENCE m MOOULE SWITCH INDICATOR MOOULEfTCCM)
REMOTE
TRANSFER
8A-1U 8A-104
SECTION SWITCH (CONVEMENCE CENTER) SECTION TRANSFER MODULE
CONTROL i l A
CASE
8A-114 8A-76
SECTION CENTER) SECTION
a S £ T CONTROLS
8A-102
DOOR LOCK c o n tr o ls
A
SECTION
RECEIVER
8A-I32
SECTION
A A A03-11-07
iftk 4200W0035
oj-n-t7
FUSE BLOCK DETAILS
T IP
[ Fu se
POWER •< -
CEIL 8A-10 H2 <I AUX

O tSIW BU TO N A ...y
A 6 » PWR-AOCY
BLOCK
S 22 fuse f CIRCUIT BREAKER A

<^20 A l 20 AMP W/REGULAR/
EXTENDED CAB
J1 <> A7 30 AMP EXCEPT
REGULAR/EXTENDED CAB
2 ORN 540
1 BLX 940
r - T CONVENIENCE
| 03 > | CENTER
L J
C \ _/C 210
'J
2 ORN 540 BASE

1 ORN 540 NON-BASE
0
A NON-BASE
2 ORN I 540
A A C 245
2 ORN
C212
2 ORN 540
1 BLK 940
A ftc » 4
2 ORN
2 ORN 540
F A A A
P-1
eA f A cr A- i F
P-1
A D A D A
P-1 i-------------------- 1 r —^ r - i
1 1 1 1 i i 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1
k . J k .J k_ j k .J k_j k_ J
L.
1
1
1
r
POWER LUMBAR REMOTE DOOR POWER DOOR DOOR
F /"S SEAT,
ADJUSTER
POWER
SEAT.
CONTROL
DOOR LOCK
LOCK
RELAY
SEAT.
ADJUSTER
LOCK
SWITCH,
LOCK
SWITCH.
I I I I I I SWITCH. SWITCH. RECEIVER SECTION SWITCH, LF RF
I I I I RH RH 8A -130
b -J b .J L .J LH SECTION
BA -130
SECTION
B A -130
SPOTLAMP SPOTLAMP POWERSEAT, SECTION
CH.
ADJUSTER SWITCH, BA -140
(POLICE (POLICE
PACKAGE) PACKAGE) LH
04-18-97
SECTION B A -140 4208W0637
HOT WITH HEADLIGHT SWITCH
[ M PARK OR HEADLIGHT
]
(SUBURBAN, SECTION SECTION

UTILITY ONLY) 8A -63 8A -63
SECTION 03-11-97
8A -92
4206W 0038
FUSE BLOCK DETAILS
W/AUTOMAUC
TRANSFER
CASE
E> POLICE
PACKAGE
1
l>
&>
.35 CRT 8 .35 CRY 8 .35 CRY
A /* V H /A L 1
r“ r — i r — ■»
lF 5 1 1 1 1
I 1 1 1 1
u-'iTj k mm «J t . j
CONVENIENCE DAYTIME AUTOMATIC
CENTER RUNNING TRANSFER
LAMPS CASE
(DRD/RADIO TRANSFER
CASE
OVERRIDE CONTROLS
SWITCH
SECTION
8A -150 03-11-97
4200W 0039
HOT IN ACCY OR RUN ■ ■ HOT IN RUN. BULB TEST OR START

]| ]
I I I I I I I I I I I i
I I I I I I I I I I I I
k .J L. J k. J k_ J k .J
WINDOW WINDSHIELD WINOSHCLO POWER TRANSMISSION KSTRUMENT
WINDOW CONTROLS CLUSTER
SECTION
8 A -8 I
SWITCH. REAR
SECTION SECTION
8A -92 8A -91
(SUBURBAN/
A A
UTILITY ONLY)
A 03-tl*»7
4208W0640
FUSE BLOCK DETAILS
HOT IN RUN
I I I I
I I I I
b .J L . J
STOPLAMP ELECTRONIC
SWITCH BRAKE CONTROL
SECTION MOOULE
B A -1 1 0
(EBCW)
ABS
CONTROLS
iik
0
42
036-W
11-0
9
6743
FUSE BLOCK DETAILS
I
HOT IN RUN OR START
I
r — "T-------------------- 1 UNOERH
UNOERHOOO
I K 7 f -RELAY
I FUSE-B
I S ENG~ ' | CENTER
I C 20A I A
I L8
L—.
OAS VEHICLE CONTROL MODULE

CONNECTOR IDENTIFICATION
1 539 C1 - BLU - 32 WAY
PNK - 32 WAY
C2 - RED
C3 - CLR - 32 WAY
C4 - BLK - 24 WAY
C5 - BLK - 5 WAY
B cr A— C A
P“ 1
85 A
P“ 1
AA
—- i
DA
P-1
O A
P-1 r 1■1 r ■1 i r r — i
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 | | 1 1 1 1 1 1 1 1 1 1 1 1 1
k_ J L. J k . j k- j lm mm J k . J b . j
EVAPORATIVE HEATED HEATED MASS CAMSHAFT A.I.R. EVAPORATIVE HEATED HSATEO
EMSSIONS OXYGEN OXYGEN AIRFLOW POSITION INTAKE EMISSIONS OXYGEN OXYGEN
CAMSTER SENSOR SENSOR SENSOR SENSOR REOR- CAMSTER SENSOR SENSOR

VENT BANK 1 BANK 2 ENGINE ENGINE CULATION PURGE BANK 1 BANK 1
SENSOR 1 SENSOR 1 CONTROLS CONTROLS RELAY SOLENOO VALVE SENSOR 3 SENSOR 2
ENGINE
CONTROLS ENGINE ENGINE ENGINE ENGINE ENGINE
|L 3 I o n l y | CONTROLS
CONTROLS CONTROLS CONTROLS CONTROLS
ENGINE
CONTROLS
03-11-97
4206W 0643
I
HOT IN RUN OR START
I
n under hoop
I FUSE-RELAY
I (* ECU I I CENTER
I p 20 A I A
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1 PNK 439
S I 61
.8 PNK 439
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VEHICLE IGNITION IGNITION CRANK FUEL FUEL FUEL FUEL FUEL FUEL
CONTROL COIL CONTROL SHAFT INJECTOR INJECTOR MJECTOR MJECTOR INJECTOR MJECTOR
MOOULE ENGME MOOULE POSITION

£! £ £ £ £
CONTROLS ENGINE
(VCM) ENGINE SENSOR ENGINE ENGINE ENGME ENGME ENGME
ENGINE CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS
ENGME
CONTROLS CONTROLS
A QA8 VEHICLE
CONTROL MODULE
Cl - BLU - 32 WAY
C2 - RED - 32 WAY
C3 - CLR - 32 WAY
C4 - BLK - 24 WAY
C5 - BLK - 5 WAY
03-11-97
4208W 0044
FUSE BLOCK DETAILS
A PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439
.8 PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439 .8 PNK 439
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IGNITION IGNITION VEHICLE CRANK FUEL FUEL FUEL
FUEL FUEL
FUEL FUEL
FUEL
____ FUEL FUEL FUEL
CONTROL COR. CONTROL SHAFT INJECTOR INJECTOR INJECTOR MJECTOR INJECTOR MJECTOR INJECTOR MJECTOR
MOOULE
ENGME
ENGME
CONTROLS
MOOULE
(VCM)
POSITION
SENSOR
fi
ENGME
iS
ENGME
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ENGME
IZ
ENGME
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ENGME
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ENGME
£5
ENGME
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ENGME
CONTROLS ENGME ENGINE CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS
CONTROLS CONTROLS
A
A
QA8 CONTROL MODULE
Cl - BLU - 32 WAY
C2 - RED - 32 WAY
CB - CLR - 32 WAY
C4 - BLK - 24 WAY
C5 - BLK - 5 WAY
03-TI-S 7
4206W 0645
r r r s r r
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I FUSE-RELAY
i I CENTER
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I I I I I I I I I I I I I I I I I I I I
I I I I I I I I I I I I I I I I I I I I I I
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IGNITION IGNITION VEHICLE CRANK FUEL FUEL FUEL FUEL FUEL FUEL FUEL FUEL
CONTROL cot CONTROL SHAFT INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR
MODULE ENGINE MODULE POSITION £ _#3 15 !Z £ £ £5 f?
ENGINE CONTROLS (VCM) SENSOR ENGINE ENGINE ENGINE ENGINE ENGINE ENGME ENGINE
ENCME
CONTROLS ENGINE ENGINE CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS
CONTROLS CONTROLS
QA8 VEHICLE
CONTROL MODULE
Cl - BLU - 32 WAY
C2 - RED - 32 WAY
C3 - CLR - 32 WAY
C4 - BLK - 24 WAY
C5 - BLK - 5 WAY 03-11-97
4208W0646
FUSE BLOCK DETAILS
LINEAR AIR SOLENOID BOOST PLUG FUEL HEATER SHUTOFF SOLENOID CONTROL
PWM FLOW (MAF) ENGINE SOLENOO RELAY SENSOR ENGINE SOLENOIO DRIVER MOUOULE
SENSOR CONTROLS ENGINE ENGINE ENGINE CONTROLS ENGINE ENGINE (PCM)
VALVE
CONTROLS CONTROLS CONTROLS CONTROLS CONTROLS ENGINE
SOLENOID ENGINE
CONTROLS
ENGINE CONTROLS
CONTROLS
U S 03-11-97
4206W 0647

1
I
8A - 11 • 26 ELECTRICAL DIAGNOSIS
FUSE BLOCK DETAILS
4206WQ649
I HOT AT ALL TIMES
1
HOT AT ALL TIMES
1 I HOT IN RUN ANO START
1
P — — — — — *T — — — — — — — — — — — r - — — — — — — — — — -r — — — — * i UNDERHOOD
FUSE-RELAY
POWER ^ - FRONT -► POWER M --------' > CENTER

DISTRIBUTION Uc , .
CELL 8 A -1 0 H5 ( > K9 + MIRRORS c a T a ^ lC i N3 • BL0WER
S SEATS 10 A
C 20 A
J6 L10 M3
____________________ _ _______________________________________________ _____________________________________________ __________________ J
1 ORN 1840 1 ORN 1040 5 RED 542
E6 Cl 00
S110
B8 C100
1 ORN 1840
5 RED 542
L C 298
A1 ^ C l 00
1 ORN 1040
3 RED 542
5 RED 542
1 ORN 1840
P / "'CONVENIENCE
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C 205
5 RED 1 5 4 2
N il184 0
1 ORN I
1 ORN 1840
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V-/ C203
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I 1 ORN I 184 0 .8 ORN 1040
1 ORN I 1 84 0 I 542
5 RED
A y C 236
1 ORN 184 0
S401
1 ORN 184 0 3 RED 542
3 REO 542 3 RED 542
3 REO 542
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HEATED HEATED HEATED BLOWER AUXILIARY AUXILIARY AUXILIARY
SEAT SEAT MRROR MOTOR BLOWER BLOWER BLOWER
MODULE. MOOULE. RELAY RELAY. MOTOR MOTOR MOTOR
LH RH SECTION HIGH RELAY. RELAY. RELAY,
8 A -6 1
SECTION SECTION SECTION LOW MEDIUM HIGH
8 A -1 4 3 8 A -1 4 3 8 A -6 3
SECTION SECTION SECTION 04-18-97
8 A -6 3 8 A -6 3 8 A -6 3 4208W0660
FUSE BLOCK DETAILS

A/C Com pressor Clutch
Relay............................... In Underhood Fuse-Relay Center, L R of Engine
Compartment, on Fender.............................................. 6 ...... 10
A ir Injection Reaction (A.I.R.)

Pump R elay...................... In Underhood Fuse-Relay Center, L R of Engine
Compartment, on Fender........................................... .. 5 ...... 9 ...... 202-60
Audio Alarm M od ule............. Under L H o f IP, at R H o f Convenience Center................ .. 3 3 .... 44
Auxiliary Battery R e lay.......... L R of Engine Compartment, on Fender, near Underhood

Fuse-Relay Center.................................................... .. 5 ...... 9
A uxiliary Blow er M otor Relay,

H ig h ................................ O n top of Auxiliary H V A C Plenum, near R R
W heelhousing......................................................... ... 6 6 .... 85.... 202-60

L o w ................................. O n top o f Auxiliary H V A C Plenum, near R R
W heelhousing......................................................... ... 6 6 .... 85 .... 202-60

M e d iu m ............ ............... O n top of Auxiliary H V A C Plenum, near R R
W heelhousing............................................................ 6 6 .... 85 .... 202-60
A uxiliary C ooling Fan Relay.... L R of Engine Compartment............................................ 4 ...... 7 ...... 202-60
Auxiliary H V A C Control Logic

M o d u le ............................ In Overhead Console................................................... .. 5 3 .... 6 8 .... 202-25
A uxiliary H V A C Control
Module, Fro nt................... Front of Overhead Console, near W indshield....................,. 5 3 .... 6 8 .... 202-26
M odule, R e a r.................... Rear of Overhead Console M olding, in Headliner............. , 5 3 .... 6 8 .... 202-26
A uxiliary M ode D oo r M otor... In A uxiliary H V A C Plenum, forward o f L R Wheelhousing... . 6 6 .... 85
A uxiliary Power Connectors.... Center lower R H of IP, L H o f A sh T ra y ........................ „ 4 8 .... 63
Auxiliary Temperature D oor

M o to r............................... In Auxiliary H V A C Plenum, near L R W heelhousing......... . 6 6 .... 85
Backup Lam p Sw itch (MG5).... L H o f Transmission, below Shift Tower.......................... . 2 7 .... 38
Backup Lam p Sw itch (M W 3)... L H top o f Transm ission................................................ . 2 6 .... 36
Camshaft Position Sensor....... In Distributor............................................................. . 1 2 .... 16
Cargo Lam p Switch (Pickup).... Center o f IP, center L H of R a d io ................................... . 4 8 .... 63
C igar Ligh te r....................... Low er R H center o f IP, L H o f A sh T ray......................... . 4 9 .... 64
Clutch Pedal Position Switch.... A t top of Clutch Pedal................................................ . 4 1 .... 5 3 .... 202-61
Convenience Center.............. Under L H o f IP, on B u lkh e ad ....................................... . 3 3 .... 44
Courtesy Lam p, L H IP .......... Under L H o f IP .......................................................... . 4 2 .... 54
Courtesy Lam p, R H .............. Under R H Side of IP
Courtesy Lam p, L F D o o r....... L H of L F Door, m idway u p ......................................... . 6 1 .... 79
Courtesy Lam p, R F D o o r....... R H of R F Door, m idway up......................................... . 6 1 .... 79
Courtesy Lam p, L R D o o r....... L H of L R D oor Trim, m idway u p ................................. . 6 2 .... 80

CO M PO NENT L O C A T IO N 2 0 1 -P G F IG . CONN
Courtesy Lamp, R R D o o r...... R H o f R R D oor Trim, midway up.................................. . 6 2 .... 80
Crankshaft Position Sensor...... Low er R H Front portion o f Engine Block, near Crankshaft.... 7 ...... 13
Cruise Control M o d u le .......... L H Rear Side of Engine Compartment, on Bulkh e ad ......... . 2 4 .... 3 8 .... 202-16
Cruise Control Sw itch............ In H im Signal L e v e r................................................... . 4 7 .... 61
Data L in k Connector ( D L C ) ... Under L H of IP, L H o f Steering Colum n, mounted to

bottom of Knee Bolster............................................... 4 3 .... 5 5 .... 202-30
Daytime Running Lam ps

(D R L ) M o d u le .................. Under L H of IP, taped on IP Harness.............................. , 3 4 .... 4 5 .... 202-61

(D R L ) R e la y ..................... Under L H of IP, at lower center of Convenience Center..... . 3 3 .... 44
D oor Lock Control M odule..... Attached to body, forward o f L R W heelhousing................ . 7 8 .... 104.... 202-68
D oor Lock Relay.................. Under center of IP, near Remote Control D oor Lock
Receiver................................................................. .. 4 1 .... 5 3 .... 202-68
D oor Lock Switch, L F ........... O n L F D oor Trim Panel, below Inside D oor Handle.......... . 6 1 .... 7 9 .... 202-41,
68
D oor Lock Switch, L R .......... O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 2 .... 8 0 .... 202-31
D oor Lock Switch, R F .......... O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 1 .... 7 9 .... 202-31
D oor Lock Switch, R R .......... O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 2 .... 8 0 .... 202-31
Electrochromatic Rearview
M irror with C om pass.......... O n top inside o f W indshield center, part o f Inside Rearview
M irror...................................................................... 5 4 .... 69

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing............. . 6 ...... 10
Evaporative Em issions Canister

Purge Solenoid V alve .......... A t top R H o f E n gin e ..................................................... 1 1 .... 15

Vent................................ L F o f E B C M , near Brake Master Cylinder, at L F
W heelhousing.......................................................... . 1 1 .... 15.... 202-49
Electronic Variable Orifice

(EVO)/Passlock M od ule ...... Under center of I P ...................................................... . 4 0 .... 5 2 .... 202-31
Exhaust G as Recirculation
(E G R ) Sole n oid ................. Top L H center o f Engine, above Valve C o ve r................... . 2 0 .... 2 4 .... 202-62
Fog Lam p Relay................... Under L H end o f IP, on lower L H o f Convenience Center...,. 3 3 .... 44
Fog Lam p Sw itch................. Center of IP, R H o f Steering Colum n Shift L e v e r............. . 4 8 .... 6 3 .... 202-62
Fuel Heater......................... Top rear of E n gin e ...................................................... . 6 9 .... 90
Fuel Injection Pump (D ie se l).... O n Intake M an ifold ....................................................... 2 1 .... 2 6 ....
Fuel Injectors (4 .3 L )............. In Intake M a n ifo ld ...................................................... .. 1 9 .... 2 3 .... 202-32
Fuel Injectors (5.0L, 5.7L) .... In Intake M a n ifo ld ...................................................... . 1 3 .... 17.... 202-33
Fuel Pump Balance M od u le .... Inside L H Frame Rail, near Transm ission Crossm em ber........ 6 9 .... 9 0 .... 202-63
Fuel Pump Balance R e la y...... O n Fuel Pump Balance Module, inside L H Frame Rail, near
Transm ission Crossm em ber........................................... 6 9 .... 9 0 .... 202-63
FUSE BLOCK DETAILS

Fuel Pump O il Pressure Switch
and Sender (G a s)............... Rear top center o f Engine, behind D istributor................. .. 12 .... 16.... 202-63
Fuel Pum p R e la y .................. In Underhood Fuse-Relay Center, L R o f Engine

Compartment, on Fender........................................... .. 6 ...... 10
G low Plug Control M odule..... L H rear of Engine, near Bulkhead................................ 202-46
G low Plug R elay.................. L R o f Engine, near Bulkhead....................................... .. 2 2 .... 29

Sw itch.............................. Low er L H o f I P ........................................................ .. 3 2 .... 43.... 202-34
Heated O xygen Sensors

(H 0 2 S )............................. In Exhaust Pipe, in front and back o f Catalytic Converters... 15.... 19.... 202-64
H orn R e la y .......................... O n Convenience Center, under L H o f I P ........................ .. 6 ...... 10
H V A C Control Lam p ............. Part of Heater Controls, center of IP, under R adio............ .. 5 3 .... 68
H V A C Control M od ule .......... Part of Heater Controls, center of IP, under R adio............ .. 5 3 .... 68 .... 202-35
Ignition C o il........................ R R of E n g in e ................... ........................................ .. 1 8 .... 22
Ignition Control M od ule ......... R R o f E n g in e ........................................................... .. 1 1 .... 15.... 202-64
Illum inated Vanity M irror,

L H .................................. Part of L H Sunvisor.................................................... .. 5 5 .... 70
Illum inated Vanity M irror,

R H .................................. Part of R H Su n viso r...................................................... 5 5 .... 70
Inflatable Restaint Sensing and

Diagnostic M odule (S D M )... Under Carpet Beneath D rivers Seat................................... 3 9 .... 5 1 .... 202-37
Inflatable Restraint IP M odule

Switch (P icku p )................. L H center o f IP ......................................................... ... 4 8 .... 6 3 .... 202-65
Interior Lam p Control

M o d u le ............................ Under center of I P ..................................................... ... 3 8 .... 5 0 .... 202-66
Instrument Cluster................. L H Upper End of IP ................................................... 202-28
IP Compartment B o x Lam p .... In IP Compartment B o x ................................................. 4 2 .... 54
IP Fuse B lo c k ...................... L H of IP, near L F D oo r Jamb Sw itch ............................ ,. 3 2 .... 43
Liftgate Release Sw itch .......... Center o f IP, L H of Radio
Low Coolant Level Indicator

M odule (D iesel)................. Under center of I P ......................................................„ 3 7 .... 49.... 202-66
M ass A ir Flow (M A F ) Sensor.. A t A ir Intake Duct, near A ir Filter, R H of En gin e ............„ 1 3 .... 19
M ode D oor M otor................. Under IP, on L H o f H V A C Plenum ............................... . 5 0 .... 6 5 .... 202-66
Park/Neutral Position (PN P)

Switch, Connector C l ......... A t L H center o f T ransm ission....................................... . 2 3 .... 31.... 202-67

Switch, Connector C 2 ......... A t L H center of T ransm ission....................................... . 2 3 .... 31.... 202-67
Power Am plifier R e la y .......... Under L H o f IP, R H of Brake Pedal Bracket................... . 3 4 .... 5 7 .... 202-67
Pow er Seat Lum bar Switch,

L F .................................. O n lower L F o f L F Seat.............................................. . 6 3 .... 81

Power Seat Lum bar Switch,
R F .................................. O n lower R F o f R F Seat............................................... 6 3 .... 81
Powertrain Control M odule

(P C M )............................. Under R H end o f IP, above Blow er Motor, behind IP
Compartment B o x ..................................................... 3 7 .... 49
Power W indow Master

Sw itch............................. O n L F Door, below Inside D oor H andle.......................... 6 1 .... 7 9 .... 202-37,
68
Power W indow Switch, R F ..... O n R F D oor Trim Panel, below Inside Door handle........... 6 1 .... 7 9 .... 202-31
Radio, Connector C l ............. Center o f IP ............................................................... 3 5 .... 4 6 .... 202-43
Radio, Connector C 2 ............. Center of IP ............................................................... 3 5 .... 4 6 .... 202-44
Reading Lam ps, Overhead

Console............................ N e k W indshield Centerline............................................ 5 3 .... 68
Recirculation D oor M otor....... Under IP, on H V A C Plenum .......................................... 5 0 .... 6 5 .... 202-69
Remote Control D oor Lock

Receiver........................... Under center of IP, R H of Knee B olste r.......................... 2 7 .... 4 3 .... 202-45
Remote Outside Rearview

M irror Sw itch.................... O n L F Door, below Inside D oor Handle
Spare Power Source

(Convenience Center).......... Under L H of IP, on Bulkhead........................................ 3 3 .... 44
Stoplamp Sw itch................... Top of Brake Pedal...................................................... 4 4 .... 5 7 .... 202-70
Temperature D oor M o to r........ Under IP, on center o f H V A C Plenum ............................. 5 0 .... 6 5 .... 202-69
Transfer Case Control M odule

(T C C M )........................... Under IP, on Steering Colum n Support Bracket.................. 3 8 .... 5 0 .... 202-46
Transfer Case M ode Selector

Illum ination L a m p .............. In Transfer Case Select Sw itch....................................... 4 8 .... 63
Transfer Case Select Sw itch.... Center of IP, R H of Steering Colum n Shift L e v e r............. 4 8 .... 6 3 .... 202-48
Transm ission........................ Under center of vehicle, attached to rear of Engine
(M 3 0 )..................................................................... 202-6
(M T 1 ).................................................................... 202-7
T\im/Hazard Sw itch............... Part o f Multifunction Switch, upper L H o f Steering Colum n. 4 7 .... 61
Tbm Signal Sw itch ............... Part of Multifunction Switch, upper L H of Steering Colum n. 4 7 .... 61
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender............................ 5 ...... 9
Underhood Lam p.................. Under R H of H o o d ...................................................... 7 ...... 12
Underhood Reel Lam p........... R H o f Engine Compartment, on Bulkhead
Vehicle Control M odule

( V C M ) ............................. Engine Compartment, near E B C M .................................. 3 7 .... 48
Vehicle Speed Sensor Buffer

(D iesel)............................ Under R H of IP ........................................................... 3 7 .... 4 9 .... 202-70
Wastegate Solenoid (D iesel).... Top L R of Engine, above Valve C over............................. 2 0 .... 24
Water-in-Fuel Sensor (D ie se l)... Top rear of E n gin e ....................................................... 1 9 .... 23

FUSE BLOCK DETAILS
W indow Lockout Switch, rear.. L H Front Door, forward portion of Arm Rest area.............. 3 7 .... 62
W indow Wiper/Washer Switch,

R e a r................................ Center of IP, R H o f R ad io ............................................ , 4 9 .... 6 4 .... 202-69
W indshield W iper M otor

M o d u le ............................ A t center and rear of Engine Compartment, at Bulkhead..... 4 ..... 8 ...... 202-70
W indshield Wiper/Washer
Sw itch.............................. A t Steering Colum n, part of Multifunction Lever............... , 4 7 .... 61
C O N N EC T O R S:

at Bulkhead............................................................. 4 ...... 8 ...... 202-0
C 1 0 3 .................................. Engine Harness to Fuel Pump Motor, L R of Engine

Compartment, under Brake Master C ylinder................... 1 4 .... 18.... 202-49
C105 (7 .4 L )........................ Engine Harness to Fuel Injectors, rear of Intake M an ifo ld ... 18 .... 22.... 202-3
C 1 0 7 .................................. Engine Harness to Oxygen Sensors Harness, L F of

Transm ission............................................................ 2 5 .... 34 .... 202-49
C l 13 (D ie se l)...................... Engine Harness to Engine Sensors.................................. 2 0 .... 25 .... 202-5
C 1 2 0 .................................. Engine Harness to Front Axle Actuator, rear o f Engine, near

Transm ission............................................................ 2 7 .... 37.... 202-50
C 200 (D ie se l)...................... Behind R H o f IP, near Heater Motor, in foam w rap........... 3 7 .... 49.... 202-11
C 200 (G a s).......................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 .... 49.... 202-10
C 2 0 5 .................................. A t Convenience Center................................................. 3 3 .... 44 .... 202-50
C 2 0 6 .................................. Inside lower L H A P illa r.............................................. 6 1 .... 79 .... 202-50,

51
C 2 0 7 .................................. Inside lower L H A P illa r.............................................. 6 1 .... 7 9 .... 202-51
C 207 (Upfitter O ption ).......... Inside lower L H A P illa r.............................................. 6 1 .... 7 9 .... 202-13
C 2 0 8 .................................. Inside lower L H A P illa r.............................................. 6 1 .... 7 9 .... 202-51
C 2 0 9 .................................. Inside lower L H A P illa r.............................................. 6 1 .... 79.... 202-51
C 2 1 0 .................................. A t Convenience Center................................................. 3 3 .... 44.... 202-51
C 2 1 2 .................................. Under L F Seat............................................................ 6 5 .... 83.... 202-52
C 2 1 3 .................................. Inside lower R H A P illa r.............................................. 6 1 .... 79 .... 202-52
C 2 1 5 ................ <................. Inside lower R H A P illa r.............................................. 6 1 .... 79 .... 202-52
C 2 1 8 .................................. A t Convenience Center................................................. 3 3 .... 44
C 227 (Stoplamp Sw itch )........ A t Convenience Center................................................. 4 4 .... 57 202-70
C 2 3 0 .................................. Behind R H of DP, above H V A C Evaporator H o u sin g.......... 2 7 .... 42.... 202-54
C 2 3 2 .................................. IP Harness to S IR Harness, behind R H of IP .................... 5 5 .... 7 0 .... 202-54
C 2 4 0 .................................. Crossbody Harness, approx. 100 cm from Seat Belt Switch

Breakout................................................................. 6 5 .... 83.... 202-55
C 2 6 6 .................................. IP Harness to Steering Colum n Harness, L H o f Steering

Column, near Bulkhead.............................................. 3 2 .... 43.... 202-14
COMPONENT LOCATION 201 -PG FIG. CONN

C 2 9 8 .................. Behind L H of BP, near Convenience Center, . 3 2 .... 4 3 .... 202-17,
18
C299. Behind R H o f IP, above H V A C Evaporator H o u sin g .......... 43 56. 202-19
C300. In Overhead Console.................................................... 36 61. 202-55
C 3 0 1 .................................. A t L F K ic k Panel. 47 62. 202- 20,

56
C 3 0 2 ................................ A t L F K ic k Panel........................................................ 47 62. 202-56
C 3 0 4 ................................
C 3 0 5 ................................
C 4 0 1 ................................ R R of vehicle, above Auxiliary Blow er M o to r.................. 66. 85. 202-56
C 4 1 1 ................................ A t L R of cab.............................................................. 70, 91. 202-58
C 4 1 3 ................................ L H rear of Cab
C 4 9 6 ................................ In R H B P illar ....................................................... 62. 80. 202-58
C 4 9 8 ................................ L H B P illar................................................................ 62. 80. 202-59
D IO D E :
D 2 0 3 ................................ IP Harness, at R H of Steering Colum n Support................. 4 1 .... 53
G R O M M ETS:
P 1 0 0 ................................ L R of Engine Compartment, at Bulkhead. 8
P 1 0 1 ................................ R R of Engine Compartment, at Bulkhead 12
S P L IC E S :
S101 (4.3L, 5.0L - L D , 5.7L

L D , 7.4L - M /T)............. Engine Harness, approx. 12 cm from E B C M Breakout
S101 (5.0L - H D , 5.7L - H D ,

7.4L - A / T ).................... Engine Harness, approx. 15 cm from E B C M Breakout
S101. (6.5L) Engine Harness, approx. 5 cm from Starter Solenoid

Breakout
S104 (4.3L, 5.0L - A/T, 5.7L

M /T).............................. Engine Harness, approx. 12 cm from Fuel Injector Breakout
S104 (5.0L - M/T, 5.7L -

M /T).............................. Engine Harness, approx. 10 cm from Fuel Injector Breakout
S104 (7.4L) ...................... Engine Harness, approx. 30 cm from E B C M Breakout
S108 (4.3L) ...................... Engine Harness, approx. 11 cm from Ignition C o il Breakout,

toward Starter Solenoid
S I 08 (5.0L - A/T, H D , 5.7L

A/T, H D ) ...................... Engine Harness, approx. 12 cm from Ignition C o il Breakout,
S108 (5.0L - A/T, L D , 5.7L -

A/T, L D )......................... Engine Harness, approx. 39 cm from Ignition C oil Breakout,
FUSE BLOCK DETAILS

S108 (5.0L - M/T, 5.7L -
M / T ).............................. .. Engine Harness, approx. 28 cm from Ignition C oil Breakout,
S108 (6.5L, A / T ).................,. Engine Harness, approx. 12 cm from G low Plugs Breakout
S108 (6.5L, M /T )................. . Engine Harness, approx. 5 cm from Backup Lam p Switch
Harness Breakout
S108 (7.4L) ....................... . Engine Harness, approx. 13 cm from Ignition C oil Breakout,
S I 08 (D iesel)...................... . Engine Harness, approx. 5 cm from Backup Lam p Switch

Harness Breakout toward E G R Valve
S I 1 3 ................................. . Engine Harness, approx. 19 cm from E B C M Breakout
S I 46 (7.4L) ....................... . Engine Harness, approx. 22 cm from E B C M Breakout
S I 48 (w/Leaded Fuel)........... . O xygen Sensor Harness, approx. 7 cm from R H Bank

Oxygen Sensor Breakout, toward Engine Harness
S I 48 (w/o Leaded Fu e l)........ . Approx. 19 cm into O xygen Sensor Harness
S 1 5 1 ................................. . Engine Harness, approx. 7 cm from E B C M Breakout
S161 (4.3L) .................... . . Engine Harness, approx. 30 cm from E G R Valve Breakout,

toward Taillamp Harness Breakout
S161 (5.0L - A/T, H D , M/T,

5.7L - A/T, H D , M / T )....... . Engine Harness, approx. 8 cm from E G R Valve Breakout,
toward Fuel Injector Harness Breakout
S161 (5.0L - A/T, L D , 5.7L -

A/T, L D ) ......................... . Engine Harness, approx. 27 cm from E G R Valve Breakout,
S 2 1 3 ................................. . IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
S 2 1 7 .................................. . IP Harness, approx. 16 cm from Instrument Cluster Harness

Breakout, toward Radio Connectors. Breakout
S235 (D iesel)....................... . IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
S235 (G as).......................... . IP Harness, approx. 8 cm from Steering Colum n Harness

Breakout
S 2 4 2 .................................. . IP Harness, approx. 12 cm from Inflatable Restraint Switch

Breakout
S 2 4 3 ............... ,................. , H V A C Harness, approx. 4 cm from Recirculation D oor

Breakout, toward Blow er M otor Relay
S 2 4 8 .................................. Crossbody Harness, approx. 10 cm from L F D oor Harness

Breakout
S253 (Suburban/Utility)......... Crossbody Harness, approx. 6 cm from IP Harness

Breakout, toward D oor Lock Relay Breakout
S255 (Crew C a b )................. Crossbody Harness, approx. 20 cm from C 210 Breakout,

toward C298 Breakout

S255 (Pickup/Extended C ab )... Crossbody Harness, approx. 5 cm from C231 Breakout,
toward IP Harness
S255 (Suburban/Utility).......... Crossbody Harness, approx. 18 cm from C 210 Breakout,

S256 (2-Door
Utility/Pickup/Extended
C a b )................................ Crossbody Harness, approx. 12 cm from C 210 Breakout,
S256 (4-Door Utility/

Suburban)......................... Crossbody Harness, approx. 19 cm from C 210 Breakout,
S256 (Crew C a b ).................. Crossbody Harness, approx. 1 cm from D oor Lock Relay
Breakout, toward Seat Belt Switch Breakout
S264 (Diesel, Suburban/

U tility)............................. IP Harness, approx. 4 cm from Instrument Cluster Breakout,
toward Radio Connectors Breakout
S264 (Gas, Suburban/Utility).... IP Harness, approx. 8 cm from Instrument Cluster Breakout,

S266 (Utility/Pickup/Extended
S 2 6 8 .................................. IP Harness, approx. 7 cm from Inflatable Restraint Switch

Breakout
S 2 7 0 .................................. IP Harness, approx. 13 cm from P100
S 2 7 2 .................................. IP Harness, approx. 4 cm from Auxiliary Power Outlet

Breakout
S 2 9 9 .................................. IP Harness, approx. 4 cm from Steering Colum n Harness


Suburban)......................... Rear H V A C Control Harness, approx. 31 cm from Auxiliary
H V A C Control Logic M odule Breakout, toward Front
A uxiliary H V A C Control M odule

H V A C Control Logic M odule Breakout, toward Rear
S 3 1 2 .................................. Illuminated Vanity M irror Jumper Harness, approx. 4 cm

from Inside Rearview M irror Breakout, toward L H
Illuminated Vanity M irror
S 3 1 5 .................................. Taillamp Extension Harness, approx. 17 cm from Fuel Pump

Balance M odule Breakout, toward Engine Harness
S400 (w/Auxiliary A/C).......... A u xiliary A/C Harness, approx. 17 cm from Blow er M otor
S426 (2-Door Utility)............. Front-to-Rear Body Harness, approx. 13 cm from Front

Dom e Lam p Breakout, toward Rear Dom e Lam p Breakout
FUSE BLOCK DETAILS

Suburban)......................... Front-to-Rear Bod y Harness, approx. 29 cm from Crossbody
Harness Breakout, toward Rear Dom e Lam p Breakout
S426 (Pickup/Extended Cab

w/Overhead C o n so le ).......... Dom e Lam p Harness, approx. 13 cm from C H M S L
Breakout, toward C411

w/o Overhead Console)....... Dom e Lam p Harness, approx. 22 cm from C H M S L
S426 (4-Door Utility/Suburban

w/E55 w/o C 6 9 )................ Front-to-Rear Bod y Harness, approx. 12 cm from Rear
Dom e Lam p Breakout, toward Front Dom e Lam p
Breakout
S434 (2-Door U tility )............ Front-to-Rear Bod y Harness, approx. 7 cm from Front
Dom e Lam p Breakout, toward Crossbody Harness
Breakout
S 5 0 1 .................................. Inside L F D oor Harness, at Breakout to W indow M otor

Regulator................................................................ 6 1 .... 79
GROUND DISTRIBUTION
FOG
HEADLAMP H IG H / PARK AND
LAMP.LH
LOW BEAM, LH TURN LAMP. LF
SECTION
SECTION 8 A -1 0 2 8 A -1 0 2 SECTION 8 A -1 0 2
I
I
I
/ N
I
\ _______ /
\
oN_____ V
WINOOW
WASHER W XO SHgLP
I
I
I
W V 22 (QUAD HEADLAMPS) PUMP MOTOR. WASHER
A' Ay c y
_______ A REAR PUMP MOTOR
PARK AND SECTION 8 A -9 2 SECTION 8 A -9 1
P“ “ T
HEADLAMP LOW HEADLAMP HIGH
BEAM. LH BEAM, LH TURN LAMP, L f
SECTION 9 A -1 0 2 SECTION 8 A -1 0 2 SECTION 8 A -1 0 2 I I I I

/ "N “ N \
I I I I
I I I I
\ I I I I I
/ \ L_ _ J L ..J
8 v_/ B V -/ C
1 BLK 190 1 BLK 150 1 BLK ISO .8 BLK 150 .8 BLK 150 .8 BLK 150 150
S158
.8 BLK 150
B /W \C 1 1 6
.8 BLK 150
S I 23
2 BLK 150
C l 13
LH FORWARD
LAMP GROUND
(LH RADIATOR
SUPPORT) 03-11-S7
4206W 0617
W /V 22 (QUAD HEADLAMPS)
A
HORN, RH
roc
HEADLAMP HIGH HEAOLAMP LOW PARK AND HEADLAMP H IG H / SECTION B A -40
LAMP. RH
BEAM, RH BEAM, RH TURN LAMP, RF LOW BEAM, RH
SECTION
8 A -1 0 2 SECTION 8 A -1 0 2 SECTION B A -1 0 2 SECTION 8 A -1 1 0 SECTION B A -102 I I
I I
1
\
1
“ N / “ \ \
I I
/
\
\ ( \ \ AUXILIARY ( \
1 1
I I
________ _ / COOLING FAN V
L .. J
AV
_________ / _________ /
A B BV G MOTOR A
ENGINE
HORN, LH
ELECTRICAL
SECTION B A -4 0 COOLING PARK AND
r — — *i TURN LAMP, RF
I I I I SECTION 8 A -1 1 0
W/DUAL
I I I I / s HORNS
I I I I 1 1
ONLY
I I I I
L—_ J L ..J \ / • /
AV A V -/ C
.8 BLK 250 t BLK 250 1 BLK 250 .8 BLK 250 1 BLK 250 .8 BLK 250
.8 BLK 250 t BLK 250 .8 BLK 250
2 BLK 250
Cl 12
RH FORWARO
LAMP GROUND
03-11-97
(RH FENOER)
4206W0S18
GROUND DISTRIBUTION
INFLATABLE HVAC
RESTRAINT IP CONTROL DOOR JAMB
CIGAR
AUXILIARY
MOOULE SWITCH SWITCH. RF ip
LIGHTER ASH TRAY
POWER SWITCH SECTIONS SECTION SECTION COMPARTMENT BOX
OUTLETS LAMP
SIR CONTROLS
r— — i
B A -63. 65
1
8A -114
1 1
BA-114
1 SECTION
LAMP
1
r
L
1
---------------- -------------
▲ ▲ l1 11 1 1 1 1 1 1 BA-114 SECTION 8A -114
B 8
1 1 1 1 1 1 1 1
1 1 1 1 1 1
—
__ J
i___ ____i 1_______1 L — ___1 \ J

1
1
1
F V cyci B BV BV AV
1 BLK 150 .5 BLK 150 1 BLK 150 .8 BLK 150
1 BLK 150 .5 BLK 150 .5 BLK 150 .5 BLK 150
2 8LK
150
.5 BLK 150
.35 BLK 150 .35 BLK ISO .5 BLK ISO
0.5 BLK 150

r B—/ * —
\
|
.35 BLK ISO I I I I

I I I I
I I I I
L ____J
AUXILIARY
B /* \
HEATER
CONTROL
SWITCH hA gA hA
1------- T r ------- i
SECTION | | |
BA-117 1 1 1 1 1
1 1 1 1 1
CARGO zrs SUBURBAN/ 1 1 1 1 1
LAMP r — - UTILITY
i______ i
L.
J
1
L __ _
r
1
SWITCH I I ONLY
WINDOW AUTOMATIC TRANSFER
(PICKUP)
I I WIPER/ TRANSFER CASE
SECTION
BA -117 I I WASHER CASE SELECT
I---------J SWITCH. REAR SELECT SWITCH
FOG SWITCH TRANSFER
SECTION
LAMP 8A -92 TRANSFER CONTROLS
SWITCH CASE
SUBURBAN/ CONTROLS
SECTION UTILITY 03-12-97
ONLY
BA-117 4208W0619
CQNVENCNCS
AUTOMATIC
CENTER
4208W0820
GROUND DISTRIBUTION
GASOLINE ENGINES
r — i h ea ted r — 1 FRONT r - i
UNOERHOOO / — \ UNOERHOOO J | OXYGEN 1 *AXLE 1 1 NEUTRAL
V _ / LAMP V _ / REEL b .J SENSOR L —J SENSOR J ACTUATOR

b-J POSITION
SECTION B LAMP C BANK 1 C BANK 1 AV */ TRANSFER O N ^ /C I
HEATED OXYGEN r — 1 HEATEO

I I SENSOR 1 • OXYGEN
I I ! ! SENSOR
b .J BANK 1 l v 4 .3 L
SENSOR 3 f ^ 5 .0 L BANK 1
SENSOR 2
BANK 2 1 ENGME
v S .7 L
SENSOR 2 f ' 7.4L CONTROLS
ENGME
CONTROLS 03*12-97
4208W0521
SECTION
'8 A -6 3
03-24-97
4206W 0622
GROUND DISTRIBUTION
DIESEL ENGINES
P ------------ — n UNOERHOOO
TRANSMISSION
CONTROLS
03*12-97
4208W 0624
GROUND DISTRIBUTION
GASOLINE ENGINES
W / DUAL TANKS
A AUTOMATIC
FUEL SECONDARY FUEL
TRANSFER
PUMP FUEL PUMP
CASE
AND GAUGE BALANCE
MOOULE
SENDER SENDER MOOULE
TRANSFER
SECTION SECTION SECTION CASE
8 A -8 I
—
8 A -8 1 8 A -8 1 CONTROLS
| |
r - n r n r — ^
1 1 1 1 | |
1 1 1 1 1 1 1 1
t . j b _ j k - j k . J
E 16 V - /
AY AY EY
.8 451 .5 B IK /W H T
BLK/
WHT
.5 BLK/W HT 451
RELAY A£ MASS A /C
(UNDERHOOD COMPRESSOR AIR FLOW IGNITION COMPRESSOR
VEHICLE CONTROL FUSE-RELAY PRESSURE 1 BLK/W HT (MAF) CONTROL CYCLING
A
SENSOR MOOULE SWITCH
ENGINE ENGME i f e & SECTION
CONTROLS CONTROLS 8 A -6 4
r - i P “ 1 r - i
1 1 1 1 1 1
1 1 1 1 1 1
b .4 b .J
a y B y
CY
.8 BLK/W HT
SECTION 8 A -8 1
— ENGINE — ENGINE
GROUND GROUND
03-12-97
4208W 0526
GROUND DISTRIBUTION
DIESEL ENGINES
W/DUAL
TANKS
FUEL PUMP
A _
POWERTRAIN
EVO / RELAY SECONDARY FUEL PUMP
PASSLOCK INSTRUMENT (UNDER HOOD FUEL GAUGE FUEL GAUGE (MAF)

FUSE-RELAY
(PCM ) MOOULE aUSTER SENDER SENDER SENSOR
ENGME SECTION TRANSMISSION SECTION ENGME SECTION SECTION s e c t io n /T m ENGME

CONTROLS ife & 2B5 CONTROLS 8 A -8 1 CONTROLS 8 A -8 1 8 A -8 1 8 A -8 1 CONTROLS
r ~ i ^ — mm mm — — — — ^ DATA LINK r — ^ r - i r — *i r — ^ P “ 1
P “ 1
I I 1 1 1 1 1 1 CONNECTOR (D LC ) 1 1 1 1 1 1 1 1 1 1
I
oirr*
1 1 1 1 1 1 1 SECTION 1 1 1 1 1 1 1 1 1 1
_ _. _ J b. _ J t — j ' J 8 A -5 0 b - j b .J b - j b - j b - d
D€ V ^ / C3 81 w 8 w 4 W 3 1 V -/ 5 V \- / A O Ay
EV 8 V
.8 551 .5 451 .5 451 .5 451 .8 451 .5 451

TA N / BLK/ BLK/ BLK/ BLK/ BLK/
WHT
“SK
WHT WHT WHT WHT WHT
.8 451 .5 451 451 451 .5 451 .5 451
BLK/ BLK/ BLK/
W
W nl WHT WHT WHT
. a
S215 S317 (
451
BLK/ 1 BLK 451
WHT
KWOOO .8 451
Cl
E 1 6 /* \ iL' BLK/
r ~ “ T AUTOMATIC WHT
J | TRANSFER
P101 CASE
CONTROL
0 £ C l03
MOOULE
TRANSFER
451 CASE CONTROLS
BLK/
WHT
.5 451
BLK/
WHT
,a
S I0 3
1 BLK/WHT 451
03-12-97
4200W0S27
GROUND DISTRIBUTION
DIESEL ENGINES
TAIL, STOP. TAIL, STOP. TAIL, STOP, TAIL, STOP,
TURN AND BACKUP TURN AND BACKUP LICENSE. TURN AND TURN ANO BACKUP
LAMPS. LR LAMPS. RR BACKUP LAMPS. LR LAMPS. RR
SECTION 8 A -1 I0 SECTION 8 A -1 I0 SECTION B A -1 1 0 SECTION B A -110
( )
03*24-07
4208W 0528
GROUND DISTRIBUTION
PICKUP W/DUAL REAR WHEELS
GROUND GROUND 03-12-97

4208W 0529
GROUND DISTRIBUTION
SUBURBAN/UTILITY
AUXILIARY AUXLIARY AUXILIARY

AUXILIARY MOPE TEMPERATURE POOR AUXLIARY HVAC HVAC AUXILIARY
BLOWER POOR POOR JAM8 CONTROL CONTROL HVAC CONTROL
MOTOR MOTOR MOTOR SWITCH. REAR MOOULE FRONT MOOULE REAR MOOULE
SECTION 8 A -6 3 SECTION 8 A -6 5 SECTION 8 A -6 5 SECTION 8 A -1 3 0 SECTION 8 A -6 3 SECTION 8 A -6 3 SECTION 8 A -6 3
r - T r “ ^ r - i r — n r — «i
03-12-
4208W 0830
ROOT MARKER
LAMPS
SECTION 8 A -1 1 0
8 A -1 4 -3
03-12-97
4200W 0S31
GROUND DISTRIBUTION
i i I I I I I I I I I I
L . J b .J L .J k .J k -J k . J k . J
POWER WINDOW CARGO POWER SEAT LUMBAR POWER WINDOW SEAT BELT SEAT BELT POWER SEAT
SWITCH, RF LAMP MOTOR, RF SWITCH, RR SWITCH, LF SWITCH. RF AOJUSTER
SECTION 8 A -1 4 1 SECTION 8 A -1 2 0 SECTION 8 A -7 6 SECTION 8 A -7 6 SWITCH, RF

SECTION 8 A -1 2 0
SECTION 8 A -1 4 0
03-12-97
4206W0632
r — — — — — — — — — n fr o n t
GROUND DISTRIBUTION
r — t FUEL ‘ 1 A.I.R.
I I PUMP | PUMP
I I
b .J AND
03-12-97
4208W 0534
P — — — — “ — " 1 CONVENCNCE
GROUND DISTRIBUTION
03-13-07
4206W0700

A/C Com pressor Clutch.......... Front of A/C Compressor, L F of En gin e....................... ..... 1 4 .... 18

R elay............................... In Underhood Fuse-Relay Center, L R o f Engine
A/C Com pressor C ycling

Sw itch............................. O n top R H of A/C Accumulator, R H of Engine
Compartment, on Bulkhead...................................... .... 1 7 .... 21
A/C Com pressor H igh Pressure

Cutout Sw itch ................... O n rear of A/C Compressor, L F of En gin e .................... ... 1 0 .... 14
A/C Com pressor Low Pressure

Cutout Sw itch ................... A t top of A/C Compressor, in H igh Pressure Refrigerant
L in e ..................................................................... ... 1 0 .... 14

Pump (5 .7L)..................... L F of Engine Compartment......................................... .... 9 ..... 14

Pump (7.4L)..................... Low er R F of En gin e ...................................................... 9 ...... 14

Compartment, on Fender.......................................... ... 5 ...... 9 ...... 202-60
A sh Tray L a m p .................... In A sh Tray H o u sin g................................................. ... 4 9 .... 64
Audio Alarm M odule............. Under L H of IP, at R H of Convenience Center............... ... 3 3 .... 44
Automatic Transfer Case

Control Module, Connector
C 2 .................................. Under L H of IP, near Convenience Center..................... ... 3 4 .... 45 202-60

Control Module, Connector
C 2 .................................. Under L H of IP, near Convenience Center..................... ... 3 4 .... 45 202-60
Automatic Transfer Case Select

Switch, Connector 1 ........... A t center rear of IP, near Remote Control D oor Lock
Receiver............................................................... ... 4 8 .... 6 3 .... 202-59

Switch, Connector 2 ........... A t center rear o f IP, near Remote Control D oor Lock
Receiver............................................................... ... 4 8 .... 6 3 .... 202-60
Auxiliary Blow er M o to r......... Behind R R W heelhousing........................................... ... 6 6 .... 85

H ig h ................................ O n top of Auxiliary H V A C Plenum, near R R
W heelhousing........................................................ ... 6 6 .... 8 5 .... 202-60

L o w ................................ O n top of Auxiliary H V A C Plenum, near R R
W heelhousing........................................................ ... 6 6 .... 85.... 202-60

M e d iu m ........................... O n top of Auxiliary H V A C Plenum, near R R
W heelhousing........................................................ ... 6 6 .... 85.... 202-60
Auxiliary C ooling Fan Motor.... R H o f Engine Compartment, front of Radiator................ ... 0 ..... 2
GROUND DISTRIBUTION

M o d u le ............................ In Overhead Console...................................................... 5 3 .... 6 8 .... 202-25
M odule, Front................... Front of Overhead Console, near W indshield................... ... 5 3 .... 6 8 .... 202-26
M odule, R e a r.................... Rear of Overhead Console M olding, in Headliner............. .. 5 3 .... 6 8 .... 202-26
A uxiliary M ode D oor M otor... In Auxiliary H V A C Plenum, forward o f L R Wheelhousing..... 6 6 .... 85
A u xiliary Power Connectors.... Center lower R H of IP, L H o f A sh T ra y ........................ .. 4 8 .... 63
A u xiliary Temperature D oor

M o to r.............................. In A uxiliary H V A C Plenum, near L R W heelhousing......... „ 6 6 .... 85
Backup Lam p, L H Cab

C h assis............................. Rear o f vehicle.......................................................... , 7 3 .... 97
Backup Lam p, L H
Pickup/Utility.................... Rear of vehicle.......................................................... , 7 4 .... 99
Backup Lam p, R H Cab

C h assis............................. Rear of vehicle.......................................................... , 7 3 .... 97
Backup Lam p, R H
Pickup/Utility.................... Rear o f vehicle........................................................... . 7 4 .... 99
Battery................................ R F o f Engine Compartment.......................................... . 1 ...... 4
Blow er M o to r...................... R H of IP, behind IP Compartment B o x ........................... . 5 0 .... 65
Blow er M otor Relay, H ig h ...... Behind IP Compartment Box, on H V A C Plenum .............. . 5 0 .... 6 5 .... 202-60
Brake Pressure W arning

Sw itch............................. O n rear o f E B C M casting, near Brake Master Cylinder, at
L F W heelhousing..................................................... . 6 ...... 9
Cargo D oor Contactor, L H ...... Rear Body Opening and Door, upper L H .......................... 7 6 .... 101
Cargo D oor Contactor, R H ...... Rear Body Opening and Door, upper R H ......................... . 7 6 .... 102
Cargo D oor Defogger Grid,

L R .................................. Q n L R Cargo D oor G la ss............................................ . 7 6 .... 101

R R .................................. O n R R Cargo D oor G la ss............................................ . 7 6 .... 102
Cargo Lam p (Pickup)............. Rear center of cab, above Rear W indow, part o f C H M S L ..... 6 9 .... 90
Cargo Lam p Switch (Pickup).... Center o f IP, center L H of R ad io ................................... . 4 8 .... 63
Center H igh M ount Stoplamp

(C H M S L , Pickup).............. A t top rear center o f cab.............................................. . 6 9 .... 9 0 .... 202-64

(C H M S L , Suburban/Utility)... A t top rear center of vehicle, part of R o o f...................... . 7 0 .... 9 2 .... 202-64
C igar Ligh te r....................... Low er R H center o f IP, L H o f A sh T ray......................... . 4 9 .... 64
Clearance Lamp, L F .............. Front of L R Fender..................................................... . 6 9 .... 89
Clearance Lam p, L R .............. Rear of L R Fender...................................................... . 6 9 .... 89
Clearance Lam p, R F .............. Front of R R Fender............................................ ........ . 6 9 .... 89
Clearance Lam p, R R .............. Rear o f R R Fender...................................................... . 6 9 .... 89


Clearance Lam p, R o o f.......... .. O n L H and R H top front of roof, at each end o f R oof
M arker Lam ps......................................................... . 6 9 .... 8 9 .... 202-69
Convenience Center............. .. Under L H of IP, on Bulkhead........................................ . 3 3 .... 44
Cruise Control M odule

( C C M ) .............................. L R o f Engine Compartment, on Bulkhead........................ . 3 1 .... 4 2 .... 202-29
Data L in k Connector ( D L C ) ...... Under L H of IP, L H of Steering Colum n, mounted to

bottom of Knee Bolster............................................. . 4 3 .... 5 5 .... 202-30
Daytim e Running Lam ps

(D R L ) M o d u le ................. ,. Under L H of IP, taped on IP Harness............................. . 3 4 .... 4 5 .... 202-61
Dom e Lam p, Front (Police

Package, Z 5 6 ).................. ,. Approx. 22 cm from W indshield centerline, in Headliner.... . 6 0 .... 78
Dom e Lam p, Rear (Police

Package, Z 5 6 ).................. .. Approx. 22 cm from W indshield centerline, in Headliner.... . 5 9 .... 77
D oor Jamb Switch, L F ......... ,. A t L H end of IP ......................................................... . 4 5 .... 59
D oor Jamb Switch, L R ......... ,. Center inside edge o f L H B P illa r................................. . 6 8 .... 88
D oor Jamb Switch, R F ......... ,. A t R H end of I P ........................................................ . 4 5 .... 59
D oor Jamb Switch, R R ......... .. Center inside edge of R H B P illa r................................. . 6 8 .... 88
D oor Lock Control M odule....,. Attached to body, forward of L R W heelhousing................ . 7 8 .... 104.... 202-68
D oor Lock Relay................. .. Under center of IP, near Remote Control D oor Lock
Receiver................................................................. . 4 1 .... 5 3 .... 202-68
D oor Lock Switch, L F .......... ,. O n L F D oor Trim Panel, below Inside D oor H andle.......... . 6 1 .... 7 9 .... 202-41,
68
D oor Lock Switch, L R ......... ,. O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 2 .... 8 0 .... 202-31
D oor Lock Switch, R F ......... .. O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 1 .... 7 9 .... 202-31
D oor Lock Switch, R R ......... .. O n R F D oor Trim Panel, below Inside D oor Handle.......... . 6 2 .... 8 0 .... 202-31
M irror with C om p ass......... . O n top inside o f W indshield center, part o f Inside Rearview
M irro r.................................................................... . 5 4 .... 69

M odule (E B C M )............... . Near Brake Master Cylinder, at L F W heelhousing............. . 6 ...... 10

(EVO )/Passlock M od ule ..... . Under center o f I P ...................................................... . 4 0 .... 5 2 .... 202-31
Endgate M arker Lam ps......... . O n center and bottom of Endgate................................... . 7 1 .... 94
Fog Lam p, L H .................... . A t L H lower edge o f Front Bum per and A ir Deflector...... . 0 ...... 1
Fog Lam p, R H .................... . A t R H lower edge o f Front Bum per and A ir Deflector...... . 0 ..... 1
Fog Lam p Sw itch................. . Center of IP, R H o f Steering Colum n Shift L e v e r............. . 4 8 .... 6 3 .... 202-62
Front A xle Actuator............. . R F o f Front Drive A xle ................................................ . 1 9 .... 2 8 .... 202-62
Fuel Heater......................... . Top rear o f En gin e ...................................................... . 6 9 .... 90
Fuel Pump and Sender........... In Fuel T an k.............................................................. . 7 3 .... 97
Fuel Pum p Balance M od ule ... . Inside L H Frame Rail, near Transm ission Crossm em ber...... . 6 9 .... 9 0 .... 202-63
GROUND DISTRIBUTION

Fuel Pump Balance Relay On Fuel Pump Balance M odule, inside L H Frame Rail, near
Transm ission Crossm em ber......................................... 69...... 90... 202-63
Fuel Pum p R e la y ................. In Underhood Fuse-Relay Center, L R of Engine

Compartment, on Fender............................................ 6 .... .. 10
G low Plug R elay.................. L R of Engine, near Bulkhead........................................ 22...... 29

Sw itch............................. Low er L H o f I P .......................................................... 32...... 43... 202-34
Headlamp, H igh Beam, L H

(Com posite)...................... L F of vehicle.............................................................. 4 .... .. 8
Headlamp, H igh Beam, R H

(Com posite)...................... R F of vehicle.............................................................. 4 .... .. 7
Headlamp, High/Low Beam,

L H ................................. L F o f vehicle.............................................................. 4 .... .. 8

R H ................................. R F of vehicle.............................................................. 4 .... ... 7
Headlamp, Low Beam, L H

(Com posite)...................... L F of vehicle.............................................................. 4 .... .. 8
Headlamp, Low Beam, R H

(Com posite)..................... R F of vehicle.............................................................. 4 .... .. 7
Heated M irror R e la y ............. O n Convenience Center................................................ 5 3 ..... 68

(H 0 2 S )............................ In Exhaust Pipe, in front and back o f Catalytic Converters... 15 ..... 19..., 202-64
Horn, L H ........................... A t front of vehicle....................................................... 4 ....... 8
Horn, R H ........................... A t front of vehicle....................................................... 4 .... ,. 7
H V A C Control M od ule......... Part of Heater Controls, center of IP, under R adio.............. 5 3 ...,. 68.... 202-35
Ignition Control M od ule ........ R R o f E n g in e ............................................................. 11... .. 15.... 202-64
Illum inated Vanity Mirror,

L H .................................. Part of L H Sunvisor..................................................... 5 5 ... „ 70
Illum inated Vanity Mirror,

R H ................................. Part of R H Su n viso r.................................................... 5 5 ... „ 70
Inflatable Restraint Front End

Discrim inating Se n so r........ Under front outside center of Radiator............................ 0 ..... . 2 .... 202-65
Inflatable Restraint IP
M o d u le ........................... R H of IP, above IP Compartment B o x ............................ 4 3 ... . 56

Diagnostic M odule (SDM ).... A t L F D oor S il l .......................................................... 3 9 ... . 51.... 202-37
Instrument C luster................ Upper L H end o f IP, above Steering C olum n.................... 3 2 ... . 43.... 202-38

M o d u le ........................... Under center of I P ....................................................... 3 8 ... . 50.... 202-66
IP Compartment B o x L am p ... In IP Compartment B o x ................................................ 4 2 ... . 54
License Lam ps, L H / R H .......... Rear o f vehicle, at License H older............................ ..... 7 4 ... . 98

Liftgate Defogger G rid .......... O n Liftgate G la ss................................................... .... 7 7 .... 103
Liftgate Release Sw itch .......... Center of IP, L H o f Radio

M odule (D iesel)................. Under center o f I P ...................................................... 3 7 .... 4 9 .... 202-66
Low Coolant Level Sensor

(D ie sel)............................ In Coolant Reservoir, R H of Engine Com partm ent........ .... 3 7 .... 49
M arker Lam ps, Front............. Across top front of ve h icle ....................................... .... 4 ...... 7
M ass A ir Flow (M A F ) Sensor.. A t A ir Intake Duct, near A ir Filter, R H o f En gin e ........ .... 1 3 .... 19
M ode D oor M o to r................. Under IP, on L H o f H V A C Plenum ............................ .... 5 0 .... 6 5 .... 202-66
Overhead C o n so le ................. A t top center of W indshield Centerline........................ .... 5 3 .... 68
Park and 'R im Lam p, L F ....... A t L F comer o f vehicle..................... ......... ............ .... 4 ...... 8
Park and Turn Lam p, R F ....... A t R F comer of vehicle........................................... .... 4 ...... 8

Switch, Connector C l ......... A t L H center of T ransm ission................................... ... : 2 3 .... 3 1 .... 202-67

Switch, Connector C 2 ......... A t L H center of T ransm ission................................... .... 2 3 .... 3 1 .... 202-67
Power A m plifier................... Under L H of IP, R H of Brake Pedal Bracket............... .... 3 4 .... 5 7 .... 202-40
Power Am plifier R e la y .......... Under L H of IP, R H o f Brake Pedal Bracket............... .... 3 4 .... 5 7 .... 202-67
Power Outside Rearview M irror

Motor, L H ........................ O n L F Door, near center of A P illa r.......................... .... 6 1 .... 7 9 .... 202-66,
67
Power Seat Adjuster Sw itch.... In L F Seat, on bottom, mounted to frame.................... .... 6 3 .... 81.... 202-68
Power Seat Lum bar Motor,

L F .................................. Under L F Seat, mounted to Seat fram e....................... .... 63 .... 81

R F .................................. Under R F Seat, mounted to Seat fram e....................... .... 6 3 .... 81

L F .................................. O n lower L F of L F Seat.......................................... .... 6 3 .... 81

R F .................................. O n lower R F of R F Seat.......................................... .... 6 3 .... 81

Sw itch............................. O n L F Door, below Inside D oor H andle..................... .... 6 1 .... 7 9 .... 202-37,
68

(P C M )............................. Under R H end of IP, above Blow er Motor, behind IP
Compartment B o x ................................................ .... 3 7 .... 49
Power W indow Switch, L F ..... O n L F D oor Trim Panel, below Inside D oor H andle...... .... 6 1 .... 7 9 .... 202-30
Power W indow Switch, R F ..... O n R F D oor Trim Panel, below Inside Door handle...... .... 6 1 .... 7 9 .... 202-31
Radio, Connector C l ............. Center of IP ............................................................... 3 5 .... 4 6 .... 202-43
Radio, Connector C 2 ............. Center of IP ........................................................... .... 3 5 .... 4 6 .... 202-44
Recirculation D oor M otor....... Under IP, on H V A C Plenum ..................................... .... 5 0 .... 6 5 .... 202-69
GROUND DISTRIBUTION

Receiver........................... Under center o f IP, R H o f Knee B olste r....................... .... 2 7 .... 43 .... 202-45
Seat Belt Switch, L H ............. A t L F Stationary Belt Connector................................. .... 5 6 .... 72
Seat Belt Switch, R H ............ A t R F Stationary Belt Connector................................. .... 5 6 .... 72
Secondary Fuel Gauge Sender.. Behind R H side of IP, near P C M
Selectable 4 W D Indicator
Lam p............................... Part o f Transfer Case Selector L e ve r............................ .... 5 2 .... 67
Spotlamp, L H (Z56).............. Mounted in L H A Pillar, near W indshield..................... .... 4 6 .... 60
Spotlamp, R H (Z 5 6 ).............. Mounted in R H A Pillar, near W indshield............. ....... ..... 4 6 .... 60
Spotlamp R e la y .................... Behind IP, near Convenience Center.............................
Starter R e lay........................ In Underhood Fuse-Relay Center, L R of Engine

Stoplamp R e la y .................... In Underhood Fuse-Relay Center, L R of Engine

Compartment, on Fender......................................... ..... 5 ...... 9
Tail/Stop-Ttim Lamp, L R
Cab/Chassis...................... L R comer o f vehicle...................................................... 7 3 .... 9 7 .... 202-66
Tail/Stop-T\im Lam p, L R
Pickup/Utility.................... L R comer o f vehicle...................................................... 7 4 .... 9 9 .... 202-66
Tail/Stop-Tum Lam p, R R
Cab/Chassis...................... R R comer o f vehicle................................................. .... 7 3 .... 9 7 .... 202-66
Pickup/Utility.................... L R comer o f vehicle.................................................. ... 7 4 .... 9 9 .... 202-66
Temperature D oor M o to r........ Under IP, on center of H V A C Plenum ........................... ... 5 0 .... 65.... 202-69

(T C C M )........................... Under IP, on Steering Colum n Support Bracket............... ... 3 8 .... 5 0 .... 202-46

Illum ination L a m p .............. In Transfer Case Select Sw itch.................................... ... 4 8 .... 63
Transfer Case R e lay.............. R R o f Engine Compartment, near center of Bulkhead...... ... 2 3 .... 3 0 .... 202-70
Transfer Case Select Sw itch.... Center o f IP, R H of Steering Colum n Shift L e ve r........... ... 4 8 .... 6 3 .... 202-48
Transm ission Range Switch,

Connectors C l and C 2 ........ L H o f Transm ission................................................... 202-70
T\im/Hazard Flasher.............. Mounted to Convenience Center, under L H o f IP, L H of

Steering Column, on Bulkhead.................................. ... 3 3 .... 44 .... 202-56
Underhood Fuse-Relay Center.. L R of Engine Compartment, on Fender......................... ... 5 ...... 9
Underhood Lam p.................. Under R H of H o o d ................................................... ... 7 ...... 12
Underhood Reel Lam p........... R H of Engine Compartment, on Bulkhead

( V C M ) ............................. Engine Compartment, near E B C M ................................ ... 3 7 .... 48

(D ie sel)............................ Under R H of I P ....................................................... ... 3 7 .... 49.... 202-70
W ater-in-Fuel Sensor (D ie se l)... Top rear of Engine.................................................... ... 1 9 .... 23

Water Valve (4-Door

Utility/Suburban)................ Engine Compartment, R R of Inner Fender
W indow Defogger Grid,

R e a r................................ On Rear W indow ......................................................... 5 8 .... 76
W indow Lockout Switch,

R e a r................................ L F Door, below Inside D oor Handle, part of Power W indow
Master Sw itch .......................................................... 6 1 .... 7 9 .... 202-69
W indow Washer Pump Motor,

R e a r................................ In Washer Reservoir, R F of vehicle, behind support........... 5 ..... 10
W indow W iper M otor Module,

R e a r................................ On lower Liftgate g la ss................................................ 7 1 .... 93
W indshield Washer Pump

M o to r.............................. A t W asher R eservoir.................................................... 7 ..... 11

M odule............................ A t center and rear of Engine Compartment, at Bulkhead..... 4 ..... 8 ..... 202-70

R e a r................................ Center of IP, R H of R a d io ............................................ 4 9 .... 6 4 .... 202-69
Sw itch............................. A t Steering Column, part of M ultifunction Lever............... 4 7 .... 61
C O N N EC T O R S:

at B ulkhead ............................................................. 4 ..... 8 ...... 202-0
C 1 0 2 .................................. Forward Lam ps Harness to IP Harness, L R o f Engine

Compartment, near Underhood Fuse-Relay Center,
mounted on Fender................................................... 4 ..... 8 ..... 202-2


Transm ission............................................................ 2 5 .... 3 4 .... 202-49
C 1 1 0 .................................. IP Harness to S IR Arm ing Sensor, L R of Engine

Compartment, near C l 0 2 ........................................... 3 1 .... 4 2 .... 202-49
C 1 1 6 .................................. L F of vehicle, near Core Support.................................... 7 ..... 11.... 202-49
C l 2 0 .................................. Engine Harness to Front Axle Actuator, rear of Engine, near

Transm ission............................................................ 2 7 .... 3 7 .... 202-50
C200 (D ie se l)...................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 .... 4 9 .... 202-11
C200 (G a s)......................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 .... 49 .... 202-10
C 2 0 3 .................................. Behind R H of IP, near Heater Motor, in foam w rap........... 5 0 .... 6 5 .... 202-50
C 2 0 7 .................................. Inside lower L H A Pillar............................................... 6 1 .... 7 9 .... 202-51
C 2 1 0 .................................. A t Convenience Center................................................. , 3 3 .... 44 .... 202-51
C 2 1 1 .................................. Under L F Seat............................................................ 6 5 .... 83.... 202-52
C 2 1 2 .................................. Under L F Seat............................................................ 6 5 .... 83.... 202-52

8 A - 14 - 26 E L E C T R IC A L D IA G N O S IS
G R O U N D D IS T R IB U T IO N
C 2 1 5 .............................. ... Inside lower R H A P illa r............................................... 6 1 .... 7 9 .... 202-52
C 2 1 6 .............................. ... Inside lower R H A P illa r............................................. .. 5 5 .... 7 0 .... 202-52
C 2 2 0 .............................. ... A t Convenience Center................................................. . 3 3 .... 44
C 22B .............................. ... Crossbody Harness to R F Seat Belt Switch, under R F Seat . 6 5 .... 83.... 202-54
C 2 3 2 .............................. ... IP Harness to S IR Harness, behind R H o f IP ..................... 5 5 .... 7 0 .... 202-54
C 2 4 0 .............................. ... Crossbody Harness, approx. 100 cm from Seat Belt Switch
Breakout.................................................................. 6 5 .... 83.... 202-55
C 2 6 6 .............................. ... IP Harness to Steering Colum n Harness, L H of Steering

Colum n, near Bulkhead............................................... 3 2 .... 43.... 202-14
C 2 7 1 .............................. ... In-line to Spotlamps (Z56, Police Package)...................... 202-16
C 3 0 0 .............................. ... In Overhead Console.................................................... , 3 6 .... 61 .... 202-55
C 3 0 1 .............................. ... A t L F K ic k Panel........................................................ , 4 7 .... 62 .... 202-20,

56
C 4 0 0 .............................. ... R R of vehicle, above Auxiliary Blow er M o to r.................. , 6 6 .... 85 .... 202-56
C 4 0 2 .............................. ... Top center rear o f vehicle............................................. 4 1 .... 6 7 .... 202-57
C 4 0 4 .............................. ... Top of L H D P illar....................................................... 4 5 .... 7 4 .... 202-57
C 4 0 5 .............................. ... Top of R H D Pillar...................................................... 4 5 .... 7 4 .... 202-57
C 4 0 6 .............................. ... Top of R H D Pillar...................................................... 6 8 .... 87 .... 202-57
C 4 0 7 .............................. ... Beneath L R edge of b e d ............................................... 7 4 .... 9 9 .... 202-57
C408 (Pickup/Cab)............ ... Beneath center rear edge of bed..................................... 7 4 .... 9 9 .... 202-57
C408 (Suburban/Utility)...... ... Low er center outside of Endgate.................................... 7 4 .... 9 9 .... 202-57
C 4 1 1 .............................. ... A t L R of cab.............................................................. 7 0 .... 9 1 .... 202-58
C 4 9 6 .............................. ... In R H B Pillar............................................................ 6 2 .... 80.... 202-58
C 4 9 8 .............................. ... L H B P illar................................................................ 6 2 .... 80.... 202-59
D IO D E :
D 10 4 (4 .3L)..................... ... Engine Harness, approx. 16 cm from A/C Compressor

Clutch Connector...................................................... 1 0 .... 14
D 10 4 (5.0L, 5.7 L )............. ... Engine Harness, approx. 10 cm from A/C Compressor
D 10 4 (6 .5L)..................... ... Engine Harness, approx. 28 cm from A/C Compressor

D 10 4 (7 .4L)..................... ... Engine Harness, approx. 8 cm from A/C Com pressor Clutch
Connector............................................................... 1 6 .... 20
GROMMETS:
P 1 0 0 .............................. ... L R o f Engine Compartment, at Bulkhead......................... 4 ...... 8
P 1 0 1 .............................. ... R R o f Engine Compartment, at Bulkhead......................... 7 ...... 12
P 4 0 0 .............................. ... Top rear of body, at R H Liftgate H in g e ........................... 7 1 .... 93


G R O U N D S:
G 101................. Sheet metal at R F W heelhousing..................... 2 .... .. 5
G102 (G a s)........ R F of Engine Block, near Dam per P u lle y......... 2 .... .. 5
G102 (D ie sel)..... L F of Intake M an ifold .................................. 1 .... .. 4
G103 (G a s)........ R F of Engine, near Thermostat H o u sin g .......... 14...... 18
G104(Gas, Diesel) R H top center of Cylinder Head..................... 16.... .. 20
G105 (G a s)........ R F of Engine block...................................... 1 3 ..... 17
G105 (D ie se l)..... R F of Engine block...................................... 1 3 ..... 17
G 110.................................. R R of Engine Compartment, below Heater Lines 1 6 ..... 20
G i l l .................................. R R of Engine.............................................. 1 6 ..... 20
G 112.................................. R F of Engine Compartment, at W heelhousing... 2 .... .. 5
G 113.................................. O n Radiator Support, near L H Headlam p......... 4 .... .. 8
G 115.................................. A.I.R. Pump Ground, mounted on Frame R a il... 9 .... .. 14
G 150.................................. R F of Engine, near Thermostat H o u sin g .......... 1 4 ..... 18
G 200.................................. Behind L H of IP, below Fuse Block, on Tie Bar 3 2 ..... 43
3201 ............................. Behind L H of IP, below Fuse Block, on Tie Bar 3 2 ..... 43
3202 ............................. R H o f IP, mounted to H V A C Plenum Bracket... 5 0 ..... 65
G 400.................................. R H B Pillar, near D oor Striker....................... 5 8 ..... 76
G 401.................................. Rear of L H Frame Rail, behind Bum per.......... 7 3 ..... 96
G 404.................................. Inside L H Frame Rail, near rear Crossmember.... 7 3 ..... 96
G 451.................................. A t Platform H itch........................................ 7 4 ... .. 99
S P L IC E S :
S103 (5.0L - H D , 5.7L - H D ).. Engine Harness, approx. 13 cm from E G R Valve Breakout,
S103 (5.0L - L D , 5.7L - LD)... Engine Harness, approx. 8 cm from E G R Valve Breakout,
S103 (6.5L) Engine Harness, approx. 12 cm from Starter Solenoid

Breakout
S103 (7.4L - A/T) Engine Harness, approx. 34 cm from Fuel Injector Breakout,
S I 03 (7.4L - M /T )................ Engine Harness, approx. 12 cm from E G R Breakout
S I 07 (4.3L) ........................ Engine Harness, approx. 25 cm from E G R Valve Breakout,

S I 07 (5.0L, 5.7L) ................ Engine Harness, approx. 35 cm from E G R Valve Breakout,

V toward Taillamp Harness Breakout
5107 (6.5L, H D ) .................. Engine Harness, approx. 30 cm from E B C M Breakout,

toward E G R Valve Breakout
S I 07 (6.5L, L D ) ................... Engine Harness, approx. 24 cm from E B C M Breakout,

GROUND DISTRIBUTION

S107 (7.4L) ........................ Engine Harness, approx. 18 cm from E B C M Breakout,
S 1 2 3 .................................. Forward Lam ps Harness, approx. 20 cm from L H Park

Lam p Breakout, toward W indshield Washer Pump
S 1 2 8 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp

Breakout, toward G112
S I 47 (4.3L) ........................ Engine Harness, approx. 5 cm from Fuel Injector Breakout,

toward A/C Com pressor Clutch Breakout
S147 (6.5L) ........................ Engine Harness, approx. 4 cm from Starter M otor Solenoid
Breakout
S I 47 (7.4L) ........................ Engine Harness, approx. 5 cm from E G R Valve Breakout
S I 49 (w/Leaded Fuel)............ O xygen Sensor Harness, approx. 7 cm from R H Bank

O xygen Sensor Breakout, toward L H Bank O xygen
Sensor
S I 49 (w/o Leaded Fuel)......... Approx. 25 cm into O xygen Sensor Harness
S156 (4.3L, 5.0L - M/T, 5.7L -

M/T, 7.4L - M / T ).............. Engine Harness, approx. 16 cm from V S S Connector
S I 56 (5.0L, 5.7L - A/T, H D )... Engine Harness, approx. 12 cm from V S S Connector
S156 (5.0L, 5.7L - A/T, LD).... Engine Harness, approx. 20 cm from V S S Connector
S156 (7.4L - A/T)................. Engine Harness, approx. 23 cm from V S S Connector
S 1 5 8 .................................. In W asher Pump Jumper Harness
S162 (4.3L, 5.0L, 5.7L - L D ) .. Engine Harness, approx. 17 cm from Starter Solenoid
Breakout, toward L H Oxygen Sensor Breakout
S162 (5.0L -H D , 5.7L - H D ) ... Engine Harness, approx, 43 cm from L H O xygen Sensor
Breakout, toward Starter Solenoid Breakout
S162 (7.4L - A/T)................. Engine Harness, approx. 40 cm from L H O xygen Sensor

S162 (7.4L - M /T )................ Engine Harness, approx. 15 cm from R H Bank O xygen

Sensor Breakout, toward Starter Solenoid Breakout
S I 67 (A ll Except Z56, Police

Package).......................... Engine Harness, approx. 18 cm from G115
S I 67 (Z56, Police Package

O n ly)............................... Battery Harness, approx. 35 cm from C l 21
S185 (4.3L, 5.0L, 5.7L) ..... Engine Harness, approx. 41 cm from E G R Breakout, at
Diode D 10 4
S I 85 (6.5L) ........................ Engine Harness, approx. 28 cm from A/C Com pressor ,

Clutch Connector, at Diode D 10 4
S185 (7.4L) ........................ Engine Harness, approx. 17 cm from A/C Com pressor
Clutch Connector, at Diode D 104

S I 86 (4.3L, 5.0L, 5.7L) ........ Engine Harness, approx. 41 cm from E G R Breakout, at
Diode D 104
S I 86 (6.5L) ........................ Engine Harness, approx. 28 cm from A/C Com pressor

S186 (7.4L) ........................ Engine Harness, approx. 17 cm from A/C Com pressor

Breakout
S215 (D iesel)....................... IP Harness, approx. 8 cm from Instrument Cluster Breakout,

S215 (G as).......................... IP Harness, approx. 12 cm from Instrument Cluster

Breakout, toward Radio Connectors Breakout

Breakout
S 2 4 4 .................................. H V A C Harness, approx. 8 cm from Recirculation D oor

Breakout, toward H igh Blow er M otor Relay
S 2 5 1 .................................. Crossbody Harness, approx. 13 cm right o f L F D oor

Harness Breakout, toward IP Harness Breakout
S 2 5 9 .................................. Crossbody Harness, approx. 7 cm into Seat Belt Switch,

toward C299
S 2 9 8 .................................. IP Harness, approx. 24 cm from Instrument Cluster

Breakout, toward Radio Breakout
S 3 0 2 .................................. Selectable 4 W D Harness, approx. 10 cm from Transfer Case

Relay Breakout, toward Front A xle Switch

Suburban)......................... Rear H V A C Control Harness, approx. 10 cm from A u xilia iy
5316 (Suburban/Crew
Cab/Utility)....................... Illuminated Vanity M irror Jumper Harness, approx. 11 cm
toward L H Illuminated Vanity M irror
5317 (G as).......................... Taillamp Extension Harness, approx. 10 cm from Fuel Pum p

and Sender Breakout, toward Engine Harness
S317 (D iesel)....................... Taillamp Extension Harness, approx. 10 cm from Fuel Pum p

S319 (G as).......................... Taillamp Extension Harness, approx. 7 cm from Fuel Pump

and Sender Breakout, toward balance Fuel Pum p Balance
M odule Breakout
S403 (w /Auxiliary H V A C ) ...... Auxiliary H V A C Harness, approx. 7 cm from Blow er M otor

Resistor Breakout, toward Blow er M otor
S410 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 37 cm from R R D oor

Jamb Switch Breakout, toward R H D oor Speaker
Breakout
8A - 14 - 30 ELECTRICAL DIAGNOSIS____________________________________ __________
GROUND DISTRIBUTION

Suburban)......................... Front-to-Rear B od y Harness, approx. 12 cm from R R Door
Speaker Breakout, toward R R D oor Jamb Breakout
5410 (Suburban w/o C 69

w /ZW 9)........................... Front to rear B od y Harness, approx. 22 cm from R H rear
D oor Speaker Breakout, toward R R D oor Jamb Switch
5411 (Chassis C ab )............... Taillamp Harness, approx. 33 cm from Taillamp Extension

Harness Breakout
S411 (Fleetside/Stepside)........ Taillamp Harness, approx. 17 cm from Taillamp Extension

Harness Breakout, toward L H Taillamp
S411 (Suburban/Utility).......... Taillamp Harness, approx. 7 cm from Taillamp Trailer Tow

Harness Breakout, toward R H Taillamp
S 4 1 6 .................................. License Lam ps Harness, approx. 4 cm from Taillamp

Harness Breakout, toward R H License Lam p
S4 2 4 (2- D oor U tility)........... Front-to-Rear B od y Harness, approx. 15 cm from C H M S L

Breakout

Suburban)......................... Front-to-Rear B od y Harness, approx. 10 cm from C H M S L
Breakout
S 5 0 0 .................................. Inside L F D oor Harness, approx. 8 cm from Tweeter

Speaker Breakout, toward L F W indow Regulator............ 6 1 .... 79
S 5 0 6 .................................. Inside Power Outside Rearview M irror Harness, approx.

7 cm from Power Outside Rearview Mirror, toward C501
AUXILIARY BATTERY
[
HOT AT ALL TRIES
1
TT‘ ” IP
OG LTR 1FUSE
|BLOCK
i x >FUSE 13
■ s 20 A 1
1(3* 1
L - I■— — — J
A ORN |6 4 0
SEE FUSE
£264 #•m m m mma BLOCK DETAILS
PAGE S A -1 1 -1 2
.8ORN I 640
l
r - y 1 LfTGATE
I P 1 RELEASE
| 1 | SWITCH
l _
~ EHONE
GROUND
03-19-97
4208W0684

Auxiliary Battery.................. L F of Engine Compartment............................................. 1 ..... 4
Auxiliary Battery R e la y .......... L R of Engine Compartment, on Fender, near Underhood

Fuse-Relay Center..................................................... 5 ...... 9
IP Fuse B lo ck ...................... L H o f IP, near L F D oor Jamb Sw itch ............................. 3 2 .... 43
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender.................. ......... 5 ...... 9
G R O M M ETS:
P 1 0 0 .................................. L R of Engine Compartment, at Bulkhead......................... 4 ... . 8
G R O U N D S:
G 107.................................. L H front Fender (A uxiliary Battery Ground)
S P L IC E S :
5141 .............................. Auxiliary Battery Harness, approx. 18 cm from Underhood

Fuse-Relay Center
5142 .............................. Auxiliary Battery Harness, approx. 18 cm from Underhood

Fuse-Relay Center
S235 (D iesel)....................... IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
S235 (G as).......................... IP Harness, approx. 8 cm from Steering Colum n Harness

Breakout
CRUISE CONTROL
GASOLINE ENGINE
03-25-97
420BW2216
CRUISE
CONTROL
MODULE
STOPLAMP SPEED
SWITCH STO PLAM P/auTC H SENSOR
INPUT SWITCH INPUT INPUT VCM SIGNAL GROUNO
03-11-87
4208W0651
CRUISE CONTROL
DIESEL ENGINE
HOT IN RUN HOT AT ALL TIMES HOT IN RUN
M8 '
BRAKE STQP/HAZ CRUISE POWERTRAIN
FUSE 18 FUSE 1 FUSE 6 CONTROL
10 A 20 A 10 A MODULE
N3<> C7 I N7 (PCM)
I 1 440 ^ SEE FUSE
BLOCK DETAILS ENGINE
PAGE 8 A -1 1 -2 7
CONTROLS
.33 BRN 441 1 ORN 140
SEE FUSE
BLOCK OETAILS
PAGE B A -11-11
C13 A
SPEED
I CRUISE ON RES/ACCEL SET/COAST SIGNAL
INPUT SIGNAL SIGNAL INPUT
) • S299
A iiy » c 2 oioyct b 1,V - a3 'Y ’
.35 BRN
41 I .5 GRY/8LK I 87 I .5 BRN I 4.
.5 CRY I 397 I -5 OK BLU I 84 I
K ' ■ / C204 C ' l ' ______ ? v l / _ _ ^ v l /
Ely0.5 PPL I 420

Cl
r — — n ELECTRONIC BRAKE A
I I CONTROL MODULE (EBCM)
03-25*97
C — — J ABS CONTROLS 4200W0652

Clutch Pedal Position Switch.... A t top o f Clutch Pedal................................................ . 4 1 .... 5 3 .... 202-61
Cruise Control M odule (C C M ). L R of Engine Compartment, on Bulkhead........................ . 3 1 .... 4 2 .... 202-29
Cruise Control Sw itch............ In Turn Signal L e v e r................................................... . 4 7 .... 61

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing............. . 6 ...... 10
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. . 3 2 .... 43
Powertrain Control M odule Under R H end of IP, above Blow er Motor, behind IP
(P C M )............................. Compartment B o x .................................................... . 3 7 .... 49
Stoplamp Switch................... Top o f Brake Pedal..................................................... . 4 4 .... 5 7 .... 202-70
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender........................... . 5 ...... 9
Vehicle Control M odule (V C M ) Engine Compartment, near E B C M ................................. . 3 7 .... 48

(D ie sel)............................ Under R H of IP .......................................................... . 3 7 .... 4 9 .... 202-70
C O N N EC T O R S:

at Bulkhead............................................................ . 4 ...... 8 ...... 202-0
C200 (D ie se l)...................... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-11
C200 (G a s)......................... Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-10
C 204 (D ie se l)...................... Behind R H of IP ........................................................ . 3 7 .... 4 9 .... 202-12
C227 (Stoplamp Sw itch)......... A t Convenience Center................................................ .. 4 4 .... 5 7 .... 202-70
Colum n, near Bulkhead............................................. .. 3 2 .... 4 3 .... 202-14
G R O M M ETS:
P 1 0 0 .................................. L R o f Engine Compartment, at Bulkhead......................... . 4 ........ 8

P 1 0 1 .................................. R R o f Engine Compartment, at B ulkhead ........................ , 7 ....... 12
G R O U N D S:
G103 (G a s)......................... R F of Engine, near Thermostat H o u sin g .......................... „ 1 4 .... 18

G 104.................................. R H top center of Cylinder Head..................................... 1 6 .... 20
S P L IC E S :
S101 (4.3L, 5.0L - L D , 5.7L -

L D , 7.4L - M /T)................ Engine Harness, approx. 12 cm from E B C M Breakout
S101 (5.0L - H D , 5.7L - H D ,

7.4L - A / T )...................... Engine Harness, approx. 15 cm from E B C M Breakout
S101 (6.5L) ........................ Engine Harness, approx. 5 cm from Starter Solenoid

Breakout
CRUISE CONTROL

S103 (6.5L) Engine Harness, approx. 12 cm from Starter Solenoid
Breakout
S103 (7.4L - A/T), Engine Harness, approx. 34 cm from Fuel Injector Breakout,
S103 (7.4L - M / T )................ Engine Harness, approx. 12 cm from E G R Breakout
S I 52 (4.3L, 5.0L - L D , 5.7L -

L D , 7.4L) ........................ Engine Harness, approx. 7 cm from E B C M Breakout
S I 52 (5.0L - H D , 5.7L - H D).. Engine Harness, approx. 13 cm from E B C M Breakout
S I 52 (6.5L) ........................ Engine Harness, approx. 4 cm from IP Harness Breakout,

toward P101
S 1 5 3 .................................. IP Harness, approx. 13 cm from P100, toward C C M


5220 .............................. IP Harness, approx. 6 cm from Steering Colum n Harness

Breakout, toward C l 00
5221 .............................. IP Harness, approx. 40 cm from Instrument Cluster

Breakout
S222 IP Harness, approx. 20 cm from Inflatable Restraint Switch

Breakout
S299 IP Harness, approx. 4 cm from Steering Colum n Harness

DIAGNOSIS - CRUISE CONTROL

TROUBLESHOOTING HINTS: follow ing the placement o f the Ignition Sw itch in
1. C H E C K condition of B R A K E Fuse 18, ST O P /H A Z R U N before enabling Cruise Control operations.
Fuse 1, C R U IS E Fuse 6, and E C M -B Fuse (Diesel 5. Loose, binding, or poorly adjusted Cruise Control
Engines only). If any fuse is open, L O C A T E and Linkage for G asoline Engines may induce erratic
R E P A IR cause o f overload and R E P L A C E fuse. operation. C H E C K that throttle linkage is properly
2. C H E C K that G rounds G 104 and G 103 (G asoline installed and adjusted. Refer to C ru ise C on trol
Engines only) are clean and tight. Section.
3. C H E C K for Diagnostic Trouble Codes (D T C s) which 6. If the Cruise Control is engaged, and the vehicle
would impact operation of Cruise Control. Refer to the continually accelerates, L O C A T E and R E P A IR short
Driveability and Em issions section for the specific to voltage on G R Y / B L K (87) wire between Cruise
engine type for repair procedures. Control Sw itch and Cruise Control M odule (Gasoline
4. If the C ru ise Control is reported as inoperative, Engines) or P C M (Diesel Engines). T his condition
C H E C K that the Stoplamp Switch to Cruise Control w ill generate D T C 76 with Diesel Engines.
M od u le input is functioning properly. T h is input 7. If either the S E T C R U IS E Pushbutton or the R/A
function requires that the Cruise Control M odule Sw itch Contact are held in place for over 25.5
(G asoline En gin es) or Pow ertrain Control M odule seconds, the C ru ise C o n tro l System w ill cease
(P C M , D ie se l E n gin e s) receive a brake-on input operating. The engine must be turned O F F to reset this
input.
8. R E F E R to E N G IN E C O N T R O L S for the appropriate • C H E C K for a broken or partially broken wire inside

gasoline engine to address any diagnostics related to the insulation which could cause system malfunction
opens or shorts on the V C M signal from the L T but prove G O O D in a Continuity/Voltage check with a
B L U / B L K (396) wire. sy ste m d isc o n n e c te d . T h e se c irc u its m ay be
9. If the S E T C R U IS E Pushbutton w orks w ith the intermittent or resistive when loaded, C H E C K by
O FF-O N -R /A Sw itch in the O F F position, C H E C K for m onitoring for a voltage drop w ith the system
a short to voltage on the G R Y (397) wire between the operational (under load).
Cruise Control Sw itch and the Cruise Control M odule • C H E C K fo r proper in sta lla tio n o f afterm arket
(Gasoline Engines) or the P C M (Diesel Engines) electronic equipment which may affect the integrity of
other systems. See Troubleshooting Procedures.
GASOLINE ENGINE CRUISE CONTROL IS INOPERATIVE

TEST RESULT ACTION
1. Verify that no Diagnostic Trouble Test lamp lights. G O to Step 2.
C o d e s (D T C s ) are set w hich Test lamp does not light. L O C A T E and R E P A IR open in the
w ou ld im pact C ru ise C o n tro l B R N (41) wire between IP Fuse Block
operations. Disconnect Connector and Cruise Control Module.
at Cruise Control Module. Place
Ignition Switch in R U N . Connect
test lamp between Cruise Control
M odule Connector Cavity F B R N
(41) wire and ground.
2. Connect self-powered test lamp Test lamp lights. G O to Step 3.
between Cruise Control M odule Test lamp does not light. L O C A T E and R E P A IR open in
C o n n e c t o r C a v it y E fo r B L K / W H T (451) wire between Cruise
B L K / W H T (451) wire and ground. Control M odule and Ground
G103/G104.
3. Place Cruise Control Sw itch in Test lamp lights. G O to Step 6.
O N . Connect test lam p between Test lamp does not light. G O to Step 4.
Cruise Control M odule Connector
Cavity A for G R Y (397) wire and
ground C266.
4. D isc o n n e c t C o n n e c to r at the Test lamp lights. G O to Step 5.
Steering C olum n. C onnect test Test lamp does not light. L O C A T E and R E P A IR open in B R N
lamp between Connector C 266 Pin (41) wire between IP Fuse Block and
A 1 3 fo r B R N (4 1 ) w ire and Connector C266.
ground.
5. Connect self-powered test lamp Test lamp lights. L O C A T E and R E P A IR open in G R Y
between Connector C 266 Cavity (397) wire between Connector C266
A 13 for B R N (41) pigtail wire and and Cruise Control Module.
Cavity A 1 2 for G R Y (397) pigtail Test lamp does not light. L O C A T E and R E P A IR open in B R N
wire at Cruise Control Switch. (41) pigtail wire or in G R Y (397)
pigtail wire in the Steering Column. If
wires are good, R E P L A C E the Cruise
Control Switch.
6. Place the Cruise Control Switch in Test lamp lights. L O C A T E and R E P A IR short to voltage
OFF. Connect test lamp between in D K B L U (84) wire between the
Cruise Control M odule Connector Cruise Control Switch and the Cruise
Cavity B for D K B L U (84) wire Control Module.
and ground.
Test lamp does not light. G O to Step 7.
CRUISE CONTROL
TEST RESULT ACTION

7. Turn Cruise Control O N. Connect Test lamp lights. G O to Step 9.
test lamp between Cruise Control Test lamp does not light. G O to Step 8.
M odule Connector Cavity B for
D K B L U (84) wire and ground.
A c t u a t e th e S E T / C O A S T
pushbutton.
8. Disconnect Connector C266 at the Test lamp lights. L O C A T E and R E P A IR open in D K
S t e e r in g C o lu m n . C o n n e c t B L U (84) pigtail wire in the Steering
self-powered test lamp between Colum n. If wire is good, R E P L A C E
Cruise Control M odule Connector the Cruise Control Switch.
Cavity B and Connector C266 Pin Test lamp does not light. L O C A T E and R E P A IR open in D K
A 1 4 for D K B L U (84) wire. B L U (84) wire between Connector
C 266 and Cruise Control Module.
9. Connect test lamp between Cruise Test lamp lights. G O to Step 10.
Control M odule Connector Cavity Test lamp does not light. G O to Step 11.
G for W H T (17) wire and ground.
10. Disconnect Connector at Stoplamp Test lamp lights. A D JU S T or R E P L A C E Stoplamp Switch.
Switch. Connect self-powered test These contacts are supposed to be open
lamp at Stoplamp Switch between without the Brake Pedal being actuated
P ins E and F. Test lamp does not light. L O C A T E and R E P A IR short to voltage in
W H T (17) wire between the Stoplamp
Switch and Cruise Control Module.
G for W H T (17) wire and ground.
Actuate the Brake Pedal.
12. Disconnect Connector at Stoplamp Test lamp lights. A D J U S T or R E P L A C E Stoplamp
Switch. Connect self-powered test Switch.
lam p between Stoplam p Sw itch Test Lam p does not light. L O C A T E and R E P A IR open in W H T
Connector C avity F and Cruise (17) wire between Stoplamp Switch
Control M odule Connector Cavity and Cruise Control Module.
G for W H T (17) wire.
D for P P L (420) wire and ground.
14. Disconnect Connector at Stoplamp Test lamp lights. G O to Step 15.
Switch. Connect self-powered test Test lamp does not light. A D J U S T or R E P L A C E Stoplamp
lamp at Stoplamp Switch between Switch.
P ins D and C.
15. C o n n e c t te st la m p b e tw e e n Test lamp lights. L O C A T E and R E P A IR open in P P L
Stoplam p which Connector Cavity (420) wire between Stoplamp Switch
D for B R N (441) wire and ground. and Cruise Control Module.
Test lamp does not light. L O C A T E and R E P A IR open in B R N
(441) wire between IP Fuse Block and
Stoplamp Switch. A lso, C H E C K for
Diagnostic Test Codes related to the
Antilock Brake System.
16. C onnect D M M between C ruise A voltage is observed. G O to Step 17.
Control M odule Connector Cavity N o voltage. G O to Step 18.
K for D K G R N /W H T (817) wire
and ground.
TEST RESULT ACTION

17. Disconnect Connector C 4 at Vehicle Battery voltage. L O C A T E and R E P A IR short to voltage
Control M odule. Connect D M M in D K G R N /W H T (817) wire between
between Cruise Control M odule Cruise Control M odule and Vehicle
C o n n e c to r C a v it y K fo r D K Control Module.
G RN/W H T (817) wire and ground. N o voltage.
R E P L A C E Vehicle Control Module.
18. D isc o n n e c t C o n n e c to r C 4 at Test lamp lights. G O to Step 19.
Vehicle Control Module. Connect Test lamp does not light.
L O C A T E and R E P A IR open in D K
self-powered test lamp between
G R N /W H T (817) wire between Vehicle
Vehicle Control M odule Connector
Control M odule and Cruise Control
C 4 Cavity 3 and Cruise Control
Module.
M odule Connector Cavity K for
D K G R N /W H T (817) wire.
19. Connect self-powered test lamp Test lamp lights. L O C A T E and R E P A IR short to ground
between Cruise Control M odule in D K G R N /W H T (817) wire between
C o n n e c to r C a v ity K fo r D K Vehicle Control M odule and Cm ise
G R N / W H T (8 1 7 ) w ire an d Control Module.
ground.
20. Connect Connector C 4 at Vehicle Voltmeter does not respond. G O to Step 24.
C o n tro l M o d u le . P re p a re to Voltmeter indicates voltage of up to 5 G O to Step 21.
operate the vehicle at speed. Leave volts as a function o f speed.
the C r u is e C o n t r o l M o d u le
Connector disconnected. Connect
D M M between C ru ise C on trol
M odule Connector Cavity K for
D K G R N / W H T (817) wire and
ground. Operate the vehicle at
speed and observe for a voltage
between 0 and 5 volts depending
upon speed. Leave the Radio off.
21. Continue to operate the vehicle at Voltmeter indicates 0 volts. R E P L A C E Radio.
speed. H im on the Radio. Voltmeter indicates voltage up to 5 R E P L A C E Cm ise Control M odule
volts as a function o f speed. (AT). For M/T, G O to step 22.
22. Connect a test lamp from Pin C Test lamp lights. L O C A T E and R E P A IR open in
for the B R N /W H T (379) wire at B R N / W H T (379) wire between the
the Clutch Pedal Position Switch Clutch Pedal Position Sw itch and the
to ground. Cm ise Control Module.
23. Connect test lam p from C ruise Test lamp lights. L O C A T E and R E P A IR open in
Control M odule Pin D to Pin 22 at BR N /W H T (379) wire between the
V C M C o n n e c to r C 4 fo r the Clutch Pedal Position Switch and V C M .
B R N /W H T (379) wire. Test lamp does not light. R E P L A C E the Clutch Pedal Position
Switch.
24. Turn Ig n itio n Sw itch to O FF. Test lamp lights. L O C A T E and R E P A IR a short to ground
Disconnect V C M Connector C4. in L T B L U / B L K (396) wire between
Connect a self-powered test lamp Cruise Control Module and V C M .
from L T B L U / B L K (396) wire at
Cruise Control M odule Pin C to
ground.
25. H im Ignition Switch and Cruise Measured voltage above 4.5v. C H E C K for poor connections at V C M .
Control M odule to O N Connect a If O K , Replace V C M .
D M M from the D K G R N / W H T
Measured voltage below 4.5v. C H E C K for poor conections at Cm ise
(817) wire at V C M Connector C 4
Control Module. If O K , R E P L A C E
to ground.
Cm ise Control M odule .
8A - 3 4 ■ 8 ELECTRICAL DIAGNOSIS
CRUISE CONTROL
GASOLINE ENGINE CRUISE CONTROL DOES NOT DISENGAGE WITH THE ACTUATION
OF THE BRAKE PEDAL
TEST RESULT ACTION
1. Disconnect Connector at C ruise Test lamp remains illuminated. G O to Step 2.
Control M odule. Place Ign ition Test lamp turns OFF. R E P L A C E Cruise Control Module.
Sw itch in R U N . Connect a test
lam p betw een C ru ise C o n tro l
Connector Cavity D for P P L (420)
wire and ground. Observe that the
test lamp lights. Actuate the Brake
Pedal.
2. Disconnect Connector at Stoplamp Test lamp lights. L O C A T E and R E P A IR short to voltage
Switch. Connect test lamp between on P P L (420) or B R N A V H (3 7 9 ) wire
S to p la m p S w itc h C o n n e c to r between Stoplamp Switch and Cruise
Cavity C for P P L (420) wire and Control M odule, Electronic Brake
ground. Control M odule, Clutch Pedal Position
Switch or Vehicle Control Module.
Test lamp does not light. A D J U S T or R E P L A C E Stoplamp
Switch.
GASOLINE ENGINE CRUISE CONTROL WILL NOT RESUME/ACCELERATEflTAP-UP

TEST RESULT ACTION
1. Disconnect Connector at Cruise Test lamp lights. G O to Step 2.
C o n tro l M o d u le . D is c o n n e c t Test lamp does not light. L O C A T E and R E P A IR open in
C o n n e c to r C 2 6 6 at S te e rin g G R Y / B L K (87) wire between
Colum n. Connect self-powered test Connector C 200 and Cruise Control
lam p betw een C ru ise C o n tro l Module.
M odule Connector Cavity C and
C o n n e cto r C 2 6 6 P in A 1 5 fo r
G R Y / B L K (87) wire.
2. Place C ruise Control Sw itch in Test lamp lights. R E P L A C E Cruise Control Module.
O N . C onnect self-pow ered test Test lamp does not light. L O C A T E and R E P A IR open in
lam p between C onnector C 2 6 6 G R Y / B L K (87) pigtail wire in Steering
Cavity A 1 3 for B R N (41) pigtail Column. If wire is good, then
w ir e a n d C a v i t y A 1 5 f o r R E P L A C E the Cruise Control Switch.
G R Y / B L K (8 7 ) p ig ta il w ire .
Actuate the R/A position on the
Cruise Control Switch.
DIESEL ENGINE CRUISE CONTROL INOPERATIVE

TEST RESULT ACTION
1. Verify that no Diagnostic Trouble Test lamp lights. G O to Step 4.
C o d e s (D T C s ) are set w hich Test lamp does not light.
G O to Step 2.
w ou ld im pact C ru ise C o n tro l
operations. Place Ignition Switch
in R U N . Disconnect Connector C2
at Pow ertrain C ontrol M odule.
C o n n e c t te st la m p b e tw e e n
P o w e rtra in C o n t r o l M o d u le
C onnector C 2 C a v ity A l l for
G R Y (397) wire and ground. Place
Cruise Control Switch in O N.
2. D isconnect C onnector C 2 6 6 at Test lamp lights. G O to Step 3.
Steering Colum n. C onnect test
lamp between Connector C 266 Pin
A 1 3 fo r B R N (4 1 ) w ire and
Connector C200.
ground.
3. Connect self-powered test lamp Test lamp lights. L O C A T E and R E P A IR open in G R Y
between Connector C 266 Cavities (397) wire between Connector C266
A 13 for B R N (41) pigtail wire and and Powertrain Control Module.
A 12 for G R Y (397) pigtail wire. Test lamp does not light. L O C A T E and R E P A IR open in B R N
(41) pigtail wire or in G R Y (397)
pigtail wire in the Steering Column. If
wires are good, then R E P L A C E the
Cruise Control switch.
4. C o n n e c t te st la m p b e tw e e n Test lamp lights. G O to Step 6.
P o w e rt ra in C o n t r o l M o d u le
Connector C 2 Cavity B l l for D K
B L U (8 4 ) w ire and g ro u n d .
Actuate the S/C sw itch on the
5. D isconnect C onnector C 2 6 6 at Test lamp lights. L O C A T E and R E P A IR open in D K
S t e e r in g C o lu m n . C o n n e c t B L U (84) wire between Connector
self-powered test lamp between C 266 and Powertrain Control Module.
Connector C 266 Cavities A 13 for
Test lamp does not light. L O C A T E and R E P A IR open in D K
B R N (41) pigtail wire and A 1 4 for
B L U (84) pigtail wire in the steering
D K B L U (8 4 ) p ig t a il w ire .
column. If wire is good, then
Actuate the S/C sw itch on the
R E P L A C E the Cruise Control Switch.
P o w e rtra in C o n t r o l M o d u le Test lamp does not light.
G O to Step 8.
C onnector C 2 C a v ity B IO for
W H T (17) wire and ground.
7. Disconnect Connector at Stoplamp Test lamp lights. A D J U S T or R E P L A C E Stoplamp
Switch. Connect self-powered test Switch. T his contact is supposed to be
lam p between Stoplam p Sw itch open.
Pins F and E.
Test lamp does not light. L O C A T E and R E P A IR short to voltage
on W H T (17) wire between Stoplamp
Switch and Powertrain Control Module.
8. Actuate the Brake Pedal. Test lamp lights. G O to Step 11.
8A - 3 4 • 10 ELECTRICAL DIAGNOSIS
CRUISE CONTROL
TEST RESULT ACTION

9. Disconnect Connector at Stoplamp Test lamp lights. G O to Step 10.
Switch. Connect test lamp between Test lamp does not light. L O C A T E and R E P A IR open in O R N
S to p la m p S w itc h C o n n e c to r (140) wire between DP Fuse B lo ck and
Cavity E for O R N (140) wire and Stoplamp Switch.
ground.
10. Connect self-powered test lamp Test lamp lights. L O C A T E and R E P A IR open in W H T
between Stoplamp Switch Pins E (17) wire between Stoplamp Switch
and F. Actuate the Brake Pedal. and Powertrain Control Module.
Test lamp does not light. A D J U S T or R E P L A C E Stoplamp
Switch. T his contact is supposed to be
closed with the Break Pedal actuated.
11. C o n n e c t te st la m p b e tw e e n Test lamp lights. R E P L A C E Powertrain Control Module.
P o w e rt ra in C o n t r o l M o d u le Test lamp does not light. G O to Step 12.
Connector C 2 Cavity B 9 for P P L
12. Disconnect Connector at Stoplamp Test lamp lights. G O to Step 13 (A/T) or Step 14
Switch. Connect test lamp between (M/T).
Stoplam p Sw itch C a vity F for Test lamp does not light. L O C A T E and R E P A IR open in B R N
B R N (441) wire and ground. (441) wire between IP Fuse B lo ck and
Stoplamp Switch.
13. W ith a self-pow ered test lam p Test lamp remains on. A D J U S T or R E P L A C E Stoplamp
backprobe Stoplam p Sw itch P in s Switch.
E and F. O bserve that the test Test lamp turns OFF. L O C A T E and R E P A IR open in P P L
lam p lights. Actuate the Brake (420) wire between Stoplamp Switch
Pedal. and Powertrain Control Module.
14. Connect test lamp from P P L (420) Test lamp lights. G o to Step 15.
wire at Clutch Pedal Sw itch to Test lamp does not light. L O C A T E and R E P A IR open in the
ground. P P L (420) wire between Stoplamp
Switch and Clutch Pedal Position
Switch.
15. C o n n e c t te st la m p fro m the Test lamp lights. L O C A T E and R E P A IR open in BRN /
B R N / W H T (379) wire at Clutch W H T (379) wire between the Clutch
Pedal Position Sw itch to ground. Pedal Position Switch and the P C M .
Test lamp does not light. R E P L A C E Clutch Pedal Position Switch.
DIESEL ENGINE CRUISE CONTROL DOES NOT DISENGAGE WITH THE ACTUATION OF
THE BRAKE PEDAL
TEST RESULT ACTION
1. D is c o n n e c t C o n n e c to r C 2 at Test lamp remains on. G O to Step 2.
P o w e rt ra in C o n t r o l M o d u le Test lamp turns OFF. R E P LA C E PCM .
(P C M ). Place Ignition Sw itch in
R U N . Connect test lamp between
P C M Connector C 2 P in B 9 for
P P L (4 2 0 ) w ire and gro u n d .
Observe that the test lamp lights.
Actuate the Brake Pedal.
2. Disconnect Connector at Stoplamp Test lamp lights. L O C A T E and R E P A IR short to voltage
Switch. Connect test lamp between on P P L (420) wire between Stoplamp
Stoplamp Sw itch Connector Pin E Switch and P C M and Electronic Brake
for P P L (420) wire and ground. Control Module.
Test lamp does not light. A D JU ST or R E P L A C E Stoplamp Switch.
DIESEL ENGINE CRUISE CONTROL WILL NOT RESUME/ACCELERATE/TAP-UP

TEST RESULT ACTION
1. D iscon n ect C onnector C 2 6 6 at Test lamp lights. G O to Step 2.
S t e e r in g C o lu m n . C o n n e c t
Connector C 2 6 6 P in s A 1 3 for
B R N (41) pigtail wire and A 1 5 for
G R Y / B L K (87) pigtail wire. Slide
the Cm ise Control Switch to the
R/A position and observe the test
lamp.
Test lamp does not light. L O C A T E and R E P A IR open in the
G R Y / B L K (87) pigtail wire in the
Steering Colum n. If wire is O K , then
R E P L A C E Cruise Control Switch.
2. D isc o n n e c t C o n n e c to r C l at Test lamp lights. R E P L A C E PCM .
P o w e rt ra in C o n t r o l M o d u le
(P C M ). Connect self-powered test
lamp between P C M Connector C l
Pin D IO and Connector C266 Pin
A 15 for G R Y / B L K (87) wire.
Test lamp does not light. L O C A T E and R E P A IR open in
G R Y / B L K (87) wire between
Connector C266 and P C M .
CIRCUIT OPERATION The Cruise Control Switch consists o f two switches

and provides three separate inputs to the Cruise Control
Gasoline Engines M odule. The Cruise Control Sw itch consists o f a S/C
The Cruise Control M odule contains a Stepper M otor (Set/Cruise) pushbutton and a three position O ff-On-R/A
w hich positions a cable connected to the throttle. The Slider Switch. W ith the three-position O ff-O n-R/A Slider
Cruise Control Cable operates the throttle in the same Switch in the center O N position, the O N input is delivered
m anner that the Accelerator Cable does. The C ruise by the G R Y (387) wire to the Cruise Control Module. This
Control Cable is wound on a reel in the module, and the input enables Cruise Control M odule response to the other
Stepper M otor turns the reel in one direction or another to two switch inputs. Placing the Cruise Control Sw itch’s
control the position of the throttle and thus control vehicle O ff-O n-R/A Slid er Sw itch in the O F F position while
speed. W hen the Cruise Control System is idle or disabled, C ruise C ontrol is engaged w ill disengage the Cruise
the Stepper M otor is disengaged, and the Cruise Control Control System without retaining speed setpoint memory.
Cable is free to move in accordance with motion o f the The S/C pushbutton input is delivered by the D K B L U
Accelerator Cable. W hen Cruise Control is on, the Stepper (84) wire. The pushbutton input must be present in order to
M otor w ill engage the cable and position the cable to initially engage Cruise Control. W ith Cruise Control not
maintain a minimum speed. Use o f the Accelerator to yet engaged, this pushbutton input sets the speed at which
increase speed is permitted, but release o f the Accelerator die Cruise Control M odule w ill operate until otherwise
w ill not decrease speed to less than the speed set by the directed. Once Cm ise Control is initially engaged, this
Cruise Control Module. Also, the Cruise Control System same “ set” input can be used for two other functions. If
w ill not lim it speed when the vehicle coasts down a hill. the S/C pushbutton is pressed for a short time (less than
The C ru ise C ontrol M od ule is powered w ith the second), the input w ill cause the Cruise Control M odule to
Ignition Switch in R U N by C R U IS E Fuse 6 through the tap-down the speed setpoint by 1.6 kph (1 mph). Repeated
B R N (41) wire. This fuse also provides operating voltage tap-down operations can be performed as long as the
for the Cruise Control Sw itch located on the Steering vehicle speed remains above die lower lim it for Cm ise
Colum n in the M ulti-Function Lever. The Cruise Control Control operation. Cruise Control w ill not engage with
M odule is grounded by the B L K / W H T (451) wires at vehicle speeds low er than 40 kph (25 mph). If the
Grounds G 103 and G104.
CRUISE CONTROL
pushbutton is pressed fo r a longer period o f time, the The other Stoplamp Switch input on the W H T (17)
Cruise Control M odule w ill disengage the throttle and wait wire is used to check Stoplamp Switch operation before
for the pushbutton to be released and the vehicle w ill coast. engaging Cruise Control. Power to Stoplamp Sw itch Pin B
W hen the pushbutton is released, the Cruise Control is available when the Ignition Switch is in R U N through
M odule w ill reengage with the current speed as the control the O R N (140) wire. After the Ignition Switch is placed in
setpoint. R U N , the Brake Pedal must be actuated to provide cruise
The R/A (Resume/Accelerate) input is provided on the input through the W H T (17) wire. After Stoplamp Switch
G R Y / B L K (87) wire. The O ff-O n-R/A Slider Sw itch’s R/A operations are confirmed, the Cruise Control M odule w ill
position is a momentary contact switch like a pushbutton. respond to a set input.
T h is switch input also has three functions. If Cruise The Cruise Control M odule monitors a vehicle speed
Control was operating and then disengaged by actuation of signal from the V C M on the D K G R N /W H T (817) wire.
the Brake Pedal, this input w ill cause the Cruise Control This 4000 pulses per mile input is used for setting and for
M odule to resume operations at the previous set speed controlling vehicle speed. This input w ill generate an R M S
setpoint If the engine has been turned O F F or the Cruise voltage of between 0-5 volts depending upon speed when
Control Sw itch has been placed in O F F since the previous measured with a high input impedance voltmeter.
operation, no response w ill occur. The Cruise Control M odule signals the V C M that
W ith Cruise Control already engaged, an R/A input Cruise Control is engaged on the L T B L U / B L K (396) wire.
w ill tend to cause the vehicle to accelerate. If the switch is The V C M m ay use th is in fo rm atio n in con trol o f
pressed for a short time (less than a second), the Cruise transm ission shifting. If a new V C M is installed, it must be
Control M odule w ill tap-up speed by 1.6 kph (1 mph). The told that the Cruise Control M odule is present by engaging,
tap-up operation may be repeated. If the switch is actuated disengaging, and reengaging Cruise Control. Refer to
for a longer period o f time, the Cruise Control M odule w ill Engine Controls section for the specific engine.
increase vehicle speed (accelerate) over time until the
switch is released. W hen the switch is released, the current Diesel Engines
speed becomes the new speed setpoint. Accelerating with The Cruise Control System for the Diesel Engine
the Cruise Control Switch while the vehicle operates under operates in much the same manner as that for Gasoline
heavy load or prolonged accelerating with the Cruise Engine. However, fuel flow is controlled electronically for
Control Switch may cause the Automatic Transm ission to the Diesel Engine rather than air flow control by throttle
downshift. A s with the use o f the Accelerator, engine cable as with the Gasoline Engine. The functions o f the
damage may occur if the engine speed becomes excessive. Gasoline Engine’s Cruise Control M odule are incorporated
The Cruise Control M odule monitors two Stoplamp into the Diesel Engine’s P C M . The P C M also provides a
Switch inputs. Voltage is supplied to Stoplamp Switch high engine speed lim it w hich is not available in the
Pin F from B R A K E Fuse 18 (Hot in R U N ). The Stoplamp G asoline En gin e ’s Cruise Control M odule. D iagnostic
Sw itch sends an enable signal from Pin C to the Cruise Trouble Codes D T C -71 for prolonged voltage (over 25.5
Control M odule over the P P L (420) wire. W ith the Brake seconds) on the S/C input and D T C 76 for prolonged
Pedal released, this signal is present, and Cruise Control voltage on the R/A input are also provided by the P C M .
operations may be engaged. The loss o f this voltage, as The P C M w ill disengage Cruise Control for either D T C .
when the Brake Pedal is actuated, w ill cause the Cruise Refer to Engine Controls.
Control M odule to disengage. The Cruise Control M odule
retains p re vio u s speed setpoint inform ation in case
operations are resumed. Intermittent opens or shorts to
ground on the P P L (420)- wire w ill also cause Cruise
Control to disengage.
BLANK
HORNS
13
Islli
PACKAGE ONLY
03-20-97
4206W0569

Horn, L H ............................ A t front of vehicle...................................................... . 4 ..... 8
Horn R e la y ......................... O n Convenience Center, under L H of IP ......................... . 6 ...... 10
Horn, R H ............................ A t front of vehicle...................................................... . 4 ..... 7
Horn Sw itch......................... Top of Steering Colum n under Steering W heel Pad........... . 4 7 .... 61
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender........................... . 5 ...... 9
C O N N EC T O R S:

at Bulkhead............................................................ . 4 ...... 8 ...... 202-0
C 1 0 1 .................................. Engine Harness to Forward Lam ps Harness, L R o f Engine

Compartment, near Underhood Fuse-Relay Center.......... . 4 ...... 8 ...... 202-49
C 1 0 2 .................................. Forward Lam ps Harness to IP Harness, L R of Engine

mounted on Fender................................................... . 4 ..... 8 ...... 202-2
C 2 1 0 .................................. A t Convenience Center................................................ . 3 3 .... 4 4 .... 202-51
C 2 4 2 .................................. IP Harness, L H o f Steering Colum n, near Bulkhead (Z56,

Police Package)
C 2 4 4 .................................. IP Harness, L H of Steering Colum n, near Bulkhead (Z56,

Police Package)
C 2 6 6 .................................. IP Harness to Steering Colum n Harness, L H of Steering

Column, near Bulkhead
G R O U N D S:
G 112 .................................. R F of Engine Compartment, at W heelhousing.................. . 2 ...... 5
S P L IC E S :
S I 13................................... Engine Harness, approx. 19 cm from E B C M Breakout
S 1 2 4 .................................. Forward Lam ps Harness, approx. 26 cm from L H Headlamp

Breakout, toward W indshield W asher Pump
S 1 2 8 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp

HORNS
DIAGNOSIS - HORNS
TROUBLESHOOTING HINTS: check with a system disconnected. These Circuits may
1. C H E C K condition of H O R N fuse. If fuse is open, be intermittent or resistive when loaded, and if
L O C A T E and R E P A IR source o f overload. R E P L A C E possible, should be checked by m onitoring for a
fuse. voltage drop with the system operational (under load).
2. C H E C K that Ground G112 is clean and tight. 4. C H E C K fo r proper in sta lla tio n o f afterm arket
3. C H E C K for a broken (or partially broken) wire inside electronic equipment which may affect the integrity of
o f the in su la tio n w hich cou ld cause a system other systems. See Troubleshooting Procedures.
malfunction but prove G O O D in a Continuity/Voltage
HORN(S) INOPERATIVE
TEST RESULT ACTION
1. Is vehicle equipped with both L H Yes. G O to Step 2.
and R H Horn (with V 2 2 only)? No. G O to Step 5.
2. D oes L H Horn operate? Yes. G O to Step 3.
No. G O to Step 5.
3. Backprobe R H H orn Connector Test lamp does not light. L O C A T E and R E P A IR open in B L K
with a test lamp from Cavity A to (250) wire between R H H orn and
B+. G112.
Test lamp lights. G O to Step 4.
4. Backprobe R H H orn Connector Test lamp lights. R E P L A C E R H Horn.
with a test lamp from Cavity B to Test lamp does not light. L O C A T E and R E P A IR open in D K
ground. Press the Horn Switch. G R N (29) wire between R H Horn and
S I 24.
5. Disconnect L H Horn Connector, Test lamp lights. G O to Step 6.
connect a test lamp from L H Horn Test lamp does not light. G O to Step 7.
Connector C avity B to ground.
Press Horn Switch.
6. C onnect a test lam p from L H Test lamp lights. R E P L A C E L H Horn.
Horn Connector Cavity A to B+. Test lamp does not light. L O C A T E and R E P A IR open in
B L K (2 5 0 ) wire between L H Horn and
G112.
7. Reconnect L H H orn Connector. Test lamp does not light. L O C A T E and R E P A IR open in O R N
Rem ove H orn Relay from Horn (740) wire from H O R N M IN I F U S E to
Relay Socket. Connect a test lamp Horn Relay.
from H orn Relay Cavity C 3 to Test lamp lights. G O to Step 8.
ground.
8. M o m e n ta rily connect a fu sed H om (s) sound. G O to Step 9.
jumper from Horn Relay Cavity H om (s) did not sound. L O C A T E and R E P A IR open in D K
C 3 to Cavity D l. G R N (29) wire between Horn Relay
and L H Horn.
9. Connect a test lamp from Horn Test lamp lights. G O to Step 10.
Relay Cavity D 3 to ground. Test lamp does not light. L O C A T E and R E P A IR open in O R N
(740) wire between H O R N M IN I
F U S E and Horn Relay Socket.
TEST RESULT ACTION

10. Connect a test lamp from Horn Test lamp lights. R E P L A C E Horn Relay.
Relay Cavity C l to B+. Press horn Test lamp does not light. G O to Step 11.
button.
11. D i s c o n n e c t H o r n S w it c h Test lamp does not light. R E P L A C E Horn Switch.
Connector. In the Steering Wheel, Test lamp lights. C H E C K for an open in 28 (B L K )
connect a test lam p from Horn w iring between Horn Switch and Horn
Switch terminal (feed side) to B+. Relay. If O K , R E P L A C E Horn Brush
Press H orn Button. and Horn Slip Ring.
HORN(S) SOUND CONTINUOUSLY WITHOUT HORN SWITCH DEPRESSED

TEST RESULT ACTION
1. Rem ove H orn Relay from Socket. H om (s) do not stop. L O C A T E and R E P A IR short to B + in
D K G R N (29) wire between Fuse-Relay
Center and L H Horn or R H Horn (with
V22).
H om (s) stop. G O to Step 2.
2. Connect a test lamp from Horn Test lamp does not light. R E P L A C E Horn Relay.
Relay Cavity C l to B+. Test lamp lights. G O to Step 3.
3. Disconnect Remote Control Door Test lamp lights. G o to Step 4.
L o c k Receiver, Connect a test Test lamp does not light. Replace Remote Control D oor Lock
lamp from Horn Relay Cavity C l Receiver.
to B+.
4. Disconnect C 210 at Convenience Test lamp lights. G o to Step 5.
Center. Connect a test lamp from Test lamp does not light. Locate and R E P A IR Short to ground in
Connector C 210 Cavity F to B+. (B L K ) 28 W ire between Connector
C 210 at convenience center and
Remote Control D oor Lock Receiver.
5. D i s c o n n e c t H o r n S w it c h Test lamp lights. R E P L A C E Horn Switch.
Connector in the Steering Wheel Test lamp does not light. C H E C K for a short to ground in B L K
connect a test lamp from Horn (28) wire between Horn Switch and
Switch terminal (feed side) to B+. Horn Relay or in Horn Brush/Hom
Slip Ring.
CIRCUIT OPERATION Relay is grounded, the relay energizes and the contacts
Voltage is applied at all times to the H orn Relay close, applying battery voltage directly to the L H Horn and
through the H O R N M in i Fuse. W hen the Horn Switch is R H H orn (w ith V 2 2 only). Because the H o m (s) are
pressed, the H orn Sw itch contacts close, providing a grounded at Ground G112, the Hom (s) w ill sound as long
ground to the coil o f the Horn Relay. W hen the Horn C oil as the Horn Switch is pressed.
8A - 5 0 - 0 ELECTRICAL DIAGNOSIS_________________
DATA LINK CONNECTOR (DLC) PIN ASSIGNMENT
r — — — — — — — — — iip

Data L in k Connector ( D L C ) ... Under L H of IP, L H o f Steering Colum n, mounted to
bottom of Knee Bolster............................................. . 4 3 .... 5 5 .... 202-30

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing............. . 6 ..... 10

(EVO )/Passlock M o d u le ...... Under center o f I P ...................................................... . 4 0 .... 5 2 .... 202-31
Inflatable Restraint Sensing and

Diagnostic M odule (S D M )... A t L F D oor S i l l ......................................................... . 3 9 .... 5 1 .... 202-37
IP Fuse B lo ck ...................... L H o f IP, near L F D oor Jamb Sw itch ............................. . 3 2 .... 43

(P C M ).............................. Under R H end of IP, above Blow er Motor, behind IP
Compartment B o x ................... ................................. . 3 7 .... 49
R a d io .................................. Center of IP

Receiver........................... Under center of IP, R H of Knee B o lste r.......................... . 2 7 .... 4 3 .... 202-45
Trapsfer-Qise Control M odule

(T C C M )..^ ....................... Under IP, on Steering Colum n Support Bracket................. . 3 8 .... 5 0 .... 202-46

( V C M )............................. Engine Compartment, near E B C M ................................... 3 7 .... 48
CONNECTORS:
at B ulkhead ................... ......................................... . 4 ..... 8 ...... 202-0
C 200 (D ie se l)...................... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-11
C 200 (G a s).......................... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 49 .... 202-10
C 2 3 1 .................................. IP Harness to S IR Harness............................................ . 5 5 .... 7 0 .... 202-54
C 2 9 8 .................................. Behind L H o f IP, near Convenience Center...................... . 3 2 .... 4 3 .... 202-17,

18
GROMMETS:
P 1 0 1 .................................. R R o f Engine Compartment, at Bulkhead........................ . 7 ...... 12
GROUNDS:
G 103 (G a s).......................... R F of Engine, near Thermostat H o u sin g .......................... . 1 4 .... 18
G 104 .................................. R H top center o f Cylinder Head..................................... . 1 6 .... 20
G 200................................... Behind L H o f IP, below Fuse Block, on H e B a r.............. . 3 2 ... . 43
SPLICES:

Breakout

S103 (7.4L - A/T)................. Engine Harness, approx. 34 cm from Fuel Injector Breakout,
S I 03 (7.4L - M /T )................ Engine Harness, approx. 12 cm from E G R Breakout
S I 5 0 .................................. Engine Harness, approx. 13 cm from E B C M Breakout

Breakout


S 2 7 2 .................................. IP Harness, approx. 4 cm into A uxiliary Power Outlet

Breakout
S280 (D iesel)....................... IP Harness, approx. 5 cm from D L C Breakout
DIAGNOSIS - DLC PIN ASSIGNMENT

6. If Transfer Case Control M odule is not able to flash
D T C ’s, check for an open in O R N (1568) wire
TROUBLESHOOTING HINTS: between component and D L C terminal 13.
1. C H E C K condition o f A U X P W R Fuse. If Fuse is 7. If EVO /Passlock M odule is not accessible with a scan
open, L O C A T E and R E P A IR source o f overload. tool, check for an open in P P L (1807) wire between
R E P L A C E Fuse. component and Splice S280.
2. C H E C K Grounds G103, G104, and G 200 are clean 8. Check for proper installation of aftermarket electronic
and tight. equipm ent that m ay affect the integrity o f other
3. C H E C K for 12 volts at terminal 16 (C K T 840) of the systems.
D A T A L IN K C O N N E C T O R . R E P A IR if necessary. • C H E C K for a broken or partially broken wire inside
4. C H E C K term inal 4, C K T 150 and term inal 5, o f the in s u la tio n w h ich c o u ld cau se sy ste m
C K T 451 for continuity to ground. R E P A IR if malfunction but prove G O O D in a Continuity/Voltage
necessary. check with a system disconnected. These Circuits may
be intermittent or resistive w hen loaded, and if
DATA UNE(S) possible, should be checked by m onitoring for a
1. Check for proper connection o f scan tool to Data L in k Voltage drop with the system operational or under
Connector (D LC ). load.
2. Check for loose or m issing terminals at D L C . •CH ECK fo r proper in sta lla tio n o f afterm arket
3. If V C M / P C M is not accessible with a scan tool, check electronic equipment which may affect the integrity of
for an open in P P L (1807) wire between component other system. See Troubleshooting Procedures.
and D L C terminal 2. 9. D o not clear D T C s unless directed by a diagnostic
4. If Electronic Brake Control M odule is not accessible procedure. C learing D T C s clears valuable Freeze
with a scan tool, check for an open in T A N /W H T Frame and Failure Records data.
(799) wire between component and D L C terminal 12. 10. Inspect all related w iring and connections including
5. If Inflatable Restraint Sensing and Diagnostic M odule the connections at the V C M , P C M and the A T C
not accessible with a scan tool, check for an open in Module.
T A N (8 00) w ire between com ponent and D L C
terminal 9.
11. If the serial data line is shorted to ground or voltage, power or ground. After repairing a D T C U1026, clear
all systems connected to the serial data line w ill not D T C s from all systems capable of storing this D T C .
communicate properly. System s capable of storing loss The scan tool’s Diagnostic Circuit Check can be used
of communications D T C s (D T C s with the letter U as a to: M onitor the C lass 2 serial data circuit for Node
prefix) w ill have these codes stored in memory. If a A live / S O H messages, store loss o f communications
D T C U 1026 is stored in the V C M , P C M memory, D T C s, and clear loss of communications D T C s. The
check for the same D T C stored in the E B C M . The scan tool Diagnostic Circuit Check status o f Active
E B C M also monitors the Node A live / S Q H message indicates that the module previously communicated
from the A T C Module. If the E B C M also has a D T C with the scan tool, but currently not communicating. If
U 1026 stored, check the A T C for an intermittent a module is not listed at all, that indicates the module
malfunction. If the A T C M odule does not have a D T C never successfully established communications with
U 1026 stored, check for an open in the serial data line the scan tool. Refer to Electrical Diagnosis for any
between the V C M , P C M and the ATC. Check the unlisted modules.
V C M , P C M for intermittent operation due to a loss of
SCAN TOOL WILL NOT COMMUNICATE WITH COMPONENTS ON UART DATA LINE
(CKT 800)
TEST RESULT ACTION
1. Disconnect scan tool from vehicle. Communications can be established. G O to Step 2.
O btain same m odel year vehicle Communications could not be Scan tool may be malfunctioning. Refer
with same systems. Connect scan established. to scan tool instruction manual.
tool to D a ta L in k C o n n e cto r
(D LC ). Ignition Switch to R U N .
A t t e m p t to e s t a b l i s h
communications.
2. Reconnect scan tool to original Com m unications can be established. G O to Step 7.
vehicle. Ignition Switch to R U N . Communications could not be G O to Step 3.
A t t e m p t t o e s t a b l i s h established.
com m unications with Inflatable
Restraint Sensing and Diagnostic
Module.
3. Ignition Switch OFF. Disconnect Resistance greater than 10M ohms. G O to Step 4.
all m odules connected to D L C Resistance less than 10M ohms. L O C A T E and R E P A IR short to ground
terminal 9. W ith a D M M , measure in T A N (800) wire.
resistance on D L C from terminal 9
to terminal 4 (ground).
4. Ignition Sw itch to R U N . W ith a Voltage less than 1.0 V D C . G O to Step 5.
D M M , measure voltage on D L C Voltage greater than 1.0 V D C . Ignition Switch OFF. L O C A T E and
from term inal 9 to term inal 4 R E P A IR short to voltage in T A N (800)
(ground). wire.
5. Ig n itio n S w itc h O F F . W ith a Resistance less than 5.0 ohms. G O to Step 6.
D M M m easure resistance from Resistance greater than 5.0 ohms. L O C A T E and R E P A IR open in T A N
D L C terminal 9 to terminal 5 on (800) wire.
the Inflatable Restraint Sensing
and Diagnostic Module.
6. Ensure the Ignition Switch is OFF. Communications can be established. C H E C K A L L connector(s) at the
Connect the Inflatable Restraint Inflatable Restraint Control M odule and
Sensing and Diagnostic Module. D L C for poor connections. System is
Ignition Switch to R U N . Attempt operating properly.
to establish communications. Com m unications cannot be established. C H E C K for power and ground to
module. If O K , R E P L A C E the
Inflatable Restraint Control Module.
TEST RESULT ACTION

7. Ignition Switch OFF. Disconnect Resistance less than 5.0 ohms. C H E C K for power and ground to
Inflatable Restraint Sensing and module. C H E C K T A N (800) wire for
Diagnostic M odule. W ith a D M M an intermittent open or short. C H E C K
m easure resistance from D L C connections at module and scan tool at
terminal 9 to Inflatable Restraint the D L C .
Sensing and D iagnostic M odule Resistance greater than 5.0 ohms. L O C A T E and R E P A IR open in T A N
C o n n e c t o r U A R T d a ta lin e
(800) wire between Inflatable Restraint
(C K T 800) terminal.
Control M odule and the D L C .
SCAN TOOL WILL NOT COMMUNICATE WITH COMPONENT ON CLASS-2 DATA UNE
(CKT 1807) PCM/VCM
TEST RESULT ACTION
1. Disconnect scan tool from vehicle. Com m unications can be established. G O to Step 2.
O btain same m odel year vehicle Com m unications cannot be established. Scan Tool may be malfunctioning.
with same systems. Connect scan
Refer to scan tool instruction manual.
to o l to D a ta L in k C o n n e cto r
(D L C ). Ignition Switch to R U N .
communications.
2. C on n ect scan tool to o rig in a l Com m unications can be established. C H E C K P P L (1807) wire for an
vehicle. Ignition Switch to R U N . intermittent open or short.
A t t e m p t t o e s t a b l i s h Com m unications cannot be established.
G O to Step 3.
co m m u n ica tio n s w ith V e h icle
C o n tro l M o d u le
( V C M ) / P o w e r t r a in C o n t r o l
M odule (P C M ).
3. Ignition Switch OFF. Disconnect Resistance greater than 10M ohms. G O to Step 6.
the V C M / P C M . W ith a D M M , Resistance less than 10M ohms.
G O to Step 4.
measure resistance on D L C from
terminal 2 to terminal 4 (ground).
4. Disconnect the Electronic Brake Resistance greater than 10M ohms. R E P L A C E the Electronic Brake
Control M odule (E B C M ). W ith a Control M odule (E B C M ).
D M M , measure resistance on D L C Resistance less than 10M ohms.
G O to Step 5.
from term inal 2 to term inal 4
(ground).
5. D isc o n n e c t the E V O / P a sslo c k Resistance greater than 10M ohms. R E P L A C E the EVO /Passlock M odule /
M od ule and Autom atic Transfer Automatic Transfer Case Control
C ase C o n tro l M o d u le . W ith a Module.
D M M , measure resistance on D L C Resistance less than 10M ohms. L O C A T E and R E P A IR short to ground
from term inal 2 to term inal 4 P P L (1807) wire.
(ground).
6. Ignition Switch to R U N . W ith a Voltage less than 1.0 V D C . G O to Step 7.
D M M , measure voltage on D L C Voltage greater than 1.0 V D C . L O C A T E and R E P A IR short to voltage
from term inal 2 to term inal 4 in P P L (1807) wire.
(ground).
D M M m easure resistance from Resistance greater than 5.0 ohms. L O C A T E and R E P A IR open in P P L
D L C terminal 2 to terminal 11 of (1807) wire.
C 4 on the V C M connector G as
Engine or terminal C 8 o f C 3 on
the P C M C o n n e c to r, D ie s e l
Engine.
TEST RESULT ACTION

8. Check for power and ground to Circuits are not suspect. G O to Step 9.
V C M / P C M . C h e ck fo r proper Circuits are suspect. L O C A T E and R E P A IR suspect circuits.
c o n n e c t io n s at V C M / P C M G O to Step 7.
connector and scan tool at D L C .
9. Connect the V C M / P C M . Ignition Communications can be established. Check P P L (1807) wire for an
S w itc h to R U N . A tte m p t to intermittent open or short.
estab lish com m unications w ith Communications cannot be established. V C M / P C M is suspect, refer to
V C M /P C M . S E C T IO N 6, Engine Controls for
further diagnosis.
SCAN TOOL WILL NOT COMMUNICATE WITH ELECTRONIC BRAKE CONTROL MODULE
(EBCM) (CKT 799)
TEST RESULT ACTION
1. Disconnect scan tool from vehicle. Communications can be established. G O to Step 2.
O btain same m odel year vehicle Communications could not be Scan tool may be malfunctioning. Refer
with same systems. Connect scan established. to scan tool instruction manual.
tool to D a ta L in k C o n n e cto r
(D LC ). Ignition Switch to R U N .
communications.
2. C onnect scan tool to o rig in a l Communications can be established. G O to Step 7 .
vehicle. Ignition Switch to R U N . Com m unications could not be G O to Step 3.
A t t e m p t t o e s t a b l i s h established.
com m unications w ith Electronic
Brake Control M odule (E B C M ).
3. Ignition Sw itch OFF. Disconnect Resistance greater than 10M ohms. G O to Step 4.
Electronic Brake Control M odule Resistance less than 10M ohms. L O C A T E and R E P A IR short to ground
(E B C M ). W ith a D M M , measure in T A N /W H T (799) wire.
resistance on D L C from terminal
12 to terminal 4 (ground).
4. Ignition Switch to R U N . W ith a Voltage less than 1.0 V D C . G O to Step 5.
D M M , measure voltage on D L C Voltage greater than 1.0 V D C . Ignition Switch OFF. L O C A T E and
from terminal 12 to terminal 4 R E P A IR short to voltage in TAN /W H T
(ground). (799) wire.
D M M m easure resistance from Resistance greater than 5.0 ohms. L O C A T E and R E P A IR open in
D L C terminal 12 to terminal F of T AN /W H T (799) wire.
C l on the E le c tr o n ic B ra k e
Control M odule (E B C M ).
6. Ensure the Ignition Switch is OFF. Communications can be established. C H E C K A L L connector(s) at the
Reconnect the Electronic Brake E B C M and D L C for poor connections.
Control M odule (E B C M ). Ignition System is operating properly.
S w itc h to R U N A tte m p t to Communications cannot be established. Check for power and ground to
establish communications. Electronic Brake Control M odule
(E B C M ). If O K , R E P L A C E the
Electronic Brake Control Module
(E B C M ).
8A-50-6 ELECTRICAL DIAGNOSIS_________________
DATA UNK CONNECTOR (DLC) PIN ASSIGNMENT
TEST RESULT ACTION

7. Ignition Switch OFF. Disconnect Resistance less than 5.0 ohms. C H E C K for power and ground to
Electronic Brake Control M odule Electronic Brake Control M odule
(E B C M ). W ith a D M M measure (E B C M ). C H E C K T A N /W H T (799)
resistance from D L C terminal 12 wire for an intermittent open or short.
to E le c t r o n ic B ra k e C o n tro l C H E C K connections at module and
M odule (E B C M ) terminal F o f C l. scan tool at the D L C .
Resistance greater than 5.0 ohms. L O C A T E and R E P A IR intermittent
open in T A N /W H T (799) wire between
module and D L C .
TRANSFER CASE CONTROL MODULE (TCCM) WILL NOT FLASH DTC’s (CKT 1568)
TEST RESULT ACTION
1. I g n i t i o n S w i t c h to O F F . Test lamp does not light. G O to Step 2.
Disconnect Transfer Case Control Test lamp lights. L O C A T E and R E P A IR short to ground
M odule (T C C M ). Connect a self in O R N (1568) wire between D L C and
powered test lamp on D L C from
module.
terminal 13 to ground.
2. Connect a self powered test lamp Test lamp does not lig h t L O C A T E and R E P A IR open in O R N
on D L C from term inal 13 to (1568) wire between D L C and module.
terminal D 3 o f the Transfer Case Test lamp lights.
G O to Step 3.
C o n t r o l M o d u le ( T C C M )
connector.
3. Ig n it io n S w itc h O N . W ith a Voltage greater than 0.5 v o lt Ignition Switch OFF. L O C A T E and
D M M , measure voltage on D L C R E P A IR short to voltage in O R N
from term inal 13 to terminal 4 (1568) wire.
(ground). Voltage greater than 0.5 volt. C H E C K A L L connector(s) at the
T C C M and D L C for poor connections.
Check for power and ground to
module. If O K , R E P L A C E the Transfer
Case Control M odule (T C C M ).
CIRCUIT OPERATION
A scan tool can be connected to the Data L in k
Connector (D L C ), this allow s the scan tool to communicate
w ith the D ie se l Pow ertrain C ontrol M od ule (P C M ) ,
Gasoline Vehicle Control M odule (V C M ) , the Inflatable
R e stra in t C o n tro l M o d u le , E V O / P a sslo c k M o d u le ,
Automatic Transfer Case Control Module, Transfer Case
Control M odule, or the Electronic Brake Control Module.
System operations can then be monitored for diagnostic
purposes.
BLANK
DEFOGGER
REAR DEFOGGER
I HOT M RUN
GROUNO GROUND
DEFOGGER
HEATED OUTSIDE REARVIEW MIRROR
HOT IN RUN
PACE 8 1 -6 1 -0
I
SEE SUBURBAN
UTILITY W /O
LFTGATE
CROSS BODY
GROUND 03-17*97
4206W0663
DEFOGGER

Cargo D oor Contactor, L H ..... Rear Body Opening and Door, upper L H ......................... . 7 6 .... 101
Cargo D oor Contactor, R H ..... Rear Body Opening and Door, upper R H ......................... . 7 6 .... 102

L R .................................. O n L R Cargo D oor G la ss............................................ . 7 6 .... 101

R R .................................. O n R R Cargo D oor G la ss............................................ . 7 6 .... 102
Convenience Center.............. Under L H of IP, on B ulkhead ....................................... . 3 3 .... 44
H V A C Control M od ule.......... Part of Heater Controls, center of IP, under R ad io............. . 5 3 .... 6 8 .... 202-35
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................ . 3 2 .... 43
W indow Defogger Switch,

R e a r................................ Center of IP, part o f Heater C ontrols.............................. . 5 8 .... 76

Motor, L H ........................ O n L F Door, near center of A P illa r.............................. . 6 1 .... 7 9 .... 202-66,
67
Power Outside Rearview

M irror, R H ....................... O n L F Door, near center of A P illa r.............................. . 6 1 .... 7 9 .... 202-66,
67
W indow Defogger Grid, Rear... O n Rear W in d o w ....................................................... . 5 8 .... 76
Underhood Fuse-Relay Center.. L R of Engine Compartment, on Fender........................... . 5 ..... 9
CONNECTORS:
at Bulkhead............................................................ . 4 ..... 8 ...... 202-0
C 2 0 7 .................................. Inside lower L H A P illa r............................................. . 6 1 .... 7 9 .... 202-51
C 2 1 4 .................................. Inside lower R H A P illa r............................................. . 6 1 .... 7 9 .... 202-52
C 2 2 2 .................................. A t Convenience Center................................................. . 4 7 .... 62 .... 202-53
C 2 9 3 .................................. Inside lower L H A Pillar
C 2 9 8 .................................. Behind L H of IP, near Convenience Center..................... .. 3 2 .... 43.... 202-17,

18
C 4 0 4 .................................. Top o f L H D P illar....................................................... 4 5 .... 7 4 .... 202-57
C 4 0 5 .................................. Top of R H D Pillar....................................................... 4 5 .... 74 .... 202-57
C 4 0 6 .................................. Top of R H D Pillar......................................................, 6 8 .... 87.... 202-57
C 5 0 1 .................................. In-line to L H Power Outside Rearview M irro r................. .. 6 1 .... 7 9 .... 202-21
C 6 0 1 .................................. In-line to R H Power Outside Rearview M irro r.................. , 6 1 .... 7 9 .... 202-59
GROUNDS:
G 200.................................. Behind L H of IP, below Fuse Block, on Tie B a r............... . 3 2 .... 43
G 400.................................. R H B Pillar................................................................ . 3 6 .... 60
GROMMETS:
P 4 0 0 .................................. Top rear of body, at R H Liftgate H in ge ........................... 7 1 .... 93
P 5 0 0 .................................. A t L F D oor................................................................ . 6 1 .... 79


P 6 0 0 .................................. A t R F D o o r............................................................... 6 1 .... 79
SPLICES:
Breakout

Breakout
S 2 5 1 .................................. Crossbody Harness, approx. 13 cm right of L F D oor


toward C299

Breakout

S410 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 37 cm from R R Door

Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 12 cm from R R Door
S410 (Suburban w/o C 69

w /ZW 9)........................... Front to rear Body Harness, approx. 22 cm from R H rear
S425 (2-Door Utility w/Cargo

D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from C H M S L
Breakout, toward L H D oor Speaker Breakout

w/Rear Heat)..................... Front-to-Rear Body Harness, approx. 14 cm from L R
Speaker Breakout

w/o Rear H eat)................. Front-to-Rear Body Harness, approx. 11 cm from Crossbody
Harness Breakout, toward L H Speaker Breakout

w/o C 6 9 )......................... Front-to-Rear Body Harness, approx. 11 cm from Rear
Dom e Lam p Breakout, toward L R Speaker
S 5 0 6 ................. ;............... Inside Power Outside Rearview M irror Harness, approx.

7 cm from Power Outside Rearview M irror, toward C501
DEFOGGER
DIAGNOSIS - REAR WINDOW DEFOGGER
TROUBLESHOOTING HINTS: HEATED OUTSIDE REARVIEW

MIRRORS
DEFOGGER 1. C H E C K condition of H I D M IR Fuse 2 and H T R A/C
1. C H E C K to see that R R D E F O G and H T R A/C Fuses Fuse 12. If either fuse is open, L O C A T E and R E P A IR
are not open. If open, L O C A T E and R E P A IR source cause of overload and R E P L A C E fuse.
o f overload, then R E P L A C E fuse(s). 2. C H E C K that Ground G 202 is clean and tight.
2. C H E C K that Grounds G 200 and G 400 are clean and 3. If Power Outside Rearview M irror heating elements
tight. operate, but the Heater/HVAC Control M odule does
3. C H E C K that Rear Defogger G rid(s) is continuous and not light, R E P L A C E Heater o r H V A C C on trol
free from damage. R E F E R to End Gate Section. Module.
4. If vehicle is not equipped with a Liftgate, then 4. If the Rear Defogger Switch L E D Indicator does not
C H E C K that L H /R H D oor Contact Switch contacts extinguish after a nom inal 10 minute time delay,
are clean and free from obstructions. R E P L A C E Heater/HVAC Control Module.
5. If the Rear Defogger G rid(s) do not automatically shut 5. S E E Interior Lam ps D im m ing, page 8A -117 for
O F F after 10 minutes, then the Solid State Time Delay d ia gn o sis o f indicators at H eater/H V AC C ontrol
Relay for the Rear Defogger Switch may have failed. Module.
6. If the Rear Defogger Switch light indicator does not • C H E C K for a broken (or partially broken) wire
illuminate but the Defogger G rid(s) defogs, the L E D inside the insulation which could cause system
may have failed. m a l f u n c t io n b u t p r o v e G O O D in a
• C H E C K for a broken (or partially broken) wire inside c o n t in u it y / v o lt a g e c h e c k w ith a sy ste m
o f the in s u la tio n w h ich c o u ld cau se sy ste m disconnected. The circuits may be intermittent or
malfunction but prove G O O D in a continuity/voltage resistive when loaded, and if possible, should be
check with a system disconnected. These circuits may checked by monitoring for a voltage drop with the
be interm ittent or resistive when loaded, and if system operational (under load).
possible, should be checked by m onitoring for a • C H E C K for proper installation o f aftermarket
voltage drop with the system operational (under load). electronic equipm ent w hich m ay affect the
• C H E C K fo r p rop er in sta lla tio n o f afterm arket integrity o f other systems. S E E Troubleshooting
electronic equipment which may affect the integrity of Procedures.
REAR WINDOW DEFOGGER INOPERATIVE BUT GRID TESTS GOOD

TEST RESULT ACTION
1. Is this a Suburban/Utility equipped Yes. G O to Step 2.
with Cargo D o o rs? No. G O to Step 4.
2. D oes one Cargo D oo r Defogger Yes. G O to Step 3.
G rid not w ork w hile the other No. G O to Step 4.
does?
3. D iscon n e ct C onnector C 222 at N o continuity. L O C A T E and R E P A IR open in P P L
C o n ve n ie n ce Center. U s in g a (293) wire between Splice S425 and
se lf-p ow e re d test lam p, C lo se the inoperative Cargo D oor Defogger
C a r g o D o o r s . C H E C K fo r Grid. C H E C K contact resistance at
continuity from Connector C222 Cargo D oor Contact.
Cavity A to the inoperative Cargo Continuity. L O C A T E and R E P A IR open in B L K
D oor Defogger Grid. (150) wire between inoperative Cargo
D oor Defogger Grid and Splice S410.
C H E C K contact resistance at Cargo
D oor Contact.
TEST RESULT ACTION

4. Disconnect Heater/HVAC Control Test lamp lights. G O to Step 5.
M odule Connector C l. Connect a Test lamp does not light. L O C A T E and R E P A IR open in O R N
test lam p from H e a te r/ H V A C (1440) wire between Underhood Fuse-
C ontrol M od ule C onnector C l Relay Center and Heater/HVAC Control
Cavity A to ground. Module.
5. C o n n e c t a te st la m p fro m Test lamp lights. G O to Step 6.
H e ater/ H V A C C o n tro l M o d u le Test lamp does not light. L O C A T E and R E P A IR open in B R N
Connector C l Cavity B to ground. (141) wire between IP Fuse Block and
Heater/HVAC Control Module.
6. Connect a self-powered test lamp Test lamp lights. G O to Step 7.
fro m H e a t e r/ H V A C C o n t r o l Test lamp does not light. L O C A T E and R E P A IR open in B L K
M odule Connector C l Cavity C to (150) wire between Heater/HVAC
ground. Control M odule and Ground G200.
7. D isconnect Connector C 2 2 2 at Test lamp lights. G O to Step 8.
Convenience Center. Connect a Test lamp does not light. L O C A T E and R E P A IR open in P P L
self-powered test lam p between (293) wire between Heater/HVAC
Convenience Center Cavity A for Control M odule and Convenience
Connector C222 and Heater/HVAC Center.
C ontrol M o d u le C onnector C l
Cavity D.
8. C O N N E C T Heater/HVAC Control Test lamp lights. G O to Step 9.
M o d u le C o n n e c to r C l. P lace Test lamp does not light. R E P L A C E Heater/HVAC Control
Ignition Switch in O N . Press Rear M odule (or Rear Defogger Switch).
Defogger Switch push button on
H eater/H V A C C o n tro l M od ule.
C o n n e c t a te st la m p fro m
Convenience Center Cavity A for
Connector C 222 to ground. The
Rear Defogger Switch L E D should
be i l l u m i n a t e d o n the
Heater/HVAC Control Module.
9. C O N N E C T C onnector C 2 2 2 at Test lamp does not light. L O C A T E and R E P A IR open in P P L
Convenience Center. Ensure that (293) wire between Convenience Center
the Rear Defogger Switch L E D is Connector C222 and Cargo Door/Rear
e x tin g u ish e d . P re ss the R e a r W indow Defogger Grid.
D e fogger Sw itch. U sin g a test Test lamp lights. L O C A T E and R E P A IR open in B L K
lamp, Locate the side o f the grid (150) wire between Cargo Door/Rear
which lights the test lamp when W indow Defogger G rid and Ground
probed to ground. G400.
LH HEATED OUTSIDE REARVIEW MIRROR ELEMENT INOPERATIVE

TEST RESULT ACTION
1. Disconnect connector at L H Power Test lamp lights. G O to Step 2.
Outside Rearview Mirror. Connect Test lamp does not light. L O C A T E and R E P A IR open in B L K
a self-powered test lamp between (150) wire between L H Power Outside
Power Outside Rearview M irror Rearview M irror and Splice S506.
Connector Cavity H and ground.
2. C onnect unpow ered test lam p Test lamp lights. Replace L H Power Outside Rearview
b e tw e e n L H P o w e r O u tsid e Mirror.
Rearview M irror Connector Cavity Test lamp does not light. L O C A T E and R E P A IR open in O R N
A and ground. Actuate the Heated (267) wire between Heated M irror
M irror Switch. Relay and L H Power Outside Rearview
Mirror.
DEFOGGER
RH HEATED OUTSIDE MIRROR ELEMENT INOPERATIVE

TEST RESULT ACTION
1. Disconnect connector at R H Power Test lamp lights. G O to Step 2.
Outside Rearview M irror. Connect Test lamp does not light. L O C A T E and R E P A IR open in B L K
a self-powered test lamp between
(150) wire between R H Power Outside
Pow er Outside Rearview M irro r
Rearview M irror and Ground.
Connector Cavity H and ground.
2. Connect test lamp between R H Test lamp lights. R E P L A C E R H Power Outside
Pow er Outside Rearview M irro r Rearview Mirror.
Connector Cavity A and ground. Test lamp does not light.
L O C A T E and R E P A IR open in O R N
Actuate the Heated M irror Switch. (267) wire between Heated M irror
Relay Connector C 210 and R H Power
Outside Rearview Mirror.
BOTH HEATED OUTSIDE REARVIEW MIRROR ELEMENTS INOPERATIVE

TEST RESULT ACTION
1. Disconnect Connector C207/C214. Test lamp lights. G O to Step 2.
Connect self-powered test lam p Test lamp does not light. L O C A T E and R E P A IR open in B L K
between C onnector C 207/C 214
(150) wire between Splice S506 and
Cavity E and Ground G202.
Ground G202.
2. Connect Connector C207/C214. Test lamp lights. C H E C K Heated M irror Relay Cavity 3
D isc o n n e c t the Heated M irro r for loose or damaged connections.
R e la y . C o n n e c t a test lam p R E P A IR as necessary.
between the Heated M irro r at Test lamp does not light. G O to Step 3.
C a v it y 3 and g ro u n d . T u rn
Ignition Switch to R U N and press
the Heated M irror Switch.
3. D is c o n n e c t S p lic e S 4 2 5 at Test lamp lights. G O to Step 4.
C o n ve n ie n ce Center. C on n ect Test lamp does not light. L O C A T E and R E P A IR open in P P L
self-powered test lam p between (293) wire between Heated M irror
Splice S425 and Heated M irro r Relay at Cavity 1 and Splice S425.
Relay at Cavity 1.
CIRCUIT OPERATION HEATED POWER OUTSIDE

REARVIEW MIRROR
DEFOGGER W hen the Ig n itio n Sw itch is in R U N , pow er is
W ith the Ignition Switch in R U N , voltage is supplied available to the Heater/HVAC Control M odule B R N (141)
to the Rear Defogger Switch at the Heater/HVAC Control from H T R -A /C Fuse 12 through the wire. Also, power is
Module. W hen the Rear Defogger Switch is pressed, the available at all times to the Heated M irror Relay contacts
contact closes, which provides voltage to the L E D Indicator from the H T D M IR Fuse 2 through the O R N (140) wire.
and the Rear Defogger Grid. The Rear W indow s w ill heat W hen the Heated M irror Pushbutton is pressed, the Solid
to remove fog from the surface o f the window. State Timer actuates the Heated M irror Relay to apply
The Solid State Time Delay w ill automatically turn-off voltage through the O R N (1040) wire to both Pow er
the D e fo g g e r G rid s and the L E D at the end o f Outside Rearview M irro r heating elements. Since the
approximately 10 minutes. The Defogger G rids are also heating elements are both grounded through the B L K (150)
automatically turned off if the Rear Defogger Switch is wires to Ground G202, both elements are energized. W hile
pressed again or the Ignition Switch is turned to the O F F the relay is energized, the local light emitting diode (L E D )
postion. indicator is illuminated. The Solid State Timer times for 10
F o r the Suburban/U tility w ith C argo D o o rs, the minutes nominally, then de-energizes the relay. Depressing
Defogger G rids can be energized only with the Cargo the pushbutton again re-initiates the timed operation. The
D oors closed. relay is also de-energized with the Ignition Switch out of
the R U N position.
HVAC BLOWER CONTROL
FRONT HVAC BLOWER, W/O A/C
i HOT AT ALU TIMES

] HOT IN RUN
03-11-97
4206W0592
HVAC BLOWER CONTROL
FRONT HVAC BLOWER, W / A/C
HOT AT ALL TIMES HOT IN RUN
S RED |
S110
i 542
SEE POWER
DISTRIBUTION
i
PAGE 8 A - 1 0 - 3
5 RED 542
5 RED I 542
HVAC BLOWER CONTROL
AUXILIARY HEATER BLOWER, W/O A/C
HVAC BLOWER CONTROL
AUXILIARY BLOWER, W / A/C W/O HEATER
AUXILIARY
G400
'REAR BODY
GROUNO
4208W059S
HVAC BLOWER CONTROL
AUXILIARY BLOWER, W/ A/C, W / HEATER
HVAC BLOWER CONTROL

Auxiliary A/C Control M odule,
Fro nt............................... In Overhead Console.................................................... 53.... .. 6 8 ..... 202-26
A uxiliary A/C Control M odule,

R e a r................................ In rear Headliner......................................................... 53.... .. 6 8 ..... 202-26
A uxiliary Blow er M o to r......... Behind R R W heelhousing.............................................. 66...... 85
A uxiliary Blow er M o to r......... Behind R R W heelhousing.............................................. 66.... .. 85
A u xiliary Blow er M otor Relay,

H ig h ................................ O n top o f A uxiliary H V A C Plenum, near R R
W heelhousing........................................................... 66.... .. 85 ... .. 202-60

L o w ................................. O n top o f Auxiliary H V A C Plenum, near R R
W heelhousing........................................................... 66.... .. 8 5 ..... 202-60

M e d iu m ........................... O n top of Auxiliary H V A C Plenum, near R R
W heelhousing........................................................... 6 6 ..... 85 ... „ 202-60
Blow er M otor Relay, H ig h ...... Behind IP Compartment Box, on H V A C Plenum ............... 5 0 ..... 6 5 ... . 202-60
A uxiliary Blow er R esistor...... O n top of A uxiliary H V A C Plenum, near R R

W heelhousing........................................................... 6 6 ..... 85
A uxiliary Heater Control

M odule, R e a r.................... L H of IP, R H o f Steering C olu m n.................................. 5 3 ... .. 6 8 ... . 202-26
A uxiliary H V A C Control Logic

M o d u le ............................ In Overhead Console.................................................... 5 3 ... .. 6 8 ... . 202-25
M odule, Fro n t................... Front of Overhead Console, near W indshield..................... 5 3 ... „ 6 8 ... . 202-26
M odule, R e a r.................... Rear o f Overhead Console M olding, in Headliner.............. 5 3 ... „ 6 8 ... . 202-26
M odule, F ro n t................... Front of Overhead Console, near W indshield..................... 5 3 ... .. 6 8 ... . 202-26
Blow er R esistor.................... O n top o f H V A C Plenum .............................................. 5 0 ... , 6 5 ... . 202-61
Blow er Switch, Connector C 2 .. O n top o f H V A C Plenum .............................................. 5 0 ... .. 6 5 ... . 202-28
Convenience Center.............. Under L H o f IP, on B ulkhead ........................................ 3 3 ... „ 44
Heater Control M odule, Front... Part of H V A C C o n tro ls................................................ 5 3 ... . 6 8 ... . 202-35
Heater Control M odule, Rear.... Part of H V A C C on trols................................................ 5 3 ... . 6 8 ... . 202-35
H V A C Control M od ule .......... Part o f Heater Controls, center of IP, under R ad io............. 5 3 ... . 6 8 ... . 202-35
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. 3 2 ... . 43
Underhood Fuse-Relay Center.. L R of Engine Compartment, on Fender............................ 5 ..... . 9
CONNECTORS:
C 1 0 0 .................................. Engine Harness to IP Harness, L R o f Engine Compartment,
at Bulkhead............................................................. 4 ..... . 8 ..... . 202-0
C 2 0 3 .................................. Behind R H of IP, near Heater Motor, in foam w rap........... 5 0 ... . 6 5 ... . 202-50
C 2 0 5 .................................. A t Convenience Center................................................. 3 3 ... . 44 ... . 202-50


C 2 2 1 ................................... A t Convenience Center................................................. . 4 7 .... 6 2 .... 202-53
C 2 3 0 .................................. Behind R H of IP, above H V A C Evaporator H o u sin g ............ 2 7 .... 4 2 .... 202-54
C 3 0 0 .................................. In Overhead Console.................................................... . 3 6 .... 6 1 .... 202-55
C 4 0 0 .................................. R R of vehicle, above Auxiliary Blow er M o to r.................... 6 6 .... 8 5 .... 202-56
C 4 0 1 .................................. R R of vehicle, above Auxiliary Blow er M o to r.................. . 6 6 .... 85.... 202-56
GROUNDS:
G 105 .......................... ....... R F of Engine block..................................................... .. 1 3 .... 17
G 2 0 0 .......................... ....... Behind L H of IP, below Fuse Block, on Tie B a r.............. . 3 2 .... 43
G 202 .......................... ....... R H of IP, mounted to H V A C Plenum Bracket.................. .. 5 0 .... 65
G 400 .......................... ....... R H B Pillar, near D oor Striker...................................... . 5 8 .... 76
GROMMETS:
P 1 0 1 .......................... ....... R R of Engine Compartment, at Bulkhead........................ . 7 ..... 12
SPLICES:
S I 10 (5.0L, 5.7L) ........ ....... Engine Harness, approx. 23 cm from E B C M Breakout,
S I 10 (7.4L) ................ ....... Engine Harness, approx. 26 cm from E B C M Breakout, near

S I 47 (4.3L) ................ ....... Engine Harness, approx. 5 cm from Fuel Injector Breakout,
S I 47 (5.0L, 5.7L) ........ ....... Engine Harness, approx. 5 cm from E G R Valve Breakout,
S I 47 (6.5L) ................ ....... Engine Harness, approx. 4 cm from Starter M otor Solenoid
Breakout
S I 47 (7.4L) ................ ....... Engine Harness, approx. 5 cm from E G R Valve Breakout
S 2 0 4 .......................... ....... IP Harness, approx. 8 cm from D L C Harness Breakout,

toward C l 00
S 2 1 7 .......................... ....... IP Harness, approx. 16 cm from Instrument Cluster Harness

S 2 1 8 .......................... ....... IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S 2 4 4 .......................... ....... H V A C Harness, approx. 8 cm from Recirculation D oor


Breakout
5305 (4-Door Utility/

Suburban)......................... Rear H V A C Control Harness, approx. 25 cm from A uxiliary
Auxiliary H V A C Control M odule

HVAC BLOWER CONTROL

Auxiliary H V A C Control Module

A uxiliary H V A C Control Module
S400 (w /Auxiliaiy A / C )......... Auxiliary A/C Harness, approx. 17 cm from Blow er M otor
S400 (rear Heat & A/C )......... A uxiliary Heat and A/C Harness, approx. 4.5 cm from
Blow er M otor Relays, toward Blow er M otor
S401 (w /Auxiliary H V A C )...... A uxiliary H V A C Harness, approx. 13 cm from Blow er

Resistor Breakout, toward Blow er M otor Relays
S403 (w /Auxiliary H V A C )...... A uxiliary H V A C Harness, approx. 7 cm from Blow er M otor

S410 (2-Door U tility )............ Front-to-Rear Bod y Harness, approx. 37 cm from R R D oor
Breakout
S410 (4-D oor Utility/

Suburban)......................... Front-to-Rear Body Harness, approx. 12 cm from R R D oor
S410 (Suburban)................... Front to rear B od y Harness, approx. 12 cm from R H rear

D oor Speaker Breakout, toward R R D oor Jamb Breakout
S410 (Suburban w/o C 69

w /ZW 9)........................... Front to rear Body Harness, approx. 22 cm from R H rear

S440 (4-D oor Utility/Suburban

w/o C 6 9 ).......................... Front-to-Rear Bod y Harness, approx. 7 cm from Crossbody
Harness Breakout, toward Front Dom e Lam p Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 13 cm from Crossbody

DIAGNOSIS - HVAC BLOWER CONTROL
TROUBLESHOOTING HINTS: (FRONT 3. C H E C K that A uxiliary H igh Blow er Relay, Auxiliary

BLOWER) M edium Blow er Relay, and A uxiliary Low Blower
1. C H E C K that Blow er Fuse 3 and H T R -A /C Fuse 12 Relay are properly mated to their Connectors.
are not open. If either fuse is open, L O C A T E and 4. Heater Blow er operations at Single Speed independent
R E P A IR source o f overload. R E P L A C E fiise(s). o f Switch setting or variations in Blow er speed while
2. C H E C K that Grounds G 105 and G 202 are clean and d rivin g m ay indicate that the A u x ilia ry B lo w e r
tight. Resistor C oils are contacting one another.
3. C H E C K that Front H igh Blow er Relay is properly
mated to its Connector. TROUBLESHOOTING HINTS:
4. Heater Blow er operations at Single Speed independent (GENERAL)
of Switch setting or variations in Blow er speed while 1. See Section 8A-65 for diagnosis of Ventilation System
driving may indicate that the Front Blow er Resistor controls.
C oils are contacting one another. 2. See Section 8 A -6 4 for d iagn osis o f Com pressor
5. C y clic or periodic B lo w e r operations at reduced Controls.
speeds may be caused by operation of the Therm 3. See Section 8A-61 for diagnosis o f the Rear W indow
Lim it in the Front Blow er Resistor, if provided. Defogger Controls.
4. See Section 8A-117 for diagnosis o f the Instrument
TROUBLESHOOTING HINTS: Panel Dim m ing System.
(AUXILIARY BLOWER) 5. C H E C K for broken (or partially broken) wire inside of
1. C H E C K that R R H V A C Fuse 5, Blow er Fuse 3, and insulation which could cause system malfunction but
IL L U M Fuse 14 are not open. If any fuse(s) is open, prove G O O D in a continuity/voltage check with a
L O C A T E and R E P A IR source of overload. R E P L A C E syste m d isco n n e cte d . T h e se c irc u it s m ay be
fuse(s). intermittent or resistive when loaded, and if possible,
2. C H E C K that Grounds G 200 and G 400 (Heater without should be checked by m onitoring for a voltage drop
A/C) or G 400 (Heater with A/C) are clean and tight. with the system operational (under load).
6. C H E C K fo r proper in sta lla tio n o f afterm arket
electronic equipment which may affect the integrity of
BLOWER MOTOR INOPERATIVE (HEATER WITH A/C)

TE S T RESULT ACTIO N
1. D isconnect C onnector for P P L Test lamp lights. G O to Step 2.
(65) wire at Blow er Motor. Place Test lamp does not light G O to Step 3.
Ign ition Sw itch in R U N . Place
Blow er Switch in H I. Connect a
test lamp from Blow er M otor P P L
(65) wire Connector Cavity A to
ground.
2. D is c o n n e c t B lo w e r M o t o r Test lamp lights. R E P L A C E Blow er Motor.
Connector for the B L K (250) wire. Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connect a self-powered test lamp (250) wire between Blow er M otor and
between Blow er M otor B L K (250) Connector C203, or B L K (150) wire
w ire C o n n e c to r C a v ity A to between Connector C203 and Ground
ground. G105.
HVAC BLOWER CONTROL
TEST RESULT ACTIO N

3. R e m o ve H ig h B lo w e r M o to r Test lamp lights. G O to Step 4.
Relay. Connect a self-powered test Test lamp does not light. L O C A T E and R E P A IR open in P P L
lam p from H igh Blow er M otor (65) wire between H igh Blow er M otor
Relay socket Cavity C l to Blow er Relay and Blow er Motor.
M otor P P L (65) wire Connector
Cavity A.
4. Connect a test lamp from H igh Test lamp lights. R E P L A C E H igh Blow er M otor Relay.
Blow er M otor Relay socket Cavity Test lamp does not light. G O to Step 5.
C 2 to ground.
5. Disconnect Connector C 2 (center) Test lamp lights. R E P L A C E H V A C Control Module.
at H V A C C o n t r o l M o d u le . Test lamp does not light. L O C A T E and R E P A IR open in B R N
C on n ect a test lam p between (141) wire between IP Fuse B lo ck and
H V A C Control M odule Connector
H V A C Control Module.
C 2 Cavity G to ground.
BLOWER MOTOR INOPERATIVE (HEATER WITHOUT A/C)

TEST RESULT ACTIO N
1. Disconnect Connector at Blow er Test lamp lights. G O to Step 2.
Motor. Place Ignition Sw itch in Test lamp does not light. G O to Step 3.
R U N . Place Blow er Switch in H I.
Connect a test lamp from Blow er
M otor P P L (65) wire Connector
Cavity A to ground.
2. Connect a self-powered test lamp Test lamp lights. R E P L A C E Blow er Motor.
between Blow er M otor B L K (150) Test lamp does not light. L O C A T E and R E P A IR open in B L K
w ire C o n n e c to r C a v ity A to (150) wire between Blow er M otor and
ground. Ground G202.
3. R e m o v e H ig h B lo w e r M o to r Test lamp lights. G O to Step 4.
Relay. Connect a self-powered test Test lamp does not light. L O C A T E and R E P A IR open in P P L
lam p from H igh Blow er M otor (65) wire between H igh Blow er M otor
Relay socket Cavity C l to Blow er Relay and Blow er Motor.
M otor Connector Cavity A.
4. Connect a test lam p from H igh Test lamp lights. R E P L A C E H igh Blow er M otor Relay.
C 2 to ground.
5. D is c o n n e c t C o n n e c to r C 2 at Test lamp lights. R E P L A C E Heater Control Module.
Heater Control Module. Connect a Test lamp does not light.
L O C A T E and R E P A IR open in B R N
test lamp between Heater Control
(141) wire between IP Fuse B lo ck and
M odule Connector C 2 Cavity G to Heater Control Module.
ground.
BLOWER MOTOR INOPERATIVE IN HIGH (HEATER WITH OR WITHOUT A/C)

TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Test lamp lights. G O to Step 3.
P la ce B lo w e r S w itc h in H I. Test lamp does not light. G O to Step 2.
R e m o ve H ig h M o to r B lo w e r
M otor Relay. Connect a test lamp
betw een H ig h B lo w e r M o to r
Relay socket Cavity C 2 to ground.
2. D isc o n n e c t C o n n e c to r C 2 at Test lamp lights. R E P L A C E Heater Control M odule or
Heater Control M odule or H V A C H V A C Control Module.
C o n t ro l M o d u le . C o n n e c t a Test lamp does not light. L O C A T E an R E P A IR open in O R N
self-powered test lam p between (52) wire between Heater Control
Heater Control M odule or H V A C M odule or H V A C Control M odule and
C ontrol M o d u le Connector C 2 H igh Blow er M otor Relay.
Cavity H and H igh Blow er M otor
Relay socket Cavity C2.
3. Connect a test lamp between H igh Test lamp lights. L O C A T E and R E P A IR open in R E D
Blow er M otor Relay socket Cavity (542) wire between Underhood
A 2 and ground. Fuse-Relay Center and H igh Blow er
M otor Relay.
4. Connect a self-powered test lamp Test lamp lights. R E P L A C E H igh Blow er M otor Relay.
betw een H ig h B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in B L K
R e la y so cke t C a v ity A 1 and (150) wire between H igh Blow er M otor
ground. Relay and Ground G105 or G202.
BLOWER MOTOR INOPERATIVE IN MED-2 (HEATER WITH OR WITHOUT A/C)

TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Test lamp lights. R E P L A C E Blow er Resistor.
P la c e B lo w e r S w itc h in M 2 Test lamp does not light. G O to Step 2.
position (next to H I). Disconnect
C onnector at B lo w e r Resistor.
C on n ect a test lam p between
Blow er Resistor Connector Cavity
D and ground.
2. D isc o n n e c t C o n n e c to r C 2 at Test lamp does not light. L O C A T E and R E P A IR open in L T
Heater Control M odule or H V A C B L U (72) wire between Heater Control
C o n t ro l M o d u le . C o n n e c t a M odule or H V A C Control M odule and
self-powered test lamp between Blow er Resistor.
C o n n e c to r C 2 C a v it y A and Test lamp lights. R E P L A C E Heater Control M odule or
Blow er Resistor Connector Cavity H V A C Control Module.
D.
HVAC BLOWER CONTROL
BLOWER MOTOR INOPERATIVE IN MED-1 (HEATER WITH OR WITHOUT A/C)

TEST RESULT ACTIO N
P la ce B lo w e r S w itc h in M l Test lamp does not light. G O to Step 2.
position (next to LO ). Disconnect
C onnector at B lo w e r Resistor.
C and ground.
2. D isc o n n e c t C o n n e c to r C 2 at Test lamp does not light. L O C A T E and R E P A IR open in T A N
Heater Control M odule or H V A C (63) wire between Heater Control
self-powered test lam p between Blow er Resistor.
C o n n e c to r C 2 C a v it y B and Test lamp lights.
R E P L A C E Heater Control M odule or
B lo w e r R e s is t o r C o n n e c t o r
Cavity C.
BLOWER MOTOR INOPERATIVE IN LO (HEATER WITH OR WITHOUT A/C)

P la ce B lo w e r S w itc h in L O . Test lamp does not light. G O to Step 2.
Disconnect Connector at Blow er
R e sistor. C onnect a test lam p
b e t w e e n B lo w e r R e s i s t o r
Connector Cavity A and ground.
2. D isc o n n e c t C o n n e c to r C 2 at Test lamp does not light. L O C A T E and R E P A IR open in Y E L
Heater Control M odule or H V A C (60) wire between Heater Control
self-powered test lam p between, Blow er Resistor.
C o n n e c to r C 2 C a v it y C and Test lamp lights. R E P L A C E Heater Control M odule or
B lo w e r R e s is t o r C o n n e c to r H V A C Control Module.
Cavity A.
BLOWER MOTOR ONLY OPERATES IN HI (HEATER WITH OR WITHOUT A/C)

1. Place Ign itio n Sw itch in R U N . Test lamp lights. R E P L A C E H igh Blow er M otor Relay.
P la ce B lo w e r S w itc h in L O . Test lamp does not light. G O to Step 2.
R e m o v e H ig h B lo w e r M o to r
R e la y . C o n n e c t a test lam p
betw een H ig h B lo w e r M o to r
R e la y so ck e t C a v ity B 2 and
ground.
2. Disconnect Connector at Blow er Test lamp lights. R E P L A C E Blow er Resistor.
Resistor. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in D K
test lamp between Blow er Resistor B L U (101) wire between Blower
C onnector C a vity B and H ig h Resistor and H igh Blow er M otor Relay.
Blow er M otor Relay socket Cavity
B2.
BLOWER MOTOR OPERATES CONTINUOUSLY AT ANY SPEED (HEATER WITH OR

WITHOUT A/C)
TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Yes. L O C A T E and R E P A IR short to voltage
Place B lo w e r Sw itch in O FF. in P P L (65) wire between H igh Blow er
R e m o ve H ig h B lo w e r M o to r M otor Relay and Blow er Motor.
R e la y . D o e s B lo w e r M o t o r No. G O to Step 2.
operate?
2. Connect a test lamp between H igh Test lamp lights. G O to Step 3.
B lo w e r M o to r R e la y S o c k e t Test lamp does not light. G O to Step 4.
Cavity C 2 and ground.
3. D isc o n n e c t C o n n e c to r C 2 at Test lamp lights. L O C A T E and R E P A IR short to voltage
Heater Control M odule or Heater in O R N (52) wire between Heater
and A/C control Module. Connect Control M odule or H V A C Control
a test lamp between H igh Blow er M odule and H igh Blow er M otor Relay.
M otor Relay socket Cavity C 2 and Test lamp does not light. R E P L A C E Heater Control M odule or
ground. H V A C Control Module.
4. Connect a test lamp between H igh Test lamp lights. G O to Step 5.
Blow er M otor Relay socket Cavity Test lamp does not light. R E P L A C E H igh Blow er M otor Relay.
B 2 and ground.
5. Disconnect Connector at Blow er Test lamp lights. L O C A T E and R E P A IR short to voltage
R esistor. C onnect a test lam p in D K B L U (101) wire between
betw een H ig h B lo w e r M o to r Blow er Resistor and H igh Blow er
R e la y so ck e t C a v ity B 2 and M otor Relay.
ground. Test lamp does not light. G O to Step 6.
Heater Control M odule or H V A C in Y E L (60) wire between Heater
Control M odule. Connect a test Control M odule or H V A C Control
la m p fro m B lo w e r R e s is t o r M odule and Blower Resistor.
Connector Cavity A to ground. Test lamp does not light. G O to Step 7.
7. Connect a test lamp from Blow er Test lamp lights. L O C A T E and R E P A IR short to voltage
Resistor Connector C avity C to in T A N (63) wire between Heater
ground. Control M odule or H V A C Control
M odule an Blow er Resistor.
8. Connect a test lamp from Blow er Test lamp lights. L O C A T E and R E P A IR short to voltage
Resistor Connector C avity D to in L T B L U (72) wire between Heater
ground. Control M odule or H V A C Control
M odule and Blow er Resistor.
Test lamp does not light. R E P L A C E Heater Control M odule or
HVAC BLOWER CONTROL
AUXILIARY BLOWER MOTOR INOPERATIVE (HEATER WITHOUT A/C)

TEST RESULT ACTION
1. Disconnect Connector at Auxiliary Test lamp lights. G O to Step 2.
B lo w e r M otor. Place Ig n itio n Test lamp does not light. G O to Step 3.
Switch in R U N . Place Auxiliary
H eater C o n tro l Sw itch in H I.
C o n n e c t a te st la m p fro m
A u x ilia r y B lo w e r M o to r
Connector Cavity A and ground.
2. Connect a self-powered test lamp Test lamp lights. R E P L A C E A uxiliary Blow er Motor.
between Auxiliary Blow er M otor Test lamp does not light.
L O C A T E and R E P A IR open in B L K
Connector Cavity B to ground. (150) wire between Auxiliary Blow er
M otor and Ground G400.
3. Rem ove A u xilia ry H igh Blow er Test lamp lights. G O to Step 4.
M otor Relay. Connect a test lamp Test lamp does not light. L O C A T E and R E P A IR open in R E D
fro m A u x ilia r y H ig h B lo w e r
(542) wire between Underhood
M otor Relay socket Cavity 1 to
Fuse-Relay Center and Splice S401.
ground.
4. C on n ect a test lam p between Test lamp lights. G O to Step 5.
A u x ilia ry H ig h B lo w e r M o to r
Relay socket Cavity 5 and ground.
Splice S400.
5. Connect a self-powered test lamp Test does lights. G O to Step 6.
between A u xilia ry H igh Blow er Test lamp does not light.
L O C A T E and R E P A IR open in Y E L
M otor Relay socket Cavity 4 and (1172) wire between Splice S402 and
A uxiliary Blow er Motor.
Connector Cavity A.
6. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary Heater Control
Heater Control Switch. Connect a Switch.
self-powered test lam p between Test lamp does not light.
A u xilia ry Heater Control Switch
(150) wire between A uxiliary Heater
Connector Cavity B and ground. Control Switch and Ground G400.
AUXILIARY BLOWER MOTOR INOPERATIVE IN HI (HEATER WITHOUT A/C)

TEST RESULT ACTION
Place A u x ilia ry Heater Control Test lamp does not light. G O to Step 2.
Switch in H I. Remove Auxiliary
H i g h B l o w e r M o t o r R e la y .
Connect a self-powered test lamp
between A u xilia ry H igh Blow er
M otor Relay socket Cavity 2 and
ground.
2. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary Heater Control
self- powered test lamp between Test lamp does not light. L O C A T E and R E P A IR open in W H T
A u xilia ry Heater Control Switch (1924) wire between Auxiliary Heater
Connector Cavity D and Auxiliary Control Switch and Auxiliary H igh
H ig h B lo w e r M o t o r R e la y Blow er M otor Relay.
Connector Cavity 2.
TEST RESULT ACTIO N

3. C onnect a test lam p between Test lamp lights. G O to Step 4.
A u x ilia ry H ig h B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in B R N
Relay socket Cavity 5 and ground. (341) wire between Splice S400 and
A uxiliary H igh Blow er M otor Relay.
4. C onnect a test lam p between Test Lam p lights. G O to Step 5.
A u x ilia ry H ig h B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in R E D
Auxiliary H igh Blow er M otor Relay.
5. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E Auxiliary H igh Blow er
B lo w e r M otor. C onnect a M otor Relay.
self-powered test lam p between Test lamp does not light. L O C A T E and R E P A IR open in Y E L
A u x ilia ry H ig h B lo w e r M o to r (1172) wire between A uxiliary H igh
R e l a y s o c k e t C a v i t y 4 and Blow er M otor Relay and Splice S402.
Connector Cavity A.
AUXILIARY BLOWER MOTOR INOPERATIVE IN MED (HEATER WITHOUT A/C)

TEST RESULT ACTIO N
S w i t c h in M E D . R e m o v e
Auxiliary M edium Blow er M otor
Relay. Connect a self-powered test
lamp between A uxiliary M edium
2 to ground.
2. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E A uxiliary Heater Control
self-powered test lam p between Test lamp does not light. L O C A T E and R E P A IR open in R E D
A u xilia ry Heater Control Sw itch (1925) wire between A uxiliary Heater
Connector Cavity F and A uxiliary Control Switch and Auxiliary M edium
M e d iu m B lo w e r M o to r R e la y Blow er M otor Relay.
Connector Cavity 2.
Auxiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in B R N
Relay.
4. C onnect a test lam p between Test Lam p lights. G O to Step 5.
A uxiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in R E D
Relay.
HVAC BLOWER CONTROL
TEST RESULT ACTION

B l o w e r R e s i s t o r . C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR open in L T
self-powered test lamp between B L U (1072) wire between A uxiliary
A u xiliary M edium Blow er M otor M edium Blow er M otor Relay and
R e l a y s o c k e t C a v i t y 4 and Auxiliary Blow er Resistor.
A u x ilia r y B lo w e r R e sisto r
Connector Cavity A.
6. Insert A uxiliary M edium Blow er Test lamp lights. R E P L A C E Auxiliary Blow er Resistor.
Relay in its socket. Connect a test Test lamp does not light. R E P L A C E A uxiliary M edium Blow er
lam p between A u xilia ry Blow er M otor Relay.
Resistor Connector Cavity A and
ground.
AUXILIARY BLOWER MOTOR INOPERATIVE IN LO (HEATER WITHOUT A/C)

TEST RESULT ACTIO N
Sw itch in LO . Remove Auxiliary
L o w B lo w e r M o t o r R e lay.
between A u xilia ry L o w Blow er
ground.
2. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E Auxiliary Heater Control
self-powered test lam p between Test lamp does not light. L O C A T E and R E P A IR open in D K
A u xilia ry Heater Control Sw itch B L U (1926) wire between A uxiliary
Connector Cavity E and A uxiliary Heater Control Switch and A uxiliary
L o w B lo w e r M o to r R e la y
Low Blow er M otor Relay.
Connector Cavity 2.
3. C on n ect a test lam p betw een Test lamp lights. G O to Step 4.
A u x ilia ry L o w B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in B R N
Auxiliary Low Blow er M otor Relay.
4. C on n ect a test lam p between Test Lam p lights. G O to Step 5.
A u x ilia ry L o w B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in R E D
A uxiliary Low Blow er M otor Relay.
5. Disconnect Connector at A uxiliary Test lamp lights. G o to Step 6.
B l o w e r R e s i s t o r . C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR open in Y E L
self-powered test lamp between (1176) wire between Auxiliary Low
A u x ilia ry L o w B lo w e r M o to r Blow er M otor Relay and A uxiliary
R e l a y s o c k e t C a v i t y 4 and Blow er Resistor.
Connector Cavity C.
6. In se rt A u x ilia r y L o w B lo w e r Test lamp lights. R E P L A C E A uxiliary Blow er Resistor.
M otor Relay in its socket. Connect Test lamp does not light. R E P L A C E A uxiliary Low Blow er
a test lam p between A u x ilia ry M otor Relay.
C and ground.
AUXILIARY BLOWER MOTOR ONLY OPERATES IN HI (HEATER AND/OR A/C)

TEST RESULT ACTION
1. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E A uxiliary Blow er Resistor.
B l o w e r R e sis to r. D i s c o n n e c t Test lamp does not light. L O C A T E and R E P A IR open in Y E L
Connector at A u x ilia ry Blow er (1172) wire between Auxiliary Blow er
Motor. Connect a self-powered test Resistor and Splice S402.
lam p between A u xilia ry Blow er
Resistor Connector Cavity B and
Connector Cavity A.
AUXILIARY BLOWER MOTOR OPERATES CONTINUOUSLY AT ANY SPEED

(HEATER WITHOUT A/C)
TEST RESULT ACTIO N
1. Place Ign itio n Sw itch in R U N . Yes. L O C A T E and R E P A IR short to voltage
Place A u x ilia ry Heater Control in Y E L (1172) wire between Auxiliary
S w itc h O FF. D isc o n n e c t Blow er Resistor, Auxiliary H igh
Connector at A u x ilia ry B low e r Blow er M otor Relay and Auxiliary
Resistor. Remove Auxiliary H igh Blow er Motor.
B lo w e r M o to r Relay. D oe s the No. G O to Step 2.
A u xiliary Blow er M otor operate?
2. Connect Auxiliary Blow er Resistor Yes. G O to Step 3.
C onnector. Place the Ig n itio n No. G O to Step 10.
Switch in R U N . D oes Auxiliary
Blow er M otor operate?
3. In sta ll A u x ilia ry H ig h B lo w e r Test lamp lights. L O C A T E and R E P A IR short to voltage
M otor Relay in its socket. Remove on L T B L U (1072) wire between
the A uxiliary Low Blow er M otor A u xiliary M edium Blow er M otor Relay
Relay from its socket. Rem ove the and A uxiliary Blow er Resistor.
A uxiliary M edium Blow er M otor Test lamp does not light. G O to Step 4.
Relay from its socket. Connect a
test lam p between A u x i l i a r y
A and ground.
4. C on n ect a test lam p between Test lamp lights. L O C A T E and R E P A IR short to voltage
A u x ilia r y B lo w e r R e sisto r on Y E L (1176) wire between Auxiliary
Connector Cavity C and ground. Low Blow er M otor Relay and
A uxiliary Blow er Resistor.
5. Install Auxiliary M edium Blow er Test lamp lights. G O to Step 6.
Relay in its socket. Connect a test Test lamp does not light. G O to Step 8.
Resistor Connector Cavity A and
ground.
6. R e m o v e A u x i l i a r y M e d i u m Test lamp lights. G O to Step 7.
B lo w e r M o to r R e la y from its Test lamp does not light. R E P L A C E A uxiliary M edium Blow er
socket. Connect a self-powered M otor Relay.
test lamp from A uxiliary M edium
2 to ground.
HVAC BLOWER CONTROL
TEST RESULT ACTION

7. Disconnect Connector at Auxiliary Test lamp lights. L O C A T E and R E P A IR short to ground
Heater Control Switch. Connect a on R E D (1925) wire between Auxiliary
test lamp from A uxiliary Heater Heater Control Switch and Auxiliary
Control Switch Connector Cavity M edium Blow er M otor Relay.
F to ground. Test lamp does not light. R E P L A C E Auxiliary Heater Control
Switch.
from A uxiliary Low Blow er M otor Test lamp does not light. R E P L A C E Auxiliary Low Blow er
Relay socket Cavity 2 to ground. M otor Relay.
Heater Control Switch. Connect a on D K B L U (1926) wire between
test lamp from A uxiliary Heater A uxiliary Heater Control Switch and
Control Switch Connector Cavity Auxiliary Low Blow er M otor Relay.
E to ground. Test lamp does not light. R E P L A C E A uxiliary Heater Control
Switch.
between A u x ilia ry H igh Blow er Test Lam p does not light. R E P L A C E A uxiliary H igh Blow er
M otor Relay socket Cavity 2 and M otor Relay.
ground.
11. Disconnect Connector at A uxiliary Test lamp lights. LO CA TE and R E P A IR short to ground
Heater Control Switch. Connect a on W H T (1924) wire between
self-powered test lam p between A uxiliary Heater Control Switch and
A u xilia ry Heater Control Switch A uxiliary H igh Blow er M otor Relay.
Connector Cavity D and ground. Test lamp does not light. R E P L A C E Auxiliary Heater Control
Switch.
AUXILIARY BLOWER MOTOR INOPERATIVE (HEATER WITH A/C)

TEST RESULT ACTION
B lo w e r M otor. P lace Ig n itio n Test lamp does not light.
G O to Step 3.
Switch in R U N . Place A uxiliary
Blow er Sw itch at the A u xilia ry
H V A C C on trol M o d u le in H I.
Place Auxiliary Blow er Switch at
the A u x ilia r y H V A C C o n tro l
M odule in O FF. Connect a test
lam p fro m A u x i l i a r y B l o w e r
M o to r C onnector C a v ity A to
ground.
between Auxiliary Blow er M otor Test lamp does not light.
Connector Cavity B to ground.
(150) wire between A uxiliary Blow er
3. Rem ove A u x ilia ry H igh Blow er Test lamp lights. G O to Step 4.
M o to r R e la y from its socket. Test lamp does not light.
L O C A T E and R E P A IR open in R E D
C o n n e c t a te s t l a m p f r o m
(542) wire between Underhood
Fuse-Relay Center and Splice S401.
Relay socket Cavity 1 to ground.
Relay socket Cavity 5 to ground. (341) wire between IP Fuse Block and
Splice S400.
TEST RESULT ACTION

5. C onnect a test lam p between Test does lights. G O to Step 6.
A u x ilia ry H ig h B lo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in Y E L
R e l a y s o c k e t C a v i t y 4 and (1172) wire between Splice S402 and
A u x ilia r y B lo w e r M o to r A uxiliary Blow er Motor.
Connector Cavity A.
6. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary H V A C Control
H V A C Control Module. Connect a Module.
self-powered test lam p between Test lamp does not light. L O C A T E and R E P A IR open in B L K
A uxiliary H V A C Control M odule (150) wire between FronVAuxiliary
Connector Cavity B and ground. H V A C Control M odule and Ground
G400.
AUXILIARY BLOWER MOTOR INOPERATIVE IN HI (HEATER WITH A/C)

TEST RESULT ACTION
Rem ove A u xilia ry H igh Blow er Test lamp does not light. G O to Step 2.
M otor Relay from its socket. Place
A u x i l i a r y B l o w e r S w i t c h at
in H I. Place A u x ilia ry B lo w e r
S w i t c h at A u x i l i a r y H V A C
Control M odule in OFF. Connect a
2. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Front A uxiliary H V A C
self-powered test lamp between Test lamp does not light. L O C A T E and R E P A IR open in W H T
Auxiliary H V A C Control M odule (1924) wire between Front A uxiliary
Connector Cavity D and A uxiliary H V A C Control M odule and Auxiliary
H igh Blow er M otor Relay socket H igh Blow er M otor Relay.
Cavity 2.
3. Place A uxiliary Blow er Switch at Test lamp lights. G O to Step 5.
Front A u x ilia ry H V A C C ontrol Test lamp does not light. G O to Step 4.
M odule in OFF. Place A uxiliary
Blow er Switch at A uxiliary H V A C
Control M odule in H I. Connect a
4. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E A uxiliary H V A C Control
A uxiliary H V A C Control M odule (1924) wire between Auxiliary H V A C
Connector Cavity D and A uxiliary Control M odule and Splice S309.
H igh Blow er M otor Relay socket
Cavity 2.
HVAC BLOWER CONTROL
TEST RESULT ACTIO N

A u x ilia ry H ig h B lo w e r M o to r Test lamp does not light.
7. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E A uxiliary H igh Blow er
B lo w e r M otor. C onnect a test M otor Relay.
lam p between A u x ilia ry H ig h Test lamp does not light.
Blow er M otor Relay socket Cavity (1172) wire between A uxiliary H igh
4 and A u x ilia ry B low e r M otor
Blow er M otor Relay and Splice S402.
Connector Cavity A.
AUXILIARY BLOWER MOTOR INOPERATIVE IN MED (HEATER WITH A/C)

TEST RESULT ACTIO N
R e m o v e A u x i l i a r y M e d i u m Test lamp does not light.
G O to Step 2.
B lo w e r M o t o r R e la y from its
socket. Place A u x ilia ry Blow er
Switch at Front Auxiliary H V A C
Control M odule in M E D . Place
A u x i l i a r y B l o w e r S w i t c h at
in OFF. Connect a self-powered
test la m p between A u x i l i a r y
M e d iu m B lo w e r M o to r R e lay
socket Cavity 2 and ground.
2. D iscon n ect C onnector at Front Test lamp lights. R E P L A C E Front Auxiliary Heater and
A u xiliary H V A C Control Module. A/C Control Module.
Connect a self-powered test lamp Test lamp does not light.
between Front A u xilia ry H V A C
(1925) wire between Front Auxiliary
Control M odule Connector Cavity
H V A C Control M odule and Auxiliary
E and A u xiliary M edium Blow er M edium Blow er M otor Relay.
M otor Relay socket Cavity 2.
Front A u x ilia ry H V A C C ontrol
M odule in OFF. Place Auxiliary
Blow er Switch at A uxiliary H V A C
Control M odule in M E D . Connect
A uxiliary M edium Blow er M otor
A u xiliary H V A C Control M odule (1925) wire between Auxiliary H V A C
Connector Cavity E and Auxiliary Control M odule and Splice S305.
M e d iu m B lo w e r M o t o r R e lay
socket Cavity 2.
A u xiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in B R N
Relay.
TEST RESULT ACTION

Auxiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in R E D
Relay.
self-powered test lamp between B L U (1072) wire between Auxiliary
Auxiliary M edium Blow er M otor M edium Blow er M otor Relay and
R e l a y s o c k e t C a v i t y 4 an d Auxiliary Blower Resistor.
Connector Cavity A.
8. Insert Auxiliary M edium Blow er Test lamp lights. R E P L A C E Auxiliary Blow er Resistor.
M otor Relay in its socket. Connect Test lamp does not light. R E P L A C E Auxiliary M edium Blow er
A and ground.
AUXILIARY BLOWER MOTOR INOPERATIVE IN LO (HEATER WITH A/C)

TEST RESULT ACTION
1. Place Ign ition Sw itch in R U N . Test lamp lights. G O to Step 3.
Rem ove A u x ilia ry L o w B low e r Test lamp does not light. G O to Step 2.
Auxiliary Blow er Switch at Front
in LO . Place A u xilia ry Blow er
S w i t c h at A u x i l i a r y H V A C
Control Module in OFF. Connect a
self-powered test lam p between
A u x i lia r y L o w B lo w e r M o t o r
2. D isconnect Connector at Front Test lamp lights. R E P L A C E Front Auxiliary H V A C
A uxiliary H V A C Control Module. Control Module.
Connect a self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in D K
between Front A u xilia ry H V A C B L U (1926) wire between Front
Control M odule Connector Cavity Auxiliary H V A C Control M odule and
C and A u x ilia r y L o w B lo w e r Auxiliary Low Blow er M otor Relay.
3. Place Auxiliary Blow er Switch at Test lamp lights. G O to Step 5.
Front A u xilia ry H V A C C ontrol Test lamp does not light. G O to Step 4.
M odule in OFF. Place A uxiliary
Blow er Switch at Auxiliary H V A C
Control Module in LO . Connect a
A u x i l i a r y L o w B lo w e r R e la y
socket Cavity 2 and ground.
HVAC BLOWER CONTROL
TEST RESULT ACTION

self-powered test lamp between Test lamp does not light. L O C A T E and R E P A IR open in D K
A u xiliary H V A C Control Module
B L U (1926) wire between Auxiliary
Connector Cavity C and Auxiliary
H V A C Control M odule and Splice
Low Blow er M otor Relay socket S306.
Cavity 2.
5. Connect a test lam p between Test lamp lights. G O to Step 6.
A u x i l i a r y L o w B lo w e r M o to r
6. Con n ect a test lam p between Test lamp lights. G O to Step 7.
A u x i l i a r y L o w B lo w e r M o to r
Test lamp does not light. L O C A T E and R E P A IR open in R E D
A uxiliary Low Blow er M otor Relay.
B l o w e r R e s i s t o r . C o n n e c t a Test lamp does not light.
(1176) wire between A uxiliary Low
A u x i l i a r y L o w B lo w e r M o t o r
Blow er M otor Relay and A uxiliary
R e l a y s o c k e t C a v i t y 4 and
Blow er Resistor.
Connector Cavity C.
8. Insert A u x i l i a r y L o w B lo w e r Test lamp lights. R E P L A C E Auxiliary Blow er Resistor.
Relay in its socket. Connect a test Test lamp does not light. R E P L A C E A uxiliary Low Blow er
M otor Relay.
Resistor Connector Cavity C and
ground.
AUXILIARY BLOWER MOTOR OPERATES CONTINUOUSLY AT ANY SPEED

(HEATER WITH A/C)
TEST RESULT ACTIO N
1. Place Ignition Switch OFF. Place Yes. L O C A T E and R E P A IR short to voltage
A u x ilia ry Blow er Sw itch at the in Y E L (1172) wire between Auxiliary
Front A u x ilia ry H V A C Control Blow er Resistor, A uxiliary H igh
M odule in OFF. Place Auxiliary Blow er M otor Relay, and Auxiliary
B low e r Sw itch at the A u xilia ry Blow er Motor.
H V A C Control M odule in OFF. No. G O to Step 2.
Disconnect Connector at Auxiliary
B lo w e r R e sisto r. R e m o ve
A u x ilia ry H ig h Blo w e r M o to r
Relay from its socket. Does the
A u xilia ry Blow er M otor operate?
2. Connect Connector at A u xilia ry Yes. G O to Step 3.
Blow er Resistor. Place the Ignition No.
G O to Step 12.
S w i t c h in R U N . D o e s the
A u xiliary Blow er M otor operate?
3. Install the A uxiliary H igh Blow er Test lamp lights. L O C A T E and R E P A IR short to voltage
the A uxiliary Low Blow er M otor Auxiliary M edium Blow er M otor Relay
Relay from its socket. Remove the and Auxiliary Blow er Resistor.
A u xiliary M edium Blow er M otor Test lamp does not light. G O to Step 4.
test la m p between A u x i l i a r y
A and ground.
TEST RESULT ACTIO N

4. C onnect a test lam p between Test lamp lights. L O C A T E and R E P A IR short to voltage
A u x ilia ry B lo w e r R e sisto r on Y E L (1176) wire between Auxiliary
Auxiliary Blow er Resistor.
5. Install A uxiliary M edium Blow er Test lamp lights. G O to Step 6.
M otor Relay in its socket. Connect Test lamp does not light. G O to Step 9.
a test lam p between A u x ilia ry
A and ground.
Blow er M otor Relay in its socket. Test lamp does not light. R E P L A C E Auxiliary M edium Blow er
Connect a self-powered test lamp M otor Relay.
from A u xilia ry M edium Blow er
7. D isconnect C onnector at Front Test lamp lights. L O C A T E and R E P A IR short to ground
Auxiliary H V A C Control Module. on R E D (1925) wire between Auxiliary
Disconnect Connector at A uxiliary M edium Blow er M otor Relay, Front
H V A C Control Module. Connect a Auxiliary H V A C Control Module, and
test lamp from Front A u xilia ry Auxiliary Heater and A/C Control
H V A C Control M odule Connector Module.
Cavity D to ground. Test lamp does not light. G O to Step 8.
8. C o n n e c t C o n n e c t o r at F r o n t Test lamp lights. R E P L A C E Front H V A C Control
Auxiliary H V A C Control Module. Module.
C o n n e c t a te s t l a m p f r o m Test lamp does not light. R E P L A C E Auxiliary H V A C Control
Auxiliary M edium Blow er M otor Module.
from Auxiliary Low Blow er M otor Test lamp does not light. R E P L A C E Auxiliary Low Blow er
10. D isconnect Connector at Front Test lamp lights. L O C A T E and R E P A IR short to ground
A uxiliary H V A C Control Module. on D K B L U (1926) wire between
Disconnect Connector at A uxiliary Auxiliary Low Blow er M otor Relay,
H V A C Control Module. Connect a Front A uxiliary H V A C Control Module,
test lam p from A u x ilia ry L o w and Auxiliary H V A C Control Module.
2 to ground.
11. C o n n e c t C o n n e c t o r at F r o n t Test lamp lights. R E P L A C E Front Auxiliary H V A C
Auxiliary H V A C Control Module. Control Module.
C o n n e c t a te s t l a m p f r o m Test lamp does not light. R E P L A C E Auxiliary H V A C Control
A u x ilia ry L o w B lo w e r M o t o r Module.
between A u xilia ry H igh Blow er Test lamp does not light. R E P L A C E A uxiliary H igh Blow er
M otor Relay socket Cavity 2 and M otor Relay.
ground.
HVAC BLOWER CONTROL
TEST RESULT ACTIO N

13. D iscon n ect Connector at Front Test lamp lights. L O C A T E and R E P A IR short to ground
A uxiliary H V A C Control Module. on W H T (1924) wire between
Disconnect Connector at Auxiliary Auxiliary H igh Blow er M otor Relay,
H V A C Control Module. Connect a Front Auxiliary H V A C Control Switch,
self-powered test lamp between and Auxiliary H V A C Control Switch.
A u x ilia r y H ig h B lo w e r M o to r Test lamp does not light. G O to Step 14.
14. C o n n e c t C o n n e c t o r at F r o n t Test lamp lights. R E P L A C E Front A uxiliary H V A C
A uxiliary H V A C Control Module. Control Module.
Connect a self-powered test lamp Test lamp does not light. R E P L A C E A uxiliary H V A C Control
between A u xilia ry H igh Blow er Module.
ground.
AUXILIARY BLOWER SWITCH AT AUXILIARY HVAC CONTROL MODULE FUNCTIONS

WHEN AUXILIARY BLOWER SWITCH AT FRONT AUXILIARY HVAC CONTROL MODULE IS
NOT IN THE AUXILIARY POSITION (HEATER WITH A/C)
TEST RESULT ACTIO N
Front A u x ilia ry H V A C C ontrol Test lamp does not light. G O to Step 3.
M odule in OFF. Place Auxiliary
Blow er Switch at Auxiliary H V A C
C o n t r o l M o d u l e in O F F .
Disconnect Connector at A uxiliary
H V A C C on trol L o g ic M od ule.
between A uxiliary H V A C Control
Logic M odule Connector Cavity N
and ground.
A u xiliary H V A C Control Module. in O R N (1923) wire between Auxiliary
Connect a self-powered test lamp H V A C Control Logic M odule and
between Front A u xilia ry H V A C Front H V A C Control Module.
Control M odule Connector Cavity Test lamp does not light. R E P L A C E Front A uxiliary H V A C
F and ground. Control Module.
between Front A u xilia ry H V A C Test lamp does not light. L O C A T E and R E P A IR open in O R N
Control M odule Connector Cavity (1923) wire between Front Auxiliary
F and A u xilia ry H V A C Control H V A C Control M odule and Auxiliary
L o g ic M odule Connector Cavity H V A C Control Logic Module. Then,
N.
G O to Step 4.
4. Reconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary H V A C Control
H V A C C on trol L o g ic M od ule. Logic Module.
Connect a self-powered test lamp Test lamp does not light. G O to Step 5.
F and ground.
5. Disconnect Connector at A uxiliary Test lamp lights. L O C A T E and R E P A IR short to ground
H V A C C o n tro l L o g ic M o d ule. in D K B L U (77) wire between
Disconnect Connector at Auxiliary A uxiliary H V A C Control Logic M odule
H V A C Control Module. Connect a and A uxiliary H V A C Control Module.
self-powered test lamp between Test lamp does not light. R E P L A C E A uxiliary H V A C Control
A u xiliary H V A C Control M odule Module.
Connector Cavity F and ground.
AUXILIARY BLOWER SWITCH AT AUXILIARY AUXILIARY HVAC CONTROL MODULE DOES

NOT CONTROL THE AUXILIARY BLOWER WHEN SELECTED (HEATER WITH A/C)
TEST RESULT ACTION
1. Place Auxiliary Blow er Switch at Test lamp lights. G O to Step 2.
Front A u x ilia ry H V A C Control Test lamp does not light. R E P L A C E Front A uxiliary H V A C
M o d u le in R E A R . D iscon n ect Control Module.
C o n n e cto r at F ro n t A u x i l i a r y
H V A C Control Module. Connect a
Front A u x ilia ry H V A C Control
M odule Cavities B and F.
2. Disconnect Connector at A uxiliary Test lamp lights. G O to Step 3.
H V A C C o n tro l L o g ic M od ule. Test lamp does not light. L O C A T E and R E P A IR open in O R N
Connect a self-powered test lamp (1923) wire between Front A uxiliary
between Front A u xilia ry H V A C H V A C Control M odule and A uxiliary
Control M odule Connector Cavity H V A C Control Logic Module.
B and A u xilia ry H V A C Control
Lo gic M odule Connector Cavity
M.
3. Connect a self-powered test lamp Test lamp does not light in either R E P L A C E Auxiliary H V A C Control
between A uxiliary H V A C Control direction. Logic Module.
Logic M odule Cavities M and L. Test lamp lights for one direction only. G O to Step 4.
O bserve the in d ication . Then,
reverse the leads and observe the Test lamp lights for both directions. R E P L A C E A uxiliary H V A C Control
indication. Logic M odule for shorted diode. Then,
G O to Step 4.
4. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E A uxiliary H V A C Control
self-powered test lam p between Test lamp does not light. L O C A T E and R E P A IR open in D K
A u xilia ry H V A C Control L o g ic B L U (77) wire between Auxiliary
M odule Connector Cavity L and H V A C Control Logic M odule and
A uxiliary H V A C Control M odule A uxiliary H V A C Control Module.
Connector Cavity F.
AUXILIARY BLOWER MOTOR INOPERATIVE AT ANY SPEED (A/C WITHOUT HEATER)

TEST RESULT ACTION
B lo w e r M otor. P lace Ig n itio n Test lamp does not light. G O to Step 3.
S w i t c h in R U N . Place F ro n t
A u xiliary A/C Control Switch in
H I. Place Auxiliary A/C Control
Sw itch in O FF. Connect a test
la m p from A u x i l i a r y B l o w e r
M o to r C onnector C a v ity A to
ground.
between A uxiliary Blow er M otor
Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector Cavity B to ground.
(150) wire between A uxiliary Blow er
HVAC BLOWER CONTROL
TEST RESULT ACTION

3. Rem ove A u x ilia ry H igh Blow er Test lamp lights. G O to Step 4.
M o t o r R e la y from its socket. Test lamp does not light. L O C A T E and R E P A IR open in R E D
C o n n e c t a te s t l a m p f r o m (542) wire between Underhood
A u x ilia ry H ig h B lo w e r M o to r Fuse-Relay Center and Splice S401.
4. Connect a non-powered test lamp Test lamp lights. G O to Step 5.
between A u x ilia ry H igh Blow er Test lamp does not light. L O C A T E and R E P A IR open in B R N
Relay socket Cavity 5 to ground. (341) wire between IP Fuse Block and
Splice S400.
between A u x ilia ry H igh Blow er Test lamp does not light. L O C A T E and R E P A IR open in Y E L
M otor Relay socket Cavity 4 and (1172) wire between Splice S402 and
A u x ilia r y B lo w e r M o to r Auxiliary Blow er Motor.
Connector Cavity A.
6. D iscon n ect C onnector at Front Test lamp lights. R E P L A C E Front Auxiliary A/C
A u x ilia ry A/C C on trol Sw itch. Control Switch.
Connect a self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in B L K
between Fro n t A u x i l i a r y A /C (150) wire between Front/Auxiliary
Control Switch Connector Cavity A/C Control Switch and Ground G400.
B and ground.
AUXILIARY BLOWER MOTOR INOPERATIVE IN HI (A/C WITHOUT HEATER)

TEST RESULT ACTIO N
Rem ove A u xilia ry H igh Blow er Test lamp does not light. G O to Step 2.
F ro n t A u x i l i a r y A / C C o n tro l
Switch in H I. Place Auxiliary A/C
Control Switch in OFF. Connect a
2. D isconnect C onnector at Front Test lamp lights. R E P L A C E Front Auxiliary A/C
A u x ilia ry A/C C on trol Sw itch. Control Module.
Connect a self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in W H T
between F ro n t A u x i l i a r y A /C (1924) wire between Front Auxiliary
Control Switch Connector Cavity A/C Control Switch and Auxiliary
D and A u x ilia ry H ig h B lo w e r H igh Blow er M otor Relay.
3. Place Front A u xiliary A/C Control Test lamp lights. G O to Step 5.
Sw itch in O FF. Place A u xiliary Test lamp does not light. G O to Step 4.
A / C C o n t r o l S w i t c h in H I.
between A u x ilia ry H igh Blow er
ground.
TEST RESULT ACTION

4. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E Auxiliary A/C Control
A/C Control Switch. Connect a Switch.
A u x ilia ry A /C C o n tro l Switch (1924) wire between A uxiliary A/C
Connector Cavity D and Auxiliary Control Switch and Splice S440.
H igh Blow er M otor Relay socket
Cavity 2.
A u x ilia ry H ig h Blo w e r M o to r Test lamp does not light. L O C A T E and R E P A IR open in R E D
7. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary H igh Blow er
B lo w e r M otor. C onnect a test M otor Relay.
lam p between A u x i lia r y H ig h Test lamp does not light. L O C A T E and R E P A IR open in Y E L
Blow er M otor Relay socket Cavity (1172) wire between A u xiliary H igh
4 and A u x ilia ry B low e r M o to r Blow er M otor Relay and Splice S402.
Connector Cavity A.
AUXILIARY BLOWER MOTOR INOPERATIVE IN MED (A/C WITHOUT HEATER)

TEST RESULT ACTION
R e m o v e A u x i l i a r y M e d i u m Test lamp does not light. G O to Step 2.
B lo w e r M o t o r R e lay from its
socket. Place Front Auxiliary A/C
C ontrol Sw itch in M E D . Place
A uxiliary A/C Control Switch in
OFF. Connect a self-powered test
lamp between Auxiliary M edium
2 and ground.
2. D isconnect Connector at Front Test lamp lights. R E P L A C E Front A uxiliary A/C
A u x ilia ry A/C C ontrol Sw itch. Control Switch.
Connect self-powered test lamp
Test lamp does not light. L O C A T E and R E P A IR open in R E D
between F ro n t A u x i l i a r y A /C (1925) wire between Front A uxiliary
Control Switch Connector Cavity A/C Control Switch and A uxiliary
E and Auxiliary M edium Blow er M edium Blow er M otor Relay.
3. Place Front Auxiliary A/C Control Test lamp lights. G O to Step 5.
Sw itch in OFF. Place A u xiliary Test lamp does not light. G O to Step 4.
A /C C on trol Switch in M E D .
between A u x i l i a r y M e d iu m
2 and ground.
HVAC BLOWER CONTROL
TE S T RESULT ACTION
4. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E A uxiliary A/C Control
A u x ilia ry A /C C on trol Switch (1925) wire between Auxiliary A/C
Connector Cavity E and Auxiliary Control Switch and Splice S441.
M e d iu m B lo w e r M o to r Relay
socket Cavity 2.
A u xiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in B R N
Relay.
A u x ilia ry M ed ium B low e r Relay Test lamp does not light. L O C A T E and R E P A IR open in R E D
socket Cavity 1 and ground. (542) wire between Splice S401 and
Relay.
self-powered test lam p between B L U (1072) wire between Auxiliary
A u xiliary M edium Blow er M otor M edium Blow er M otor Relay and
R e l a y s o c k e t C a v i t y 4 and A uxiliary Blow er Resistor.
Connector Cavity A.
8. Insert A u xiliary M edium Blow er Test lamp lights. R E P L A C E A uxiliary Blow er Resistor.
M otor Relay in its socket. Connect Test lamp does not light. R E P L A C E Auxiliary M edium Blow er
a test lam p between A u x ilia ry Relay.
A and ground.
AUXILIARY BLOWER MOTOR INOPERATIVE IN LO (A/C WITHOUT HEATER)

TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N . Test lamp lights. G O to Step 3.
Rem ove A u x ilia ry L o w Blow er Test lamp does not light. G O to Step 2.
F r o n t A u x i l i a r y A / C C o n tro l
Sw itch in L O . Place A u x ilia ry
A / C C o n t r o l S w it c h in O F F .
between A u x ilia r y M e d iu m
2 and ground.
2. D iscon n ect C onnector at Front Test lamp lights. R E P L A C E Front A uxiliary A/C
Connect self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in D K
between F ro n t A u x i l i a r y A /C B L U (1926) wire between Front
Control Switch Connector Cavity Auxiliary A/C Control Switch and
C and A u x i lia r y L o w B lo w e r Auxiliary Low Blow er M otor Relay.
TE S T RESULT ACTION
3. Place Front A u xiliary A/C Control Test lamp lights. G O to Step 5.
Switch in O FF. Place A u xilia ry Test lamp does not light. G O to Step 4.
A / C C o n t r o l S w i t c h in L O .
between A u xilia ry L o w Blow er
ground.
4. Disconnect Connector at Auxiliary Test Lam p lights. R E P L A C E A uxiliary A/C Control
self-powered test lam p between L O C A T E and R E P A IR open in D K
Test lamp does not light.
A u x ilia ry A /C C o n tro l Switch B L U (1926) wire between Auxiliary
Connector Cavity C and A uxiliary A/C Control Switch and Splice S442.
Low Blow er M otor Relay socket
Cavity 2.
A u x ilia r y L o w B lo w e r M o t o r Test lamp does not light. L O C A T E and R E P A IR open in B R N
Auxiliary M edium Blow er M otor Test lamp does not light. L O C A T E and R E P A IR open in R E D
B l o w e r R e s i s t o r . C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR open in Y E L
self-powered test lamp between (1176) wire between Auxiliary Low
A u x ilia r y L o w B lo w e r M o to r Blow er M otor Relay and Auxiliary
R e l a y s o c k e t C a v i t y 4 and Blow er Resistor.
A u x ilia ry B lo w e r R e sisto r
Connector Cavity C.
8. Insert Auxiliary M edium Blow er Test lamp lights. R E P L A C E A uxiliary Blow er Resistor.
M otor Relay in its socket. Connect Test lamp does not light. R E P L A C E A uxiliary Low Blow er
C and ground.
AUXILIARY BLOWER MOTOR OPERATES CONTINUOUSLY AT ANY SPEED (A/C WITHOUT

HEATER)
TEST RESULT ACTIO N
1. Place Ign itio n Switch in O FF. Yes. L O C A T E and R E P A IR short to voltage
Place Front A uxiliary A/C Control in Y E L (1172) wire between Auxiliary
Sw itch in OFF. Place A u xilia ry Blow er Resistor, Auxiliary H igh
A / C C o n tro l S w it c h in O F F . Blow er M otor Relay, and Auxiliary
Disconnect Connector at Auxiliary Blow er Motor.
B l o w e r R e s i s t o r . R e m o v e No. G O to Step 2.
A u x ilia ry H ig h Blo w e r M o to r
Relay from its socket. Does the
Auxiliary Blow er M otor operate?
2. Connect Connector at A u xilia ry Yes. G O to Step 3.
Blow er Resistor. Place the Ignition No.
G O to Step 12.
S w i t c h in R U N . D o e s the
Auxiliary Blow er M otor operate?
HVAC BLOWER CONTROL
TEST RESULT ACTIO N

3. Install the A uxiliary H igh Blow er Test lamp lights. L O C A T E and R E P A IR short to voltage
the A uxiliary Low Blow er M otor A uxiliary M edium Blow er M otor Relay
Relay from its socket. Remove the and Auxiliary Blow er Resistor.
Auxiliary M edium Blow er M otor Test lamp does not light. G O to Step 4.
test lam p between A u x i l i a r y
A and ground.
4. C onnect a test lam p between Test lamp lights. L O C A T E and R E P A IR short to voltage
A u x ilia r y B lo w e r R e sisto r on Y E L (1176) wire between Auxiliary
A uxiliary Blow er Resistor.
5. Install Auxiliary M edium Blow er Test lamp lights. G O to Step 6.
M otor Relay in its socket. Connect Test lamp does not light. G O to Step 9.
a test lam p between A u x ilia ry
A and ground.
Blow er M otor Relay in its socket. Test lamp does not light. R E P L A C E Auxiliary M edium Blow er
Connect a self-powered test lamp M otor Relay.
from A u xilia ry M edium Blow er
M otor Relay socket Cavity 2 to
ground.
A u x ilia ry A/C C ontrol Sw itch. on R E D (1925) wire between A uxiliary
Disconnect Connector at Auxiliary M edium Blow er M otor Relay, Front
A/C Control Switch. Connect a Auxiliary A/C Control Switch and
test lam p from Front A u xilia ry Auxiliary A/C Control Switch.
A/C C on trol Switch Connector Test lamp does not light. G O to Step 8.
Cavity E to ground.
8. C o n n e c t C o n n e c t o r at F r o n t Test lamp lights. R E P L A C E Front A/C Control Switch.
A u x ilia ry A/C C ontrol Sw itch. Test lamp does not light. R E P L A C E Auxiliary A/C Control
C o n n e c t a te st l a m p f r o m Switch.
from A uxiliary Low Blow er M otor Test lamp does not light. R E P L A C E A uxiliary Low Blow er
A u x ilia ry A/C C ontrol Sw itch. on D K B L U (1926) wire between
Disconnect Connector at A uxiliary A uxiliary Low Blow er M otor Relay,
A/C Control Switch. Connect a Front Auxiliary A 1C Control Switch
test lam p from A u x ilia ry Low and Auxiliary A/C Control Switch.
2 to ground.
11. C o n n e c t C o n n e c t o r at F r o n t Test lamp lights. R E P L A C E Front A uxiliary A/C
C o n n e c t a te st l a m p f r o m Test lamp does not light. R E P L A C E A uxiliary A/C Control
A u x i lia r y L o w B lo w e r M o t o r Switch.
TEST RESULT ACTION

between A u xilia ry H igh Blow er Test Lam p does not light. R E P L A C E A uxiliary H igh Blow er
M otor Relay.
ground.
13. D iscon n ect C onnector at Front Test lamp lights. L O C A T E and R E P A IR short to ground
A u x ilia ry A/C C on trol Switch. on W H T (1924) wire between
Disconnect Connector at Auxiliary A uxiliary H igh Blow er M otor Relay,
A/C Control Switch. Connect a Front A uxiliary A/C Control Switch,
self-powered test lam p between and Auxiliary A/C Control Switch.
14. Reconnect C onnector at Front Test lamp lights. R E P L A C E Front A uxiliary A/C
A u x ilia ry A/C C on trol Switch. Control Switch.
Test lamp does not light. R E P L A C E A uxiliary A/C Control
between A u xilia ry H igh Blow er Switch.
ground.
AUXILIARY A/C CONTROL SWITCH FUNCTIONS WHEN THE FRONT AUXILIARY A/C
CONTROL SWITCH IS NOT IN THE REAR POSITION (A/C WITHOUT HEATER)
TEST RESULT ACTION
1. Place Front A uxiliary A/C Control Test lamp lights. R E P L A C E Front Auxiliary A/C
Sw itch in O FF. Place A u xiliary Control Switch.
A / C C o n t r o l S w it c h in O F F . Test lamp does not light. G O to Step 2.
D iscon n e ct Connector at Front
A u x ilia ry A/C C ontrol Sw itch.
between F ro n t A u x i l i a r y A /C
Control Switch Cavities B and F.
A/C Control Switch. Connect a in O R N (1923) wire between Front
self-powered test lamp between A uxiliary A/C Control Switch and
A u x ilia ry A/C C on trol Switch A uxiliary A/C Control Switch.
Connector Cavity F and ground.
Test lamp does not light. R E P L A C E Auxiliary A/C Control
Switch.
AUXILIARY A/C CONTROL SWITCH DOES NOT OPERATE THE AUXILIARY BLOWER WHEN
SELECTED (A/C WITHOUT HEATER)
TEST RESULT ACTION
1. Place Front Auxiliary A/C Control Test lamp lights. G O to Step 2.
S w i t c h in R E A R . D is c o n n e c t Test lamp does not light. R E P L A C E Front A uxiliary A/C
Connector at Front Auxiliary A/C
Control Switch.
C o n tro l Sw itch . C onnect a
F r o n t A u x i l i a r y A / C C o n tro l
Sw itch Cavities B and F.
2. Disconnect Connector at Auxiliary Test lamp lights. R E P L A C E Auxiliary A/C Control
self-powered test lamp between Test lamp does not light. L O C A T E and R E P A IR open in O R N
A u x i lia r y A/C C on trol Switch
(1923) wire between Front Auxiliary
C onnector Cavity F and Front
A/C Control Switch and Auxiliary A/C
A u x i lia r y A/C C on trol Switch
Control Switch.
Connector Cavity F.
HVAC BLOWER CONTROL
CIRCUIT OPERATION Blow er M otor through the Y E L (1172) wire. The motor
operates at its slowest speed.
FRONT BLOWER CONTROLS W hen the Auxiliary A uxiliary Heater Control Switch is
Battery voltage is supplied at all times to H igh Blow er in M E D , the Auxiliary M edium Blow er Relay is energized.
Relay Cavity A 2 through the R E D (542) wire. W hen the Current flow s to the motor through one resistor and the
Ignition Switch is O F F or the Blow er Switch at the Heater m otor operates at an interm ediate speed. W hen the
C on trol M o d u le or H V A C C on trol M o d u le is O F F , no A uxiliary Heater Control Switch is in H I, the Auxiliary
voltage is applied to the Relay C oil through the O R N (52) H igh Blow er Relay is energized. Current bypasses both
wire and the relay remains de-energized. Sim ilarly, no resistors and the motor operates at its highest speed.
voltage is applied to the norm ally closed contact at Cavity A n illum ination lamp is provided at the A u xiliary
B 2 of the relay. Battery voltage is not applied to the Heater Control Switch to facilitate Switch operations. The
B lo w e r M otor, and the m otor does not operate at any lamp is powered by the Instrument Panel Dim m ing system.
speed.
W hen the Ignition Switch is in R U N and the Blow er AUXILIARY BLOWER CONTROLS
Sw itch is in L O , voltage is applied through all three (HEATER WITH A/C)
Blow er Resistors to the norm ally closed contact in the The Auxiliary Blow er M otor is controlled by either of
relay. The relay remains de-energized. Reduced voltage is two Auxiliary Blow er Switches when optional auxiliary
applied to the Blow er M otor through the P P L (65) wire heating and air conditioning is provided. Both switches are
and the motor operates at its slowest speed. W ith the located in overhead modules, one over the Instrument Panel
Blow er Switch in either M l or M 2, current flow s through and the other in the center of the vehicle. The A uxiliary
fewer resistors in the Blow er Resistor and the Blow er Blow er M otor w ill operate from the A u xiliary Blow er
M otor runs faster. Switch at the A uxiliary H V A C Control M odule only when
W ith the Blow er Switch in H I, the Blow er Resistors the A uxiliary Blow er Switch at the Front A uxiliary H V A C
are bypassed by the energization of the H igh Blow er Relay. Control M odule is in the R E A R position. See Section
The contacts change state and Battery voltage from the 8A-65 for a description of the control priorities for the
Underhood Fuse-Relay Center is applied directly to the ventilation modes.
Motor. The Blow er M otor then operates at its fastest speed. Battery voltage is supplied when the Ignition Switch is
in R U N to Relay C o il Cavity 5 of each of the three
AUXILIARY BLOWER CONTROLS A uxiliary Blow er Relays through the B R N (341) wires.
(HEATER WITHOUT A/C) Battery voltage is also supplied when the Ignition Switch is
Battery voltage is supplied when the Ignition Switch is in R U N to contact Cavity 1 of each o f the three A uxiliary
in R U N to Relay C oil Cavity 5 of each of the three Blow er Relays through the R E D (542) wires. W ith the
A uxiliary Blow er Relays through the B R N (341) wire. Auxiliary Blow er Switch at the Front A uxiliary H V A C
Battery voltage is also supplied when the Ignition Switch is Control M odule in O F F and with the A uxiliary Blow er
in R U N to Cavity 1 of each o f the three Auxiliary Blow er Switch at the A uxiliary H V A C Control M odule in OFF, no
Relays through the R E D (542) wire. W ith the A uxiliary grounding path is provided for the Relay C oils and the
Auxiliary Heater Control Switch in OFF, no grounding path relays remain de-energized. The relay contacts remain open
is provided for the Relay C o ils and the relays remain and no voltage is supplied to the A uxiliary Blow er Motor.
de-energized. The relay contacts remain open and no W hen the Ignition Switch is in R U N and the Blow er
voltage is supplied to the Auxiliary Blow er Motor. Switch at the Front M odule is in LO , a ground path is
W hen the Ignition Switch is in R U N and the A uxiliary provided for the A uxiliary Low Blow er Relay through the
Heater Control Switch is in LO , a ground path is provided D K B L U (1925) wire to the Front Blow er Switch, then
for the A u xiliary Low Blow er Relay C o il through the D K through B L K (150) wire to Ground G400. The Relay C oil
B L U (1926) wire to the Control Switch, then through B L K energizes and the relay contacts close. T his applies Battery
(150) wire to Ground G200. The Relay C o il energizes and voltage to the A uxiliary Blow er Resistor through the Y E L
the relay contacts close. T his applies Battery voltage to the (1176) wire. Current flow s through two resistors and to the
Auxiliary Blow er Resistor through the Y E L (1176) wire. A uxiliary Blow er M otor through the Y E L (1172) wire. The
Current flow s through two resistors and to the Auxiliary motor operates at its slowest speed.
W hen the A uxiliary Blow er Switch at the Front H V A C flows to the motor through one resistor and the motor
Control M odule is in R E A R and the Auxiliary Blow er operates at an intermediate speed. W hen the A u xiliary
Switch at the Auxiliary H V A C Control M odule is in LO , Blow er Switch is in H I, the Auxiliary H igh Blow er Relay
the grounding path is different. The ground path is through is energized. Current bypasses both resistors and the motor
the D K B L U (1925) wire to the Auxiliary H V A C Control operates at its highest speed.
Module. The D K B L U (77) wire continues the ground path A n illum ination lam p is provided at each H V A C
to the Auxiliary and H V A C Control Logic Module. O R N Control M odule to facilitate Switch operations. The lamps
(77) wire continues the ground path to the Front Auxiliary are powered by the Instrument Panel Dim m ing system.
H V A C Control M odule where is continues to Ground
G400. AUXILIARY BLOWER CONTROLS (A/C
W hen the A uxiliary Blow er Switch is in M E D , the WITHOUT HEATER)
A u xilia ry M edium Blow er Relay is energized. Current The Circuit operation for the optional A uxiliary system
is sim ilar to that for the optional Auxiliary H V A C option.
HVAC COMPRESSOR CONTROL
GAS ENGINE
I HOT M RUN OR START
I ” --------- ------ 1 UNOERHOOO
! A ! IGN E
K ill 1 ^ I FUSE-RELAY
COMPRESSOR --------------------
| CENTER
L A /C COMP
1 f s FUSE ' FUSE 1 ^
CLUTCH
RELAY
I
10 A 10 A
J G 81 1 L12 1
—
— J * ________ i
6V _ / A6
U
.8PNK 639 IX .8ORN I
“ T a V -/ A 4 S 7 B
1240
EXCEPT
7.4L ENGME
7.4L ENGME .8ORN
J
1240
0
.8PNK T
1 639 1
.8PNK 639 S i4 6 # e e e i^ ^
SEE FUSE
BLOCK DETAILS
r
|
~ “ 1 AUXILIARY
| COOLMG
PAGE 8 A -1 1 -2 8
.8PNK 1 639 | | FAN RELAY
9 j j( V 8GAS)
L_ _ J
.8PNK
639
.5 OK GRN OK G R N / 459
WHT
1614
.8DK GRN/WHT .8OK GRN 59
762
.5 OK 8LU
604
.5 OK GRN
603 .8OK GRN | 59
30 1 C3 7 S*
_ S\~- 25, 9 1 C3 X
Bi
A/C S186
— ,— — — - i VEHICLE
SWITCH SWITCH A /C SWITCH A /C # — — COMPRESSOR . CXOOC
| I | COMPRESSOR SIGNAL SIGNAL REORC. SIGNAL Co m p r e s s o r I C0WTR° |- CLUTCH i 0104
| ^ | CYCLING SIGNAL O U JC H l- O C - il
S185
SWITCH CONTROL | (VCM)
i. r _____
i- 5,;
. OUTPUT | ^ Y /
.8BLK I
:T
150 f
J _ GROUND_
I
GROUND
——J
B
Ti'Zs - '
18
C3
n a/ c
| COMPRESSOR .8BLK 150
.5 | L2?
l PRESSURE
.8B WHT
LK/ 451
BLK/ 451
WHT .8B L K /
If-* i CUTOUT 451
WHT
SWITCH
L — J
II
B V -/
1■
BLK/ 451
5 BLK 150 1
WHT
1
1 BLK/WHT SEE GROUND SEE GROUND
DISTRIBUTION S I47 DISTRIBUTION
PAGE 8 A -1 4 -8 .9 PACE 8 A - I4 - 5
5 BLK 150
3 BLK
G 105 150
1 BLK/ | 451
WHT
ENGINE
GROUND
C l 0 4 (GAS, OCSEL)
~ ENGME
03-18-97
GROUND 4206W 0598
DIESEL ENGINE
"1 RECIRCULATION
HOT M RUN I DOOR MOTOR
I SECTION 8A -65
03-10-97
GROUND 4208W 0599
03-18-97
4208W 0600
CO M PO NENT L O C A T IO N 201 -P G F IG . CONN
A IC Com pressor Clutch......... Front of A/C Compressor, L F of Engine.......................... , 14.... 18

R elay............................... In Underhood Fuse-Relay Center, L R of Engine
Compartment, on Fender............................................ . 6 ..... 10

Compartment, on Bulkhead......................................... . 17.... 21

Cutout Sw itch ................... O n rear of A/C Compressor, L F of En gin e ........................ 10.... 14

L in e ....................................................................... , 10.... 14
A u xiliary Cooling Fan Relay.... L R of Engine Compartment............................................ 4 ...... 7 ...... 202-60
H V A C Control M od ule.......... Part of Heater Controls, center o f IP, under R adio............. . 5 3 .... 6 8 .... 202-35
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. , 3 2 .... 43

Compartment B o x ..................................................... . 3 7 .... 49
Underhood Fuse-Relay
Center............................. L R of Engine Compartment, on Fender............................. 5 ...... 9

( V C M ) ............................. Engine Compartment, near E B C M .................................. 3 7 .... 48
Water Valve (4-Door

C O N N EC T O R S:

at Bulkhead............................................................. 4 ...... 8 ...... 202-0
C 200 (D ie se l)...................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 .... 49.... 202-11
C 200 (G a s)......................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 .... 49.... 202-10
C 2 3 0 .................................. Behind R H of IP, above H V A C Evaporator H o u sin g.......... 2 7 .... 42.... 202-54
DIODES:
D 10 4 (4 .3L)......................... Engine Harness, approx. 16 cm from A/C Com pressor
D 10 4 (5.0L, 5 .7 L )................. Engine Harness, approx. 10 cm from A/C Com pressor

Clutch Connector...................................................... 14 .... 18
D 10 4 (6 .5L)......................... Engine Harness, approx. 28 cm from A/C Com pressor

D 10 4 (7 .4L)......................... Engine Harness, approx. 8 cm from A/C Com pressor Clutch

Connector............................................................... 1 6 .... 20
CO M PO NENT L O C A T IO N 20 1 -P G FI CONN
G R O M M ETS:
P 1 0 0 .................................. L R of Engine Compartment, at Bulkhead................. ........ 4 ...... 8

P 1 0 1 .................................. R R of Engine Compartment, at Bulkhead................. ....... 7 ...... 12
G R O U N D S:
G103 (G a s).................. ....... R F of Engine, near Thermostat H o u sin g .................. ....... 1 4 .... 18
G 104.................................. R H top center of Cylinder Head............................. ....... 1 6 .... 20
G 104 (D ie sel)............... ....... R H top of Cylinder Head...................................... ....... 1 5 .... 21
G 105.................................. R F of Engine block.............................................. ....... 1 3 .... 17
G105 (D ie sel).............. ........ R H top of Cylinder Head...................................... ....... 1 5 .... 21
G 200........................... ........ Behind L H of IP, below Fuse Block, on Tie B a r....... ....... 3 2 .... 43
S P L IC E S :
S I 03 (6.5L) ........................ Engine Harness, approx. 12 cm from Starter Solenoid

Breakout
S I 03 (7.4L - M / T )................ Engine Harness, approx. 12 cm from E G R Breakout
S I 07 (V IN M , R )................. Engine Harness, approx. 35 cm from Breakout to E G R

Valve, toward Taillamp Harness Breakout


S I 07 (6.5L, H D ) .................. Engine Harness, approx. 30 cm from E B C M Breakout,


S I 07 (7.4L) ........................ Engine Harness, approx. 18 cm from E B C M Breakout,

5146 (7.4L) ........................ Engine Harness, approx. 22 cm from E B C M Breakout
5147 (4.3L) ........................ Engine Harness, approx. 5 cm from Fuel Injector Breakout,

S I 47 (6.5L) ........................ Engine Harness, approx. 4 cm from Starter M otor Solenoid

Breakout
S I 59 (6.5L - A/T)................ Engine Harness, approx. 7 cm from E G R Valve Breakout


S I 59 (6.5L - M/T, H D ).......... Engine Harness, approx. 31 cm from G low Plugs Breakout
S I 59 (6.5L - M/T, L D ) .......... Engine Harness, approx. 6 cm from V S S Breakout

Diode D 104
S I 85 (6.5L) ........................ Engine Harness, approx. 28 cm from A/C Compressor

5185 (7.4L) ........................ Engine Harness, approx. 17 cm from A/C Compressor

5186 (4.3L, 5.0L, 5.7L) ........ Engine Harness, approx. 41 cm from E G R Breakout, at
Diode D 104



Breakout

Breakout
S 2 9 8 .................................. IP Harness, approx. 24 cm from IP Cluster Breakout,

toward Radio Breakout
DIAGNOSIS - AIR CONDITIONING COMPRESSOR CONTROLS
TROUBLESHOOTING HINTS: 6. I f the A / C C o m p re ss o r C lu tc h is o p e ra tin g

1. C H E C K A / C C o m p re sso r C lu tch op erations in continuously, C H E C K for short to ground on D K
Heating, Ventilation, and A ir Conditioning. G R N /W H T (459) wire. If shorted to ground, L O C A T E
2. C H E C K that H T R -A /C Fuse 12, IG N E M IN IF U S E , and R E P A IR source o f short.
and A/C C O M P F U S E are not open. If any Fuse is • C H E C K for broken (or partially broken) wire inside of
open, L O C A T E and R E P A IR source o f overload and insulation which could cause system malfunction but
R E P L A C E the Fuse(s). prove G O O D in a continuity/voltage check, with a
3. C H E C K that Grounds G 104 , G105 and G 200 (Diesel) syste m d isco n n e cte d . T h e se C irc u its m ay be
or Grounds G103, G104, G105 and G 200 (Gasoline) intermittent or resistive when loaded, and if possible,
are clean and tight. * should be checked by m onitoring for a voltage drop
4. C H E C K that A /C C o m p re sso r C lu tch R e la y is with the system operational (under load).
properly mated to its connector. •CH ECK fo r proper in sta lla tio n o f afterm arket
5. C H E C K condition o f Diode D104. R E P L A C E if either electronic equipment which may affect the integrity of
opened or shorted. other systems (Refer to Troubleshooting Procedures).
A/C COMPRESSOR CLUTCH DOES NOT ENGAGE

TEST RESULT ACTION
1. P e rfo rm C C O T S y st e m A i r Problem is resolved. System is operating normally. N o
C o n d it io n in g D ia g n o s is : further action necessary.
Insufficient C oolin g in Heating, G O to Step 2.
Problem remains.
Ventilation and A ir Conditioning.
2. D isc o n n e c t connector at A /C Test lamp lights. G O to Step 3.
C o m p re sso r C lu tch . Start the Test lamp does not light. L O C A T E and R E P A IR open in B L K
engine. Adjust the mode control (150) wire between A/C Com pressor
dial at the H V A C Control M odule Clutch and Ground.
to center Floor position. Adjust the
temperature control dial on H V A C
C o n tro l M o d u le to m axim u m
cooling. Place the Front Blow er
Sw itch in H I. Depress the A/C
pushbutton on H V A C C o n tro l
M odule. Observe that the L E D
illuminates. Connect self-powered
test lamp from A 1C Com pressor
C lu tch connector C a v ity A to
ground.
3. Rem ove A/C C om pressor Clutch Test lamp lights. G O to Step 4.
R elay from its socket. Connect L O C A T E and R E P A IR open in D K
self-powered test lamp between G R N (59) wire between Underhood
A /C C om pressor C lutch R e lay Fuse-Relay Center and A/C Com pressor
s o c k e t C a v it y A 6 an d A / C Clutch.
C o m p re sso r C lu tch C on n ector
Cavity B.
4. W ith the Ignition O N connect a Test lamp lights. G O to Step 5.
test lamp from A/C Com pressor Test lamp does not light. L O C A T E and R E P A IR open in O R N
Clutch Relay socket Cavity B 4 to (1240) wire from A/C Com p Fuse to
ground. A/C Com pressor Clutch Relay in
Underhood Fuse-Relay Center.
5. W ith the Ignition O N connect a Test lamp lights. G O to Step 6.
test lamp from A/C Com pressor L O C A T E and R E P A IR open in P N K
Clutch Relay socket Cavity A 4 to
(639) wire from IG N E Fuse to A/C
ground.
Com pressor Clutch Relay in Underhood
Fuse-Relay Center.
Powertrain Control M odule (P C M )
(Diesel only) or Connector C 3 at
G R N (459) wire between A/C
Vehicle Control M odule (V C M )
Com pressor Clutch Relay and
(G a s o lin e o n ly ). C o n n e c t a
Powertrain Control M odule or Vehicle
Control Module.
A/C C om pressor C lutch R e lay
so c k e t C a v ity B 6 and P C M
Connector C 3 Cavity D 5 (Diesel)
or V C M Connector C3 Cavity 1
(Gasoline).
8A ■ 6 4 - 8 ELECTRICAL DIAGNOSIS
TEST RESULT ACTION

7. Replace A/C Com pressor Clutch Test lamp lights. G O to Step 8.
Relay in its socket. Connect fused Test lamp does not light. R E P L A C E A/C Com pressor Clutch
jum per wire between Powertrain Relay.
C o n tro l M o d u le C onnector C 3
C a vity D 5 (D ie se l) or Vehicle
C o n tro l M o d u le Connector C 3
C a vity 1 (G asoline) to ground.
C o n n e c t test lam p from A /C
Com pressor Clutch Connector B
to ground.
8. Is this a gasoline vehicle? Yes. G O to Step 9.
No. G O to Step 11.
9. D is c o n n e c t C o n n e c to r C 3 at Test lamp lights. G O to Step 10.
Vehicle Control Module. Connect Test lamp does not light. L O C A T E and R E P A IR open in
a self-powered test lamp between B L K / W H T (451) wire between Vehicle
C o n n e c to r C 3 C a v ity 17 and Control M odule Connector C3 Cavity
ground. 17 and Ground.
between Vehicle Control Module Test lamp does not light. L O C A T E and R E P A IR open in
C o n n e c to r C 3 C a v ity 18 and B L K / W H T (451) wire between Vehicle
ground. Control M odule Connector C3 Cavity
18 and Ground.
b e tw e e n P o w e rtra in C o n tro l Test lamp does not light. L O C A T E and R E P A IR open in
M odule Connector C3 Cavity D 7 T A N /W H T (551) wire between
and ground. Powertrain Control M odule Connector
C 3 Cavity D 7 and Ground.
b e tw e e n P o w e rtra in C o n tro l Test lamp does not light. L O C A T E and R E P A IR open in
M odule Connector C3 Cavity D 6 B L K / W H T (451) wire between P C M
and ground. Connector C 3 Cavity D 6 and Ground.
13. C o n n e ct a test lam p between Test lamp does not light. G O to Step 15.
Vehicle Control M odule Connector Test lamp lights. R E P L A C E Vehicle Control Module.
C 3 Cavity 25 and ground.
14. D is c o n n e c t C o n n e c to r C l at Test lamp does not light. G O to Step 15.
P o w e rt ra in C o n t r o l M o d u le Test lamp lights. R E P L A C E Powertrain Control Module.
(P C M ). Connect test lamp between
P C M Connector C l Cavity C 2 and
ground.
15. D isc o n n e c t con n e cto r at A /C Test lamp lights. G O to Step 16.
Com pressor H igh Pressure Cutout Test lamp does not light. L O C A T E and R E P A IR open in D K
Sw itch. Connect a self-powered G R N (762) wire between A/C
test lam p betw een Pow ertrain Com pressor H igh Pressure Switch and
C o n tro l M o d u le C onnector C l P C M or V C M .
C a vity C 2 (D ie se l) or Vehicle
C on trol M o d u le C onnector C 3
C avity 25 and A/C Com pressor
H ig h P re ssu re C u to u t S w itch
Connector Cavity A.
16. Connect self-powered test lam p Test lamp lights. Diesel G O to Step 17. Gas G O to Step
between P ins A and B of A/C 18.
Com pressor H igh Pressure Cutout Test lamp does not light. R E P L A C E A/C Com pressor H igh
Switch. Pressure Cutout Switch.
ELECTRICAL DIAGNOSIS 8A - 6 4 ■ 9
TEST RESULT ACTION

C o m p re sso r C y c lin g S w itc h . Test lamp does not light. L O C A T E and R E P A IR open in D K
Connect self-powered test lamp G R N (603) wire between A/C
from A/C C om p re ssor C y c lin g Com pressor C ycling Switch and A/C
Sw itch connector C avity B and Com pressor H igh Pressure Cutout
A/C C om p ressor L o w Pressure Switch.
Cutout Switch Connector Cavity B.
Com pressor H igh Pressure Cutout Test lamp does not light. L O C A T E and R E P A IR open in L T
Switch and C 3 o f H V A C Module. G R N (66) wire between A/C
Connect self-powered test lamp Com pressor H igh Pressure Cutout
from Cavity B of A/C Com pressor Switch and H V A C Module.
H igh Pressure Cutout Switch and
C3 Cavity 10 of H V A C connector.
19. R e c o n n e c t c o n n e c t o r s at Test lamp lights periodically. Diesel G O to Step 20. G as G O to Step
P o w e rtra in C o n t r o l M o d u le 21.
( D ie s e l) o r V e h ic le C o n tro l Test lamp does not light periodically. R E P L A C E A/C Com pressor Cycling
M o d u le (G asolin e ). Reconnect Switch.
connector at A / C C o m p re sso r
Clutch. Connect fiised jumper wire
from A/C C om p re ssor C y c lin g
Switch Connector C avity B and
B a t t e r y V o lt a g e . C o n n e c t
self-powered test lamp at Pins A
and B o f A/C Com pressor C ycling
Switch. M onitor for Com pressor
C y c lin g . R e fe re n c e H e a te r,
Ventilation, and A ir Conditioning.
20. Remove jumper wire from Battery Test lamp lights. G O to Step 21.
V o lta g e to A / C C o m p re ss o r Test lamp does not light. L O C A T E and R E P A IR open in L T
Cycling Switch connector Cavity G R N (66) wire between H V A C Control
B. Disconnect Connector C 3 at M odule and A/C Com pressor Cycling
H V A C Control Module. Connect Switch.
C 3 C a v i t y 10 a n d A / C
C o m p re ss o r C y c lin g S w itc h
Connector Cavity A.
21. R e co n n e ct c o n n e c to r at A / C Test lamp lights. G O to Step 22.
C ycling Switch. Connect test lamp Test lamp does not light. L O C A T E and R E P A IR open in B R N
between H V A C Control M odule (141) wire between IP Fuse Block and
C o n n e c to r C 3 C a v it y 5 and H V A C Control Module.
ground.
22. Connect a self-powered test lamp Test lamp lights. R E P L A C E H V A C Control Module.
between H V A C Control M odule Test lamp does not light. L O C A T E and R E P A IR open in B L K
C o n n e c to r C 3 C a v it y 2 and (150) wire between H V A C Control
ground.
M odule and Ground G200.
CIRCUIT OPERATION The V C M or P C M modules enable A/C Com pressor

The Com pressor for the A ir Conditioning System is Clutch operations when a voltage input is received from the
driven by the Engine by means o f a Belt Drive and the H V A C Control M odule on the D K G R N / W H T (762) wire.
A / C C o m p re sso r C lu tc h . T h e C lu tc h a llo w s the Two switch contacts in series between the H V A C Control
Com pressor to be disengaged when A ir Conditioning is not M od ule and the V C M / P C M m odule can isolate this
required. voltage. The A/C Compressor H igh Pressure Cutout Switch
W hen the Ignition Switch is in R U N , Battery Voltage m onitors the com pressor h igh side pressure. W hen this
is supplied to the H V A C C on trol M od ule, the A/C pressure exceeds a limit, the switch contacts open to stop
Com pressor Clutch Relay Coil, and the normally open A/C the compressor and reduce the pressure. This switch does
Com pressor Clutch Relay contact. In the H V A C Control not operate unless conditions are unusual. The A/C
Module, Battery Voltage is also applied to a detent contact Com pressor C ycling Switch monitors compressor low side
on the temperature control dial for operation o f the Water pressure to provide freeze protection. W hen the low side
Valve (Suburban/Utility with gasoline engines only). pressure reaches a limit, the switch contacts open. W hen
The A/C Com pressor Clutch C o il must be energized to the low side pressure reaches a limit, the switch contacts
drive the A/C Com pressor Clutch. The Clutch C o il is open. W hen the pressure recovers, the contacts close. This
energized when the Clutch Relay is energized. Voltage is switch operates normally to cycle the compressor while
applied from the relay’s contact on D K G R N (59) wire to operating.
the C lu tc h C o il. D io d e D 1 0 4 in the h a rn e ss is The H V A C Control M odule places voltage on the L T
reverse-biased and prevents current flow bypassing the G R N (66) wire when the Ignition Switch is in Run, the
C lu tc h C o il to gro u n d . W h e n the R e la y C o il is Front Blow er Switch is not in OFF, and either the A/C
de-energized, the collapsing magnetic field o f the Clutch Pushbutton Switch has been depressed or the mode Control
C o il forward-biases the Diode and dissipates the energy D ial on the module is at the defrost detent. The A/C
from the magnetic field. Pushbutton Switch is a latching switch which allows a light
The A/C Com pressor Clutch Relay is energized when emitting Diode (L E D ) on the switch to be illuminated
a ground path is provided for the relay coil on the D K when the module enables compressor operations from the
G R N / W H T (459) wire. The Powertrain Control M odule switch. The mode control D ial Detent Switch does not light
(P C M ) (Diesel only) or the Vehicle Control M odule (V C M ) the L E D but does operate the compressor during defrosting
(G a so lin e o n ly ) p ro vid e s this ground path through operations to dry the air and prevent fogging.
contact-equivalents in the module. These modules may stop The H V A C Control M odule’s temperature control dial
com pressor operations w hile otherw ise enabled under detent switch operates the Water Valve (Suburban/Utility
certain operating conditions as described in the Driveability with gasoline engines only). W ith the Ignition Switch in
and Em issions sections o f this manual. R U N , adjusting the dial to a low temperature setting
applies a voltage on the G R Y / B L K (1596) wire and
energizes the valve’s solenoid. This closed the valve which
isolates Coolant R o w to the Heater Core.
BLANK
HVAC AIR DELIVERY AND TEMPERATURE CONTROLS
FRONT VENTILATION CONTROLS
HOT M RUN SEE INSTRUMENT

PANEL OiMMINC
PAGE 8 A -1 I7
r “1 -------------T IP FUSE
|M
•
64I _
HTRA /C 1| -----------
BLOCK
| P FUSE 12 I
SEE FUSE
25 A |
'N 5 I BLOCK DETAILS
L ______j r PAGE 8 A -1 1 -1 6
1 BRN
>« J
1 BRN
S268
141
1 BRN
1 BRN 141 1 DK GRN .3 5 GRY
141
G __ 1 1 /-\C3
03-10-97
4206W 0602
HVAC AIR DEUVERY AND TEMPERATURE CONTROLS
REAR VENTILATION CONTROLS (W / AUXILIARY HEAT and A/C)
HOT M RUN
SCe INSTRUMENT
t ip ruse
PANEL DIMMING
| BLOCK PAGE 8 A -1 1 7
RR HVAC
ruse 5 I
10 A .5 GRY | S
'L 7
L -I _ J A I'
1 BRN 341
r — T CONVENIENCE
I B I CENTER
I. —' .8 ORN 1923
77
03-10-97
4206W 0603
AUXILIARY
MODE DOOR MOTOR
(POSITIONER)
AUXILIARY
TEMPERATURE
DOOR MOTOR
(POSITIONER)
C 400
REAR BODY
GROUND
03-10-97
4208W 0604
VENTILATION FLOW SELECTION
i
|— ►C36 + C69 ONLY
03-11-97
420SW060S

M odule............................. In Overhead Console................................................... .. 5 3 .... 6 8 .... 202-25
Auxiliary H V A C Control
Module, R e a r.................... Rear of Overhead Console M olding, in Headliner............. .. 5 3 .... 6 8 .... 202-26
A uxiliary M ode D oor M o to r... In A uxiliary H V A C Plenum, forward of L R Wheelhousing..,.. 6 6 .... 85

M o to r.............................. In A uxiliary H V A C Plenum, near L R W heelhousing.......... .. 6 6 .... 85
Blow er Switch, Connector C2... O n top of H V A C Plenum ............................................ ... 5 0 .... 6 5 .... 202-28
Convenience Center.............. Under L H of IP, on Bulkhead....................................... .. 3 3 .... 44
H V A C Control M od ule.......... Part o f Heater Controls, center o f IP, under R ad io ............ ... 5 3 .... 6 8 .... 202-35
H V A C Control Switch/Module,
Front, A u x ilia ry ................. Front of Overhead C on sole .......................................... ... 3 3 .... 5 5 .... 202-14
IP Fuse B lo ck ...................... L H o f IP, near L F D oor Jamb Sw itch ............................ .. 3 2 .... 43
M ode D oor M otor................. Under IP, on L H of H V A C Plenum ............... ............... .. 5 0 .... 6 5 .... 202-66
Recirculation D oor M otor....... Under IP, on H V A C Plenum ........................................ .. 5 0 .... 6 5 .... 202-69
Temperature D oor Motor,

Fro n t............................... Under IP, on Heater - A/C Plenum, center area................ .. 3 2 .... 53
C O N N EC T O R S:
C 2 0 5 ................................................................................................. A t Convenience Center....................................................................................................................................... . . 3 3 ............ 44............ 202-50
C 2 3 0 .................................. Behind R H o f IP, above H V A C Evaporator H o u sin g ......... . . 2 7 .... 4 2 .... 202-54
C 3 0 0 .................................. In Overhead Console................................................... . . 3 6 .... 61..... 202-55
C 4 0 0 .................................. R R of vehicle, above Auxiliary Blow er M o to r................. . . 66..... 8 5 ............ 202-56
C 4 0 1 ................................................................................................. R R of vehicle, above Auxiliary Blow er M o to r ................................................ . . 66 ............ 8 5 ............ 202-56
G R O U N D S:
G 200 ................................................................................................. Behind L H o f IP, below Fuse Block, on Tie B a r ....................................... . . 3 2 ............ 43
G 202 ................................................................................................. R H o f IP, mounted to H V A C Plenum Bracket.................................................. . . 5 0 ............ 65
G 400 ................................................................................................. R H B Pillar, near D oor Striker .......................................................................................................... . . 5 8 ............ 76
S P L IC E S : A
S 2 1 2 ................................................................................................. IP Harness, approx. 8 cm from Inflatable Restraint Switch

Breakout
S 2 4 3 ................................................................................................. H V A C Harness, approx. 4 cm from Recirculation D oor

S 2 4 4 ................................................................................................. H V A C Harness, approx. 8 cm from Recirculation D oor

S 2 6 8 ................................................................................................. IP Harness, approx. 7 cm from Inflatable Restraint Switch

Breakout
S 2 9 8 ................................................................................................. IP Harness, approx. 24 cm from Instrument Cluster

8A - 6 5 - 6 ELECTRICAL DIAGNOSIS______________________


S 3 2 4 .................................. Taillamp Extension Harness, approx. 10 cm from G 404

Breakout, toward Engine Harness
S400 (w /Auxiliary A / C )......... A uxiliary A/C Harness, approx. 17 cm from Blow er M otor
S403 (w /Auxiliary H V A C )...... Auxiliary H V A C Harness, approx. 7 cm from Blow er M otor

Breakout

DIAGNOSIS - HVAC AIR DELIVERY AND VENTILATION
TROUBLESHOOTING HINTS: FRONT TROUBLESHOOTING HINTS:

1. C H E C K condition of H T R A/C Fuse 12. If fuse is GENERAL
open, L O C A T E and R E P A IR cause o f overload. 1. S E E Instrument Panel Dim m ing section for diagnosis
R E P L A C E fuse. of the Instrument Panel Dim m ing Lam p circuits.
2. C H E C K that Grounds G 200 and G 202 are clean and 2. If the M ode or Temperature Doors do not operate
tight. sm oothly in response to control dial changes, the
rheostat in the module m ay be bad or a ground
TROUBLESHOOTING HINTS: REAR connection from the module may be open.
AUXILIARY • C H E C K for a broken (or partially broken) wire inside
1. C H E C K condition of R R H V A C Fuse 5. If fuse is the insulation which could cause system malfunction
open, L O C A T E and R E P A IR cause o f overload. but prove G O O D in a continuity/voltage check with a
R E P L A C E fuse. sy ste m d isco n n e cte d . T h e se c irc u its m ay be
2. C H E C K that Ground G 400 is clean and tight. intermittent or resistive when loaded, and if possible,
should be checked by monitoring for a voltage drop
with the system operational (under load).
•CH ECK fo r proper in sta lla tio n o f afterm arket
FRONT VENTILATION CONTROLS INOPERATIVE

TEST RESULT ACTIO N
D isconnect C onnector at Front Test lamp does not light. L O C A T E and R E P A IR open in B R N
M ode D oor Motor. Connect a test (141) wire between IP Fuse Block and
lam p between Front M od e D o o r Splice S268.
M otor Connector Cavity 10 and
ground.
2. Connect self-powered test lam p Test lamp lights. G O to Step 3.
between Front M ode D oor M otor Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector Cavity 7 and ground. (150) wire between Splice S244 and
Ground G202.
H V A C Control Module. Connect a Test lamp does not light. L O C A T E and R E P A IR open in B R N
test lamp between H V A C Control (141) wire between Splice S268 and
M odule Connector C 3 .Cavity 5 H V A C Control Module.
and ground.
4. Connect self-powered test lamp Test lamp lights. R E P L A C E H V A C Control Module.
between H V A C Control M odule Test lamp does not light. L O C A T E and R E P A IR open in B L K
C o n n e c to r C 3 C a v it y 2 and (150) wire between H V A C Control
ground. M odule and Ground G200.
FRONT MODE DOOR MOTOR INOPERATIVE

TEST RESULT ACTIO N
1. Place Ign ition Sw itch in R U N . Smooth variable voltage observed. G O to Step 5.
D isconnect C onnector at Front N o voltage, erratic voltage, or fixed G O to Step 2.
M ode D oo r M otor. Place Front voltage observed.
B lo w e r Sw itch on the H V A C
Control M odule in LO . Observe
that the Front Blow er M otor is
operating. Connect a D M M from
Front M ode D o o r M o to r
Connector C avity 8 to ground.
Adjust the position of the M ode
C o n tro l D ia l on the H V A C
Control M odule while observing
D M M response.
H V A C Control Module. Connect a on W H T (454) wire between H V A C
test lam p from H V A C C ontrol Control M odule and Front M ode Door
M odule Connector C 3 C avity 9 Motor.
and ground. Test lamp does not light. G O to Step 3.
between H V A C Control M odule on W H T (454) wire between H V A C
C o n n e c to r C 3 C a v i t y 9 and Control M odule and Front M ode Door
ground. Motor.
8A - 6 5 - 8 ELECTRICAL DIAGNOSIS______________________
TEST RESULT ACTION

between H V A C Control M odule Test lamp does not light. L O C A T E and R E P A IR open on W H T
Connector C 3 Cavity 9 and Front (454) wire between H V A C Control
M o d e D o o r M o to r C o n n e cto r M odule and Front M ode D oor Motor.
Cavity 8.
5. Connect a test lamp between Front Test lamp lights. G O to Step 6.
M o d e D o o r M o to r C o n n e cto r Test lamp does not light. L O C A T E and R E P A IR open in B R N
Cavity 10 and ground. (141) wire between Splice S243 and
Front M ode D oor Motor.
6. Connect self-powered test lamp Test lamp lights. R E P L A C E Front M ode D oor Motor.
between Front M ode D oo r M otor Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector Cavity 7 and ground. (150) wire between Front M ode D oor
M otor and Splice S244.
FRONT TEMPERATURE DOOR MOTOR INOPERATIVE

TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Smooth variable voltage observed. G O to Step 5.
D iscon n e ct Connector at Front N o voltage, erratic voltage, or fixed G O to Step 2.
Temperature D oor Motor. Connect voltage observed.
a D M M from Front Temperature
D oor M otor Connector Cavity 8
and ground. Adjust the position of
the M od e C ontrol D ia l on the
H V A C C o n tro l M o d u le w h ile
observing D M M response.
2. D is c o n n e c t C o n n e c to r C 3 at Test lamp lights. L O C A T E and R E P A IR short to voltage
H V A C Control Module. Connect a on L T B L U (733) wire between H V A C
test lam p from H V A C C ontrol Control M odule and Front Temperature
M odule Connector C 3 C avity 8 D oor Motor.
and ground. Test lamp does not light. G O to Step 3.
between H V A C Control M odule on L T B L U (733) wire between H V A C
C o n n e c to r C 3 C a v i t y 8 and Control M odule and Front Temperature
ground. D oor Motor.
between H V A C Control M odule Test lamp does not light. L O C A T E and R E P A IR open on L T
Connector C3 Cavity 8 and Front B L U (733) wire between H V A C
Tem perature D o o r M o to r Control M odule and Front Temperature
Connector Cavity 8. D oor Motor.
5. Connect a test lamp between Front Test lamp lights. G O to Step 6.
T e m p e r a t u r e D o o r M o t o r Test lamp does not ligh t L O C A T E and R E P A IR open in B R N
Connector Cavity 10 and ground. (141) wire between Splice S243 and
Front Temperature D oor Motor.
6. Connect self-powered test lam p Test lamp lights. R E P L A C E Front Temperature D oor
between Front Temperature D oor Motor.
M o to r Connector C avity 7 and Test lamp does not light. L O C A T E and R E P A IR open in B L K
ground. (150) wire between Front Temperature
D oor M otor and Splice S244.
RECIRCULATION DOOR MOTOR FAILS IN VENT POSITION

TEST RESULT ACTION
D i s c o n n e c t C o n n e c t o r at Test lamp does not light. L O C A T E and R E P A IR open in B R N
R e c irc u la tio n D o o r M otor. (141) wire between Splice S243 and
C on n ect a test lam p between Recirculation D oor Motor.
R e c irc u la tio n D o o r M o to r
Connector Cavity 5 and ground.
between Recirculation D oor M otor Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector Cavity 7 and ground. (150) wire between Recirculation D oor
M otor and Splice S244.
3. C on n ect a test lam p between Test lamp lights R E P L A C E Recirculation D oor Motor.
R e c i r c u l a t i o n D o o r M o t o r Test lamp does not light. G O to Step 4.
Place the Front Blow er Switch on
the H V A C Control M odule in LO .
O bserve that the Front Blow er
M otor is operating. Actuate the
Recirculation Push button on the
4. D i s c o n n e c t C o n n e c t o r C 3 at Test lamp lights. G O to Step 5.
H V A C Control Module. Connect a Test lamp does not light. L O C A T E and R E P A IR open in D K
self-powered test lamp between G R N 1614 wire between H V A C
H V A C Control M odule Connector Control M odule and Recirculation Door
C 3 C avity 4 and Recirculation Motor.
D oor M otor Connector Cavity 6.
5. Is th is ve h icle equipped w ith No. R E P L A C E H V A C Control Module.
Auxiliary Cooling Fan? Yes. G O to Step 6.
6. Disconnect Connector at A uxiliary Test lamp lights. R E P L A C E H V A C Control Module.
Cooling Fan A/C Pressure Switch. Test lamp does not light. L O C A T E and R E P A IR open in D K
Connect self-powered test lamp G R N (1614) wire between Auxiliary
between A u x ilia ry C o o lin g Fan C ooling Fan A/C Pressure Switch and
A/C Pressure Sw itch Connector Splice S212. Note that Diode D101
Cavity A and Recirculation Door (Page 8A-31-0) may be open.
M otor Connector C 230 Cavity 6.
RECIRCULATION DOOR MOTOR FAILS IN RECIRCULATION POSITION

TEST RESULT ACTION
1. Place Ign ition Sw itch in R U N . Yes. R E P L A C E Recirculation Door Motor.
Place Front Blow er Switch in H I No. G O to Step 2.
at the H V A C C ontrol M odule.
D isconnect C onnector C 2 3 0 at
Recirculation D oor Motor. Is the
R ecirculation D o o r still in the
recirculation position?
H V A C Control Module. Connect Test lamp does not light. R E P L A C E H V A C Control Module.
s e lf-p o w e re d test lam p from
C3 Cavity 4 to ground.
8A - 65 ■ 10 ELECTRICAL DIAGNOSIS_____________________
TEST RESULT ACTION

3. Is this air conditioned vehicle with No. L O C A T E and R E P A IR short to ground
a 7.4 Liter Gasoline Engine. in D K G R N (1614) wire between
H V A C Control M odule and
Recirculation D oor Motor.
Yes. G O to Step 4.
Cooling Fan A/C Pressure Switch. in D K G R N (1614) wire between
Disconnect Connector at Auxiliary H V A C Control Module, A uxiliary
C ooling Fan Temperature Switch. C ooling Fan A/C Pressure Switch, and
Rem ove A u x ilia ry C o o lin g Fan Recirculation D oor Motor. If short is
Relay from its socket. Connect not found, then C H E C K that Diode
se lf -p o w e re d test lam p from D 100 has not shorted.
A u x i l i a r y C o o l i n g F a n A / C Test lamp does not light. R E P L A C E A uxiliary C ooling Fan A/C
Pressure Switch Connector Cavity Pressure Switch.
A to ground.
FRONT MODE DOOR MOTOR OPERATES WITH FRONT BLOWER SWITCH OFF
TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Test lamp lights. R E P L A C E H V A C Control Module.
Place Front Blow er Switch in O F F Test Lam p does not light. G O to Step 2.
at H V A C C o n t r o l M o d u l e .
D i s c o n n e c t C o n n e c t o r C 3 at
H V A C Control Module. Connect a
test lamp between H V A C Control
M odule Connector C 3 Cavity 3
and ground.
H V A C Control Module. Connect Test lamp does not light. L O C A T E and R E P A IR open in D K
self-powered test lam p between G R N (71) wire between H V A C Control
H V A C Control M odule Connector M odule Connectors C 2 and C3.
C 2 Cavity D and Connector C3
Cavity 3.
3. C on n ect a test lam p between Test lamp lights. R E P L A C E H V A C Control Module.
H V A C Control M odule Connector Test lamp does not light. L O C A T E and R E P A IR open in B R N
C 2 Cavity G and ground. (141) wire between Splice S268 and
H V A C Control M odule Connector C2.
REAR VENTILATION CONTROLS INOPERATIVE

TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N . Test lamp lights. G O to Step 2.
D isco n n e c t C onnector at Rear Test lamp does not light. L O C A T E and R E P A IR open in B R N
A u x i l i a r y M o d e D o o r M otor. (341) wire between Convenience Center
Connect a test lamp between Rear and Rear Auxiliary M ode D oor Motor.
A u x ilia ry M od e D o o r M otor
between R e ar A u x ilia ry M od e Test lamp does not light. L O C A T E and R E P A IR open in B L K
D oor M otor Connector Cavity 7 (150) wire between Splice S403 and
and ground. Ground G400.
TEST RESULT ACTION

3. D isconnect C onnector at Front Test lamp lights. G O to Step 4.
A uxiliary H V A C Control Switch. Test lamp does not light. L O C A T E and R E P A IR open in B R N
Connect a test lamp between Front (341) wire between Splice S400 and
A u xilia ry H V A C Control Sw itch Front Auxiliary H V A C Control Switch.
Connector Cavity G and ground.
4. Connect self-powered test lamp Test lamp lights. R E P L A C E Auxiliary H V A C Control
between Front A u xilia ry H V A C Logic Module.
Control Switch Connector Cavity Test lamp does not light. L O C A T E and R E P A IR open in B L K
B and ground. (150) wire between Splice S324 and
Splice S410.
REAR AUXILIARY MODE DOOR INOPERATIVE

TEST RESULT ACTION
Place the Blow er Sw itch at the Test lamp does not light. L O C A T E and R E P A IR open in B R N
Front A u x ilia ry H V A C Control (341) wire between Splice S400 and
M o d u l e in O F F . D i s c o n n e c t Rear Auxiliary M ode D oor Motor.
Connector at Rear Auxiliary M ode
D oor Motor. Connect a test lamp
between R ear A u x ilia ry M o d e
D oor M otor Connector Cavity 10
and ground.
between R ear A u x ilia ry M o d e Test lamp does not light. L O C A T E and R E P A IR open in B L K
D oor M otor Connector Cavity 7 (150) wire between Rear A uxiliary
and ground. M ode D oor M otor and Splice S403.
3. C o n n e ct D M M between R e a r Sm oothly variable voltage observed. R E P L A C E Rear Auxiliary M ode Door
A u x ilia ry M o d e D o o r M o to r Motor.
Connector Cavity 8 and ground. N o voltage, erratic voltage, or fixed G O to Step 4.
Adjust the position of the M ode voltage observed.
Control D ial at the Front A uxiliary
H V A C C o n tro l M o d u l e w h ile
observing D M M response.
4. Disconnect Connector at A uxiliary Test lamp lights. L O C A T E and R E P A IR short to Voltage
H V A C C on trol L o g ic M o d ule. on W H T (119) wire between Auxiliary
C onnect a test lam p between H V A C Control Logic M odule and Rear
A u xilia ry H V A C Control L o g ic Auxiliary M ode D oor Motor.
M odule Connector Cavity F and Test lamp does not light. G O to Step 5.
ground.
5. Connect self-powered test lam p Test lamp lights. L O C A T E and R E P A IR short to ground
between A uxiliary H V A C Control on W H T (119) wire between Auxiliary
Logic M odule Connector Cavity F H V A C Control Logic M odule and Rear
and ground. Auxiliary Mode D oor Motor.
6. Connect self-powered test lam p Test lamp does not light. L O C A T E and R E P A IR open in W H T
between Auxiliary H V A C Control (119) wire between Auxiliary H V A C
Logic M odule Connector Cavity F Control Logic M odule and Rear
and Rear A u xilia ry M ode D o o r Auxiliary M ode D oor Motor.
M otor Connector Cavity 8. Test lamp lights. R E P L A C E Auxiliary H V A C Control
Logic Module.
8A - 6 5 • 12 ELECTRICAL DIAGNOSIS_______________________________
REAR AUXILIARY TEMPERATURE DOOR INOPERATIVE

TEST RESULT ACTION
Place B lo w e r Switch at Front Test lamp does not light. L O C A T E and R E P A IR open in B R N
A u xilia ry H V A C Control Switch (341) wire between Splice S400 and
in OFF. Disconnect Connector at Rear Auxiliary Temperature D oor
Rear A u xiliary Temperature Door Motor.
M o t o r . C o n n e c t a test lam p
betw een R e ar A u x ilia r y
Tem perature D o o r M o to r
b e t w e e n R e a r A u x i l i a r y Test lamp does not light. L O C A T E and R E P A IR open in B L K
Tem perature D o o r M o to r (150) wire between Rear Auxiliary
Connector Cavity 7 and ground. Temperature D oor M otor and Splice
S403.
3. C o n n e c t D M M between Rear Sm oothly variable voltage observed. R E P L A C E Rear Auxiliary Temperature
A u xiliary Temperature Door M otor D oor Motor.
Connector Cavity 8 and ground. N o voltage, erratic voltage, or fixed G O to Step 4.
A d j u s t the p o s i t i o n o f the voltage observed.
Temperature Control D ial at the
Front A u x ilia ry H V A C Control
M o d u le w hile observing D M M
response.
4. Disconnect Connector at Auxiliary Test lamp lights. L O C A T E and R E P A IR short to Voltage
H V A C C o n tro l L o g ic M od ule. on D K B L U (1199) wire between
C on n ect a test lam p between Auxiliary H V A C Control Logic M odule
A u x ilia ry H V A C Control L o g ic and Rear Auxiliary Temperature D oor
M odule Connector Cavity B and Motor.
between A u xiliary H V A C Control on D K B L U (1199) wire between
Logic M odule Connector Cavity B Auxiliary H V A C Control Logic M odule
and ground. and Rear A uxiliary Temperature D oor
Motor.
6. Connect self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in D K
between A uxiliary H V A C Control B L U (1199) wire between Auxiliary
Lo gic M odule Connector Cavity B H V A C Control Logic M odule and Rear
and Rear A u xilia ry Temperature A uxiliary Temperature D oor Motor.
D o o r M otor Connector Cavity 8. Test lamp lights. R E P L A C E Auxiliary H V A C Control
Logic Module.
REAR AUXILIARY HVAC CONTROL SWITCH/MODULE DOES NOT CONTROL REAR

DOORS
TEST RESULT ACTION
D isconnect Connector at Front Test lamp does not light. L O C A T E and R E P A IR open in O R N
Auxiliary H V A C Control Switch. (1923) wire between Front A uxiliary
Disconnect Connector at Auxiliary H V A C Control M odule and Auxiliary
H V A C C o n tro l L o g ic M o d ule. H V A C Control Logic Module.
Control Switch Connector Cavity F
and Auxiliary H V A C Control Logic
Module Connector Cavity M .
A u xilia ry H V A C Control L o g ic Test lamp does not light. L O C A T E and R E P A IR open in B R N
M odule Connector Cavity J and (341) wire between Splice S308 and
ground. A uxiliary H V A C Control Logic
Module.
3. Connect fused jumper wire from Test lamp lights. G O to Step 4.
A u xilia ry H V A C Control L o g ic Test lamp does not light. R E P L A C E A uxiliary H V A C Control
M o d u le C a vity M to ground. Logic Switch.
Connect fused jumper wire from
A u xilia ry H V A C Control L o g ic
M odule Cavity J to B+. Connect
A u xilia ry H V A C Control L o gic
M odule Cavities D and B.
4. D iscon n ect C onnector at R ear Test lamp lights. G O to Step 5.
Auxiliary H V A C Control Switch. Test lamp does not light. L O C A T E and R E P A IR open in B R N
Connect a test lamp between Rear (341) wire between Splice S308 and
Auxiliary H V A C Control Switch Rear Auxiliary H V A C Control Switch.
5. Connect self-powered test lamp Test lamp lights. R E P L A C E Rear Auxiliary H V A C
between Rear A u x ilia ry H V A C Control Switch.
B and ground. (150) wire between Rear A uxiliary
S307.
8A - 6 5 - 14 ELECTRICAL DIAGNOSIS_________________________________________
FRONT AUXILIARY HVAC CONTROL SWITCH/MODULE DOES NOT CONTROL

REAR DOORS
TEST RESULT ACTION
D iscon n ect C onnector at Front Test lamp does not light. L O C A T E and R E P A IR open in B R N
A uxiliary H V A C Control Switch. (341) wire between Splice S308 and
Connect a test lamp between Front Front Auxiliary H V A C Control Switch.
A u xilia ry H V A C Control Switch
2. Connect self-powered test lamp Test lamp lights. R E P L A C E Front Auxiliary H V A C
between Front A u xilia ry H V A C Control Module.
B and ground. (150) wire between Front A uxiliary
S307.
REAR AUXILIARY MODE DOOR MOTOR INOPERATIVE FROM FRONT CONTROL MODULE
TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Smooth variable voltage observed. R E P L A C E Auxiliary H V A C Control
Disconnect Connector at Auxiliary Logic Module.
H V A C C o n tro l L o g i c Switch. N o voltage, erratic voltage, or fixed G O to Step 2.
Connect D M M from A u x ilia ry voltage observed.
H V A C C o n tro l L o g i c M o d u le
Connector C avity E to ground.
Adjust the M ode Control D ial at
the Front A uxiliary H V A C Control
M o d u le w hile m o n ito rin g the
D M M indication.
2. D iscon n ect Connector at Front Test lamp lights. L O C A T E and R E P A IR short to voltage
A u xiliary H V A C Control Switch. on L T B L U (919) wire between Front
Connect a test lamp between Front A uxiliary H V A C Control M odule and
A u xiliary H V A C Control M odule A uxiliary H V A C Control Logic
Connector Cavity J and ground. Module.
between Front A u xilia ry H V A C on L T B L U (919) wire between Front
Control M odule Connector Cavity A uxiliary H V A C Control M odule and
J and ground. Auxiliary H V A C Control Logic
Module.
4. Connect self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in L T
Control Module Connector Cavity Auxiliary H V A C Control M odule and
J and A u xilia ry H V A C Control A uxiliary H V A C Control Logic
Logic M odule Connector Cavity E. Module.
Test lamp lights. R E P L A C E Front A uxiliary H V A C
Control Module.
REAR AUXILIARY TEMPERATURE DOOR MOTOR INOPERATIVE FROM FRONT

CONTROL MODULE
TEST RESULT ACTION
1. Place Ign itio n Sw itch in R U N . Smooth variable voltage observed. R E P L A C E A uxiliary H V A C Control
H V A C C o n tro l L o g ic M od ule. N o voltage, erratic voltage, or fixed G O to Step 2.
Connector C avity A to ground.
Adjust the Temperature Control
D ial at the Front A uxiliary H V A C
Control M odule while monitoring
the D M M indication.
2. D iscon n ect C onnector at Front Test lamp lights. L O C A T E and R E P A IR short to voltage
Auxiliary H V A C Control Module. on L T B L U (733) wire between Front
Connect a test lamp between Front A uxiliary H V A C Control M odule and
Connector Cavity H and ground. Module.
between Front A u xilia ry H V A C on L T B L U (733) wire between Front
H and ground. Auxiliary H V A C Control Logic
Module.
H and A u xilia ry H V A C Control Auxiliary H V A C Control Logic
Logic Module Connector Cavity A. Module.
Test lamp lights. R E P L A C E Front Auxiliary H V A C
Control Module.
REAR AUXILIARY MODE DOOR MOTOR INOPERATIVE FROM REAR CONTROL MODULE
TEST RESULT ACTION
Connector C avity D to ground.
Adjust the M ode control D ial at
the Rear A uxiliary H V A C Control
M o d u le w h ile m o n ito rin g the
D M M indication.
2. D isco n n e ct C onnector at R ear Test lamp lights. L O C A T E and R E P A IR short to Voltage
Auxiliary H V A C Control Module. on L T B L U (920) wire between Rear
Connect a test lamp between Rear Auxiliary H V A C Control M odule and
A uxiliary H V A C Control M odule Auxiliary H V A C Control Logic
Connector Cavity J and ground. Module.
8A - 6 5 - 16 ELECTRICAL DIAGNOSIS_____________________
TEST RESULT ACTION

between Rear A u x ilia ry H V A C on L T B L U (920) wire between Rear
J and ground. Auxiliary H V A C Control Logic
Module.
between Rear A u x ilia ry H V A C B L U (920) wire between Rear
J and A u x ilia ry H V A C Control Auxiliary H V A C Control Logic
Logic M odule Connector Cavity D. Module.
Test lamp lights. R E P L A C E Rear Auxiliary Heater and
A/C Control Module.
REAR AUXILIARY TEMPERATURE DOOR MOTOR INOPERATIVE FROM REAR

CONTROL MODULE
TEST RESULT ACTION
C onnect D M M from A u x ilia ry voltage observed.
Connector C avity C to ground.
A d ju st the temperature Control
D ial at the Rear A uxiliary H V A C
Control M odule while monitoring
the D M M indication.
2. D iscon n ect C onnector at Rear Test lamp lights. L O C A T E and R E P A IR short to voltage
A u xiliary H V A C Control Module. on D K B L U (1646) wire between Rear
Connect a test lamp between Rear A uxiliary H V A C Control M odule and
Connector Cavity H and ground. Module.
between Rear A u x ilia ry H V A C on D K B L U (1646) wire between Rear
H and ground. Auxiliary H V A C Control Logic
Module.
4. Connect self-powered test lamp Test lamp does not light. L O C A T E and R E P A IR open in D K
between Rear A u x ilia ry H V A C B L U (1646) wire between Rear
H and A u xilia ry H V A C Control A uxiliary H V A C Control Logic
Logic M odule Connector Cavity C. Module.
Test lamp lights. R E P L A C E Rear Auxiliary H V A C
Control Module.
CIRCUIT OPERATION The Recirculation D oor is a two-position door and is

in the Recirculation position only when the input D K G R N
FRONT VENTILATION CONTROLS (1614) w ire is grounded through the H V A C Control
The Front A ir Delivery and Temperature Controls are M odule. F o r air conditioned vehicles with 7.4 Lite r
provided for vehicles with heating and air conditioning as Gasoline Engines, the Recirculation D oor is also grounded
well as for vehicles with heater alone. The heater only when the A u xilia ry C oolin g Fan A/C Pressure Sw itch
option’s Heater Control M odule operates sim ilarly to the (Section 8A-31) operates the Auxiliary C ooling Fan. The
H V A C Control M odule except that the A/C Push-button door is norm ally in the Outside A ir position but m oves to
and Temperature D ia l M A X Detent features are not the Inside A ir position when the input wire is grounded. A
provided for the control of the Recirculation Door. For L E D on the H V A C Control M odule is illuminated when
vehicles with air conditioning and 7.4 Liter G asoline the Recirculation D oor is grounded through the H V A C
Engines, an A u x ilia ry C o o lin g Fan is provided. See Control Module.
C ooling Fan S E C T IO N 8A-31 for more information.
The Front M ode D oor Motor, the Front Temperature REAR AUXILIARY VENTILATION
D o o r M otor, and the R ecirculation D o o r M o to r are CONTROLS
powered by the B R N (141) wires when the Ignition Switch The Rear A u xilia ry A ir Delivery and Temperature
is in R U N . Grounding for the door motors is through the C ontrols provided w ith the com bined Rear A u x ilia ry
B L K (150) wires to Ground G202. The H V A C Control Heater and A ir Conditioner option (C36 + C69) work
M odule is powered when the Ignition Switch is in R U N by independently o f the ventilation controls used for the front
the B R N (141) wires. Grounding is through the B L K (150) o f the vehicle. The front system is provided with a
wire to Ground G 200 for the IP. Recirculation D oor and door controls but the rear auxiliary
The H V A C Control M odule’s ventilation controls for system does not have this capability. The Rear A uxiliary
the Front M ode D o o r and the Recirculation D oo r are M ode D oor and the Rear Auxiliary Temperature D oor are
disabled when the M odule’s Front Blow er Switch is in the exclusively controlled from either o f two A uxiliary H V A C
O F F position. W ith the Front Blow er Switch in the H I, Control M odules. The Front A u xilia ry H V A C Control
M 2, M l, or L O positions, the ventilation controls are M od ule's Blow er Switch, located above the IP, has a
enabled. The Front Temperature D oor is not dependent on permissive position (R E A R ) which enables control from
Front Blow er M otor operations and can be controlled as the Rear A uxiliary H V A C Control Module. In the R E A R
long as the Ignition Switch is in R U N . position, if the Ignition Switch is in R U N , relay contacts in
The M ode and Temperature Doors are positioned in the A uxiliary H V A C Control Logic M odule change state to
proportion to the variable voltage signal received from the enable control input from the ventilation controls at the
H V A C Control Module. Adjusting the Temperature D ial at Rear A uxiliary H V A C Control Module. W hen the Front
the H V A C C ontrol M od ule adjusts a rheostat w hich Auxiliary H V A C Control M odule’s Blow er Switch is not in
provides a voltage signal proportional to the dial position. the R E A R p o s it io n , the lo g ic m o d u l e ’s re la y is
T his voltage is carried on the L T B L U (733) wire to the de-energized and controls inputs from the Front Auxiliary
Front Temperature D oo r M otor which then positions in H V A C Control M odule controls the doors.
response to the voltage signal. Adjusting the M ode D ial at Each control module produces a variable voltage signal
the H V A C C ontrol M od ule adjusts a rheostat w hich to the door motor. Each door motor is powered from the
provides a voltage signal proportional to the dial position. B R N (341) wires when the Ignition Switch is in the R U N
This voltage is carried on the W H T (454) wire to the Front position. D oor grounding is through the B L K (150) wires
M ode D oor M otor which then positions in response to the to Ground G400. The variable voltage signal causes the
voltage signal. door motor to operate to a position consistent with the
signal’s voltage. The voltage corresponds to the control dial
selection on the selected control module.
AUDIBLE WARNINGS
I HOT WITH HEADLIGHT SWITCH |
[ I ^ N P g K ttK A D L g j^ l
(GAS) (GAS)
(D C S E L) 03-18-87
4208W0625

Audio Alarm M odule......... ... Under L H of IP, at R H o f Convenience Center................. . 3 3 .... 44
Convenience Center.......... ... Under L H of IP, on Bulkhead........................................ . 3 3 .... 44
D oor Jamb Switch, L F ...... ... A t L H end of IP ......................................................... . 4 5 .... 59
Instrument Cluster............. ... Upper L H end of IP, above Steering C olu m n ................... . 3 2 .... 4 3 .... 202-38
IP Fuse B lo ck .................. ... L H of IP, near L F D oor Jamb Sw itch ............................. . 3 2 .... 43
K e y-In W arning Buzzer

Sw itch......................... ... In Steering C olum n..................................................... . 4 7 .... 61
Seat Belt Switch, L H ......... ... A t L F Stationary Belt Connector.................................... . 5 6 .... 72

( V C M ) ......................... ... Engine Compartment, near E B C M ................................. . 3 7 .... 48
C O N N EC T O R S:
C 1 0 0 .............................. ... Engine Harness to IP Harness, L R of Engine Compartment,

at Bulkhead............................................................ . 4 ...... 8 ...... 202-0
C 200 (G a s)......................... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-10
C 2 1 0 ...... ........................ ... A t Convenience Center................................................ . 3 3 ...... 44.... 202-51
C 2 1 1 .............................. ... Under L F Seat............................................................ . 6 5 .... 8 3 .... 202-52
C 2 6 6 .............................. ... IP Harness to Steering Colum n Harness, L H o f Steering

Column, near Bulkhead............................................. . 3 2 ...... 4 3 .... 202-14
C 2 9 8 .............................. ... Behind L H of IP, near Convenience Center....................... 3 2 ...... 4 3 .... 202-17,
18
G R O M M E T S :.
P 1 0 0 .............................. ... L R of Engine Compartment, at Bulkhead above C l 00
P 1 0 1 .............................. ... R R o f Engine Compartment, at Bulkhead........................ . 7 ...... 12
G R O U N D S:
G103 (G a s)...................... ... R F o f Engine, near Thermostat H o u sin g ......................... . 1 4 .... 18
G 104 (Gas, D ie se l)........... ... R H top center o f Cylinder Head.................................... . 1 6 .... 20
G 200.............................. ... Behind L H o f IP, below Fuse Block, on Tie B a r.............. . 3 2 .... 43
S P L IC E S :
S I 03 (5.0L - H D , 5.7L - H D ).. Engine Harness, approx. 13 cm from E G R Valve Breakout,

S I 03 (5.0L - L D , 5.7L - LD)... Engine Harness, approx. 8 cm from E G R Valve Breakout,


Breakout
S103 (7.4L - A/T )................. Engine Harness, approx. 34 cm from Fuel Injector Breakout,

Breakout
AUDIBLE WARNINGS

Breakout

S 2 1 7 .................................. IP Harness, approx. 16 cm from Instrument Cluster Harness

S 2 5 1 .................................. Crossbody Harness, approx. 13 cm right of L F Door


toward C299
5 2 9 8 ................................ IP Harness, approx. 24 cm from Instrument Cluster


DIAGNOSIS - AUDIO ALARM MODULE
TROUBLESHOOTING HINTS: 7. If the Fasten Safety Belts W arning Alarm remains

1. C H E C K that G A U G E S Fuse 4, IL L U M Fuse 14, and present after 5 seconds, the Audio Alarm M odule may
ST O P /H A Z Fuse 1 are not open. If fuse(s) is open, have failed.
L O C A T E and R E P A IR source o f overload, and 8. Failure o f two o f the three alarm functions may
R E P L A C E fuse(s). indicate Audio Alarm M odule failure.
2. C H E C K that Grounds G103, G104, and G 200 are 9. R E F E R to S E C T IO N 8A-117 for diagnosis o f the
clean and tight Instrument Panel Dim m ing System.
3. C H E C K Fasten Safety Belts Indicator for an open • C H E C K for a broken (or partially broken) wire inside
filam ent o f the in s u la t io n w h ic h c o u ld cause s y ste m
4. C H E C K that A u d io A la rm M o d u le is securely m a lfu n c tio n but prove “ G O O D” in a
mounted in Convenience Center. continuity/voltage check with a system disconnected.
5. C H E C K that the L F D o o r Jamb Sw itch operates These Circuits may be intermittent or resistive when
freely. loaded, and if possib le, sh ou ld be checked by
6. If the Lam ps-O n W arning A larm is inoperative, m onitoring for a voltage drop w ith the system
C H E C K that the Panel Dim m er Switch is not in the operational (under load).
fully dim position. • C H E C K fo r proper in sta lla tio n o f afterm arket
NO AUDIBLE WARNING ALARM FUNCTIONS

TEST RESULT ACTION
1. R em ove A u d io A la rm M o d u le Test lamp lights. G O to Step 2.
from Convenience Center. Connect Test lamp does not light. L O C A T E and R E P A IR open in O R N
a test lam p from A u d io A larm (140) wire between IP Fuse Block and
M od u le socket Term inal J2 to Convenience Center.
ground.
2. U sing a self-powered test lamp or Continuity. G O to Step 3.
ohmmeter, test continuity for B L K N o Continuity. L O C A T E and R E P A IR open in B L K
(150) w ire from A u d io A la rm (150) wire between A udio Alarm
M od ule socket Term inal K 2 to M odule and Ground G200.
Ground G200.
3. Connect a test lamp from Audio Test lamp lights. R E P L A C E Audio Alarm Module.
Alarm M odule socket Terminal K 4 Test lamp does not light. L O C A T E and R E P A IR open in P N K
to ground. (39) wire between IP Fuse B lo ck and
Convenience Center.
FASTEN BELTS WARNING ALARM FAILS ON

TEST RESULT ACTION
1. Place Ign ition Sw itch in R U N . Yes G O to Step 2.
Fasten L F Seat Belt. Is the Fasten No. System O K .
S a fe ty B e lts W a rn in g A la rm
present?
2. D isc o n n e c t the L F Seat B e lt Yes. L O C A T E and R E P A IR short to ground
Connector C 211. Is the Fasten in B L K / W H T (238) wire between
S a fe ty B e lts W a rn in g A la rm Convenience Center and Seat Belt
present? Switch. If wire is good, R E P L A C E
Audio Alarm Module.
No. Replace the Seat Belt Switch.
THE FASTEN SAFETY BELTS WARNING ALARM FAILS OFF

TEST RESULT ACTION
1. W ith Ignition Switch in R U N and Test lamp lights. G O to Step 2.
A u d io A larm M od ule removed, Test lamp does not light. L O C A T E and R E P A IR open in P N K
c o n n e c t a te s t la m p fro m (39) wire between Convenience Center
Convenience Center Terminal K 4 and IP Fuse Block.
to ground.
2. Unfasten L F Seat Belt. Connect Test lamp lights. R E P L A C E Audio Alarm Module.
test lam p fro m C o n v e n ie n c e Test lamp does not light. G O to Step 3.
Center Terminal K1 to B+.
3. D isc o n n e c t Seat B e lt S w itc h Test lamp lights. G O to Step 4.
Connector C211. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in B L K
lamp between Terminal A of the (150) wire between Seat Belt Switch
Seat Belt Switch Connector C211 Connector and ground.
and B+.
4. Connect a jumper wire between Test lamp lights. R E P L A C E Seat Belt Switch.
terminals A and B of Seat Belt Test lamp does not light. L O C A T E and R E P A IR open in
Switch Connector C211. Connect B L K / W H T (238) wire between Seat
a self-powered test lamp between Belt Switch and A udio Alarm Module.
A u d io A la rm M o d u le so ck e t
terminal K1 to ground.
AUDIBLE WARNINGS
LAMPS-ON WARNING ALARM FAILS ON

TEST RESULT ACTION
1. Place Ignition Switch in O F F or Yes. G O to Step 2.
L O C K . Place Headlamp Switch in No. System O K.
O P T position. Is the Lam ps-O n
W arning Alarm present?
2. R E M O V E A u d io Alarm M odule Battery voltage is present. L O C A T E and R E P A IR short to voltage
from Convenience Center. Connect in G R Y (8) wire between IP Fuse
V o ltm e te r fro m C o n v e n ie n c e Block and Convenience Center. If short
Center Terminal J1 to ground. to voltage is not found, G O to
Instrument Panel Dim m ing, S E C T IO N
8A-117.
Battery voltage is not present. R E P L A C E Audio Alarm Module.
LAMPS-ON WARNING ALARM FAILS OFF

TEST RESULT ACTION
1. R em ove A u d io A la rm M o d u le Battery voltage is not present. L O C A T E and R E P A IR open in P N K
from Convenience Center Socket. (39) wire between Convenience Center
Place Ig n itio n Sw itch in R U N . and IP Fuse B lo ck
Place Headlamp Switch in H E A D Battery voltage is present. G O to Step 2.
or P A R K . Adjust Dim m er Switch
to maximum brightness. Connect
vo ltm e te r fro m C o n v e n ie n c e
Center Terminal K 4 to ground.
2. C o n n e c t v o l t m e t e r f r o m Battery voltage is present. R E P L A C E A udio Alarm Module.
Convenience Center Terminal J1 Battery voltage is not present. L O C A T E and R E P A IR open in G R Y
to ground.
(8) wire between Convenience Center
and IP Fuse Block. If required, G O to
Instrument Panel Dim m ing S E C T IO N
8A-117 to L O C A T E open circuit.
FASTEN SAFETY BELTS INDICATOR FAILS OFF

TEST RESULT ACTION
1. R em ove A u d io A la rm M o d u le Fasten Safety Belts Indicator lights. R E P L A C E Audio Alarm Module.
from the C on ve n ie n ce Center. Fasten Safety Belts Indicator does not G O to Step 2.
C onnect a fused jum per from light.
A ud io Alarm M odule Terminal K 3
in the Convenience Center to B+.
2. B a ckp ro b e Instrum ent C lu ste r Fasten Safety Belts Indicator lights. L O C A T E and R E P A IR open in Y E L
Connector with a fused jumper (234) wire between Convenience Center
from Terminal 30 to B+. and Instrument Cluster.
Fasten Safety Belts Indicator does not C H E C K for an open in B L K (150)
light. wire between Instrument Cluster and
Grounds G 103 and G104. If O K ,
R E P L A C E Instrument Cluster.
FASTEN SAFETY BELTS INDICATOR FAILS ON

TEST RESULT ACTION
1. Rem ove A u d io A la rm M o d u le Fasten Safety Belts Indicator goes out. R E P L A C E A udio Alarm Module.
from Convenience Center. Place Fasten Safety Belts Indicator remains C H E C K for a short to voltage in Y E L
Ignition Switch in R U N . illuminated. (234) wire between Convenience Center
and Instrument Cluster. If O K ,
KEY-IN WARNING ALARM FAILS OFF

TEST RESULT ACTION
1. R em ove A u d io A la rm M o d u le Continuity. G O to Step 2.
fro m C o n v e n ie n c e C e n te r. N o Continuity. L O C A T E and R E P A IR open in L T
D isc o n n e c t S te e rin g C o lu m n G R N (80) wire between Convenience
Harness Connector C266. U sing a Center and Connector C266.
s e lf-p o w e re d te st m e te r o r
ohmmeter, test continuity between
Convenience Center Terminal J3
to Connector C 266 Terminal B3.
2. Place ignition key in the Ignition Continuity. G O to Step 3.
Switch. Test continuity between N o Continuity. R E P L A C E K e y-In W arning Buzzer
Connector 266 Terminals B 3 and Switch.
B4.
3. Disconnect Connector at L F D oor Continuity. G O T O Step 4.
Jam b Sw itch . Test C o n tin u ity N o Continuity. L O C A T E and R E P A IR open in T A N
between connector C 266 Terminal (159) wire between Connector C266
B 4 and L F D o o r Jamb Sw itch and L F D oor Jamb Switch.
Connector Terminal C.
4. Open L F Door. Test continuity Continuity. G O to Step 5.
between Terminals C and B of L F N o Continuity. R E P L A C E L F D oor Jamb Switch.
D oor Jamb Switch.
5. Test C ontinuity from L F D o o r Continuity. R E P L A C E Audio Alarm Module.
Jamb Switch Connector Terminal N o Continuity. L O C A T E and R E P A IR open in B L K
B to Ground G200. (150) wire between L F D oor Jamb
Switch and Ground G200.
KEY-IN WARNING ALARM FAILS ON

TEST RESULT ACTION
1. Place Ignition K e y in the Ignition Yes. G O to Step 2.
Switch. Place the ignition Switch No. G O to Step 3.
in R U N . Open L H Door. Is the
K e y-In W arning Alarm present?
2. Rem ove A u d io A la rm M o d u le Test lamp lights. R E P L A C E Audio Alarm Module.
from the C onvenience Center. Test lamp does not light. L O C A T E and R E P A IR open in P N K
C o n n e c t a te st la m p fro m (39) wire between IP fuse block and
Convenience Center Terminal K 4 Convenience Center
to ground.
AUDIBLE WARNINGS
TEST RESULT ACTION

3. Place the Ignition Switch in the Continuity to ground. L O C A T E and R E P A IR short to ground
O F F or L O C K position. Leave the in L T G R N (80) wire between
key in the Switch. Observe normal Convenience Center and Connector
A la rm con d itio n. R e m ove the C266.
A u d io A larm M od ule from the N o continuity to ground. G O to Step 4.
Convenience Center. Disconnect
S t e e r in g C o lu m n H a r n e s s
C o n n e c t o r C 2 6 6 . U s in g a
self-powered test lamp, test for
continuity between Convenience
Center Terminal J3 and ground.
4. Install the A udio Alarm M odule at Yes. R E P L A C E A ud io Alarm Module.
the Convenience Center. Is the No. G O to Step 5.
K e y-In W arning Alarm present?
5. Rem ove the key from Ign itio n Continuity to ground. R E P L A C E the K e y-In W arning Buzzer
Sw itch. Test C on tin uity in the Switch.
Steering Colum n from Connector N o Continuity to ground.
G O to Step 6.
C 266 Cavity B 3 to ground.
6. Test continuity in the Steering Continuity. R E P L A C E the K e y-In W arning Buzzer
C o lu m n from C onnector C 2 6 6 Switch.
Terminal B 3 to Terminal B4. N o Continuity. G O to Step 7.
7. T e s t C o n t i n u i t y b e t w e e n Continuity to ground. R E P L A C E the K e y-In W arning Buzzer
C onnector C 2 6 6 Term inal B 4 to Switch.
ground. N o Continuity to ground. G O to Step 8.
8. Disconnect connector at L F D oor Continuity to ground. L O C A T E and R E P A IR open in T A N
Jam b Sw itch . Test c o n tin u ity (159) wire between Connector C 266
between L F D o o r Sw itch and and L F D oor Jamb Switch.
Jam b S w itc h T e rm in a l C to N o Continuity to ground. R E P L A C E L F D oor Jamb Switch.
ground.
OVERSPEED
THE OVERSPEED WARNING ALARM IS INOPERATIVE

TEST RESULT ACTION
1. Disconnect the C 2 at the Audio Test lamp lights. R E P L A C E the M ulti-Function Alarm
A la rm M odule. D iscon n ect the Module.
C o n n e c to r C 4 at the V e h icle Test lamp does not light.
L O C A T E and R E P A IR the open in the
C o n t r o l M o d u le . C o n n e c t a
D K G R N (389) wire between the
self-powered test lam p between A udio Alarm M odule and the Vehicle
Alarm M odule Connector Terminal Control Module.
C 9 and the V e h ic le C o n tro l
M odule Connector C 4 Terminal 4
for the D K G R N (389) wire.
OVERSPEED WARNING ALARM KEY-IN WARNING ALARM

The Overspeed W arning Alarm is sounded when the The K e y-In W arning Alarm w ill sound if the ignition
vehicle exceeds 120 km/h. This speed is not adjustable, and key is in the Ignition Switch with the Ignition Switch in
it is based on a frequency signal sent from the vehicle A C C , L O C K , or O F F with the L F D oor open. W hen the
control module on D K G R N (389). This signal is also sent ignition key is in the Ignition Switch and the L F D oor is
to the Instrument Cluster for the speedometer/odometer open, the K e y-In W arning Buzzer Switch is closed as is the
function. L F D oor Jamb Switch. W hen both of these switches are
closed, ground is sensed at the A u d io Alarm M odule
CIRCUIT OPERATION activating the K e y-In W arning Alarm . The K e y-In W arning
Alarm w ill stop sounding if the ignition key is removed
FASTEN SAFETY BELTS WARNING from the Ignition Switch, the L F door is closed, or the
ALARM Ignition Switch is turned to R U N .
The Fasten Safety Belts W arning Alarm sounds when
the Ignition Switch is in the R U N , B U L B T E S T or S T A R T LAMPS-ON WARNING ALARM
position with the L F safety belt not fastened. W hen the L F The Lam ps-O n W arning A larm w ill sound if the
Safety Belt is not fastened, ground is sensed at the Audio Headlamp and Panel Dim m er Switch is in the H E A D or
Alarm Module. The alarm w ill sound for approximately P A R K position, the Panel Dim m er Switch is not in the
five seconds. The A ud io Alarm M odule’s Fasten Safety fully dim position, and the Ignition Switch in the L O C K ,
Belt W arning Alarm also incorporates an indicator within A C C , or O F F position. W hen the Headlamp and Panel
the Instrument Cluster. The Fasten Safety Belts Indicator Dim m er Switch is in the H E A D or P A R K position, voltage
works in conjunction with the Fasten Safety Belts W arning is applied through the IL L U M Fuse 14 to the Audio Alarm
Alarm . W hen the A u d io Alarm M odule receives a signal Module. W hen voltage is sensed at the Lam ps On input
that the L F Safety Belt is unfastened, the module connects terminal of the A ud io Alarm M odule and there is an
voltage to Terminal 3 for the Fasten Safety Belts Indicator. absence of voltage at the Ignition O n Input terminal, the
Lam ps-On W arning Alarm sounds. The Lam ps-On W arning
Alarm can be silenced by either turning the Headlamp
Switch to the O F F position or turning the Ignition Switch
to R U N .
INSTRUMENT CLUSTER
GASOLINE ENGINES
<
ENONE
COOLANT
TEMPERATURE
SENDER
EnSRF
CONTROLS
T FUEL r — — T KMTION
| PUMP
1 I con.
1— ■ENONE
1 1 CONTROLS
• PRESSURE
1
!
I
SWITCH
aS
■* SENDER
ENONE
T "
1
L _ J
1
08-24-07
4208W0068
CONTROLS
INSTRUMENT CLUSTER
DIESEL ENGINES
HOT IN RUN, BULB TEST OR START HOT IN RUN, BULB TEST OR START
i r HOT IN RUN, BULB TEST OR START
1
- T ■ T IP
r-r ” 1 UNOERHOOO
TRANS
Ha 4
GAUGES j FUSE 1 K 7t
ENG 1 | FUSE-RELAY
FUSE 20 FUSE 4
1BLOCK FUSE ■ CENTER
C 20 A
10 A 10 A
1 1 1
1
J7 0 ' LSO
.3 5 PNK
03*24*97
4206W0066
.8PNK
£104
____ ENGINE
150
— GROUNO
03-17-97
4206W0686
INSTRUMENT CLUSTER
GASOLINE ENGINES (DUAL TANK)
r HOT IN RUN, BULB TEST OR START
T UNDERHOOO
P — — - — — — - n UNDERHOOD
I n t W 4J I f u s e - relay
I ** “ ** FUEL
| I | PUMP , « e la y I r FUS£ |CENTCR
j | (RELAY j CENTER
10 A
G8
I---- 1_________ I
r “ *» FUEL .8PNK 1 639

1 | PUMP SEE FUSE
1! 101
J PRESSURE
S 1 4 6 # »
- ► BLOCK DETAILS
PAGE 8 A -1 1 -2 8
r C j SWITCH
1 GRY CY ANO
C2 C 100
1 CRYl 120
9 /"NCI
^ VEHICLE
I CONTROL
' LEVEL MOOULE
I OUTPUT
FUEL
LEVEL |
t JfUT_____ 2V_ J
13 V 2_7 V C 3
ENGINE
CONTROLS
PRIMARY FUEL PUMP IGNITION OUTPUT 5V .8LT GRN 1058

TANK BALANCE TO
FUEL RELAY GAUGE
LEVEL CONTROL
S324 # SIGNAL
SECONDARY
TANK FUEL
1 I 451 GROUND LEVEL SIGNAL
BLK/ I
WHT I B /* \
SECONDARY
SEE GROUND
DISTRIBUTION
D 'l 'C lC
BLK/
S
AW
FUEL
PUMP
PAGE 8 A -1 4 -9 WHT 1 BLK 150
451
S319 01
.8BLK | 150
G104 # C404
ENGNE IT - 03-31-97
GROUND 4208W0657
INSTRUMENT CLUSTER
DIESEL ENGINES (DUAL TANK)
ENONE
CONTROLS
t GRY
1GRY
.8
BLK
B /* \
FUEL .8 LT CRN 1058

PRIMARY TANK FUEL PUMP IGNITION OUT
FUEL LEVEL BALANCE RELAY PUT PUMP
SIGNAL CONTROL TO BALANCE
GAUGE
MOOULE
SECONDARY TANK
FUEL LEVEL
GROUNO SIGNAL
.8 BLK/YYHT I 451
b /* s I
SECONDARY „> ■ /
a“A
BY
.5 LT BLU I 975
o A 0 FUEL
PUMP
.5 BLK/WHT I 451
.8 BLK I 150
l # S319
m M M S103
SEE GROUNO
DISTRIBUTION
.8 BLK | 150 PAGE 8A -14-9
J ^ 1 BLK/WHT I 451
SEE GROUNO
G404
y BLK/WHT 451
DISTRIBUTION
PAGE 8A -1 4 -9
Cl 04 ____ G104
ENCWE - = r ENCWE
t _t GROUNO GROUNO
03-31-97
4200W0858
INSTRUMENT CLUSTER
ELECTRONIC PRNDL
I HOT IN RUN BULB TEST OR START
I
T IP
I FUSE
I BLOCK
20
I
10 A
1 El 1 J
AUTOMATIC .3 5 PNK
TRANMISSION l 7
CONTROLS 1020
INSTRUMENT ■B PPL/W HT .3 5 PNK 1020 .3 5 GRY INSTRUMENT
◄
PANEL DIMMING PANEL DIMMING
SECTION B A -117 1382 8 SECTION 8 A -1 1 7
7 ,
* | INSTRUMENT
(DIESEL)
_ J/^V. _ C 200
R / V P /1N N (GAS)
.5 GRY I 773
.5 BLK/WHT | 771 TRANSMISSION

C200 .5 WHT 776 .5 YEL I 772 RANGE
SWITCH
1 6LK/W HT 451
„
(PART OF PA R K /
NEUTRAL POSITION
C / " \ ._ _ l C2 SWITCH)
SEE GROUNO
DISTRIBUTION
T
S I 62 (GAS)
PAGE 8 A -1 4 -8 ,9
S107 (D C SEL)
i T i n
U m m t # S 103
I 451
BLK/
WHT
I 1 BLK/WHT 451
j j - Cl 04 . G 103
— ENGINE ENGINE
GROUNO GROUNO
03*31-87
4206W0089
INSTRUMENT CLUSTER
4.3L GASOLINE ENGINE ONLY
FROM PACE
BA-81 -0
03-31-97
4206W0781
INSTRUMENT CLUSTER

A udio Alarm M odule............. Under L H o f IP, at R H of Convenience Center................. 3 3 .... 44
Convenience Center.............. Under L H o f IP, on Bulkh e ad ........................................ 3 3 .... 44

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing.............. 6 ...... 10
Engine Coolant Temperature

Sender (G a s)..................... L H Cylinder Head, near #1 Spark P lu g............................ 1 4 .... 18

Sensor (Diesel).................. Low er L F o f Engine B lo c k ............................................ 2 1 .... 26
Fuel Gauge Sender................ In Fuel Tank............................................................... 6 9 .... 90 .... 202-63
Fuel Gauge Sender, Secondary. In A uxiliary Fuel T an k................................................. 6 9 .... 9 0 .... 202-63
Fuel Pum p (D iesel)............... Inside L H Frame Rail, below L F D o o r............................ 2 1 .... 26
Fuel Pump, Secondary

(D ie sel)............................ In Auxiliary Fuel T an k................................................. 2 1 .... 26
Fuel Pum p and Sender.......... In Fuel T ank............................................................... 7 3 .... 97
Fuel Pum p Balance M od ule.... Inside L H Frame Rail, near Transm ission Crossm em ber...... 6 9 .... 9 0 .... 202-63
Fuel Pum p Balance R e lay...... O n Fuel Pum p Balance M odule, inside L H Frame Rail, hear
Transm ission Crossm em ber......................................... 6 9 .... 90.... 202-63
Fuel Pum p O il Pressure Switch

and Sender (D iesel)............ Under Intake M anifold, center o f E n g in e ..................... . 2 0 .... 2 5 .... 202-63
Fuel Pum p O il Pressure Switch

and Sender (G a s)............... Rear top center o f Engine, behind D istributor................... 1 2 .... 16.... 202-63
Fuel Pum p R e la y .................. In Underhood Fuse-Relay Center, L R of Engine

Compartment, on Fender............................................ 6 ...... 10
Fuel Tank Pressure Sen sor...... In Fuel T ank............................................................... 7 3 .... 9 7 .... 202-64
'
Generator............................. L H front o f En gin e ...................................................... 1 ...... 3
Ignition C o il........................ R R o f E n g in e ............................................................. 1 8 .... 22

Diagnostic M odule (S D M )... A t L F D oor S il l .......................................................... 3 9 .... 51..... 202-37
Instrument C luster................. Upper L H end o f IP, above Steering C olum n.................... 3 2 .... 43 .... 202-38
IP Fuse B lo ck ...................... L H o f IP, near L F D oo r Jamb Sw itch ............................. 3 2 .... 43

M odule (D ie sel)................. Under center o f DP....................................................... 3 7 .... 49.... 202-66

(D ie sel)............................ In Coolant Reservoir, R H o f Engine Compartment............. 3 7 .... 49

(P C M ).............................. Under R H end o f IP, above Blow er Motor, behind IP
Compartment B o x ..................................................... 3 7 .... 49
Secondary Fuel Pum p............ O n inside L H Frame rail, near front o f rear Tank

Connectors C l and C 2 ........ L H o f T ransm ission..................................................... 202-70

Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender........................... . 5 ..... 9

( V C M )............................. Engine Compartment, near E B C M ................................. . 3 7 .... 48

(D ie se l)............................ Under R H of IP .......................................................... . 3 7 .... 4 9 .... 202-70
Water-in-Fuel Sensor (Diesel).... Top rear o f E n gin e ...................................................... . 1 9 .... 23
CONNECTORS:
at B ulkhead ............................................................ . 4...... 8 ...... 202-0

Compartment, under Brake Master C ylind er.................. . 1 4 .... 18.... 202-49
C 1 0 4 .................................. IP Harness to Front-to-Rear Harness, L R o f Engine

Compartment, under Brake Master C ylind er.................. . 3 1 .... 4 2 .... 202-49
C 1 3 0 .................................. Engine Harness, approx. 17.5 cm from V C M Breakout...... . 6 ..... 10.... 202-50
C 200 (D ie se l).............. ........ Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-11
C 200 (G a s)......................... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-10
C 2 3 2 .................................. IP Harness to S IR Harness, behind R H o f IP ................... . 5 5 .... 7 0 .... 202-54
C 2 9 8 .................................. Behind L H o f IP, near Convenience Center....................... 3 2 .... 4 3 .... 202-17,

18
GROMMETS:
P 1 0 0 .................................. L H rear o f Engine Compartment at Bulkhead................... . 3 ...... 7
P 1 0 1 .................................. R R o f Engine Compartment, at Bulkhead........................ . 7 ..... 12
GROUNDS:
G 103 (G a s)......................... R F o f Engine, near Thermostat H o u sin g ........................... 1 4 .... 18
G 104 .................................. R H top center o f Cylinder Head..................................... . 16.... 20
G 1 0 5 .................................. R F o f Engine block..................................................... . 1 3 .... 17
G 200 .................................. Behind L H o f IP, below Fuse Block, on Tie B a r.............. . 3 2 .... 43
G 404 .................................. Inside L H Frame rail, near rear Crossmember
SPLICES:
S100 (4.3L, 7.4L) ................ Engine Harness, approx. 23 cm from E B C M Breakout,
toward Taillam p Harness

S100 (6.5L - A/T)................. Engine Harness, approx. 31 cm from Taillamp Harness

Breakout
S100 (6.5L - M / T )................ Engine Harness, approx. 37 cm from E B C M Breakout,

S103 (VIN W )...................... Engine Harness, approx. 11 cm from Breakout to E G R

Valve, toward Fuel Injector Breakout
8A - 81 -1 0 ELECTRICAL DIAGNOSIS
INSTRUMENT CLUSTER

S103 (V IN M R ) .................. Engine Harness, approx. 11.5 cm from Breakout to E G R
Valve, toward Taillamp Harness
S I 03 (V IN J)....................... Engine Harness, approx. 12 cm from Fuel Injector , toward

Taillamp Harness
S103 (Diesel)....,................... Engine Harness, approx. 11.5 cm from Breakout to Glow

Plugs, (R H side) toward P101
S I 06 (4.3L) ...................... Engine Harness, approx. 4 cm from Breakout to E G R Valve

Breakout, toward Fuel Injector Breakout
S I 06 (5.0L, 5.7L) .............. Engine Harness, approx. 17 cm from E G R Valve Breakout,

toward Fuel Injector Breakout
5106 (7.4L) ........... ............. Engine Harness, approx. 7 cm from E G R Valve Breakout,
5107 (4.3L) ........................ Engine Harness, approx. 25 cm from E G R Valve Breakout,

S107 (5.0L, 5.7L) .............. Engine Harness, approx. 35 cm from E G R Valve Breakout,
S I 07 (6.5L, H D ) ................. Engine Harness, approx. 30 cm from E B C M Breakout,

S I 07 (6.5L, L D )................... Engine Harness, approx. 24 cm from E B C M Breakout,

5107 (7.4L) ........................ Engine Harness, approx. 18 cm from E B C M Breakout,

5108 (4.3L) ........................ Engine Harness, approx. 11 cm from Ignition C o il Breakout,

S I 08 (5.0L - A/T, H D , 5.7L - Engine Harness, approx. 12 cm from Ignition C oil Breakout,
A/T, H D ) .......................... toward Starter Solenoid
S108 (5.0L - A/T, L D , 5.7L - Engine Harness, approx. 39 cm from Ignition C o il Breakout,
A/T, L D ) ......................... toward Starter Solenoid
S108 (5.0L - M/T, 5.7L - M /T) Engine Harness, approx. 28 cm from Ignition C oil Breakout,
S108 (6.5L, A / T )................ Engine Harness, approx. 12 cm from G low Plugs Breakout
S I 08 (6.5L, M /T )................. Engine Harness, approx. 5 cm from Backup Lam p Switch

Harness Breakout
S I 08 (7.4L) ........................ Engine Harness, approx. 13 cm from Ignition C oil Breakout,

5147 (4.3L) ....................... Engine Harness, approx. 5 cm from Fuel Injector Breakout,


Breakout
S I47 (7.4L) .................................... Engine Harness, approx. 5 cm from EGR Valve Breakout

S I 62 (4.3L, 5.0L, 5.7L - LD)... Engine Harness, approx. 17 cm from Starter Solenoid
Breakout, toward L H O xygen Sensor Breakout
S162 (5.0L -H D , 5.7L - HD).... Engine Harness, approx. 43 cm from L H Oxygen Sensor
S162 (7.4L - A/T)................. Engine Harness, approx. 40 cm from L H O xygen Sensor

S162 (7.4L - M / T )................ Engine Harness, approx. 15 cm from R H Bank Oxygen

S211 (D ie sel)....................... IP Harness, approx. 16 cm into Instrument Cluster Breakout
S211 (G a s).......................... IP Harness, approx. 4 cm from Engine Harness Breakout

(C200)

Breakout


S232 (V IN W, M , R ) ............ Engine Harness, approx. 7 cm in Breakout to E G R Valve
S232 (4.3L) ........................ Engine Harness, approx. 7 cm into E G R Valve Breakout
S232 (5.0L - H D , 5.7L - H D ).. Engine Harness, approx. 10 cm from E G R Valve Breakout
S232 (5.0L - L D , 5.7L - LD)... Engine Harness, approx. 27 cm from E G R Valve Breakout
S232 (7.4L) ........................ Engine Harness, approx. 4 cm into E G R Valve Breakout



S317 (D iesel)....................... Taillamp Extension Harness, approx. 10 cm from Fuel

Gauge Sender Breakout, toward Engine Harness


and Sender Breakout, toward balance Fuel Pum p Balance
M odule Breakout
S 3 2 4 .................................. Taillamp Extension Harness, approx. 10 cm from G 404


Harness Breakout, toward C 409
8A - 81 - 12 ELECTRICAL DIAGNOSIS_______________________________
INSTRUMENT CLUSTER
DIAGNOSIS - INSTRUMENT CLUSTER

TROUBLESHOOTING HINTS: Instrument Cluster gauge of 10% of visible scale is
1. C H E C K condition of T R A N S , G A U G E S , E N G 1, P K norm ally acceptable dynamic error, as introduced by
L P S, and IG N E F U S E (S). If Fuse is open, L O C A T E sloshing o f fuel in the Fuel Tank during acceleration
and R E P A IR cause o f overload and R E P L A C E or braking is also acceptable as long as the gauge
Fuse(s). indicates reasonable, during steady state conditions.
2. C H E C K that G ro u n d s G 1 0 3 , G 1 0 4 and G 4 0 4 Errors due to non-linearity as in temperature senders
(Gasoline) or Grounds G104, G105, G 200 and G 404 or in Fuel Tank construction are also acceptable.
(Diesel) are clean and tight. Gauge accuracy should be sufficient to avoid false or
3. If two or more Instrument Cluster indications (gauges misleading indications. If the indications are false or
or lam ps) are not operating, C H E C K power and misleading, corrective action is required.
ground circuits which are common to the indications. 7. If the odometer functions, but the speedometer does
4. The C H E C K G A U G E S indication is illuminated when not, R E P L A C E the Instrum ent C luster. If the
the Ignition Sw itch is placed in R U N . It remains speedometer is inaccurate in read test but the odometer
illuminated until the Engine O il Pressure increases to is accurate, R E P L A C E the Instrument Cluster.
n o rm a l o p e ra tin g p re ssu re and the in d ic a tio n • C H E C K for a broken (or partially broken) wire inside
extinguishes. If the indicator does not illuminate with of the insulation which could cause system failure but
the Ignition Switch in R U N , and the bulb does not prove G O O D in a Continuity/Voltage check with a
have an open filament, then perform the O il Pressure syste m d iscon n e cte d . T h ese C irc u its m ay be
Gauge indicates high pressure at all times diagnosis. If intermittent or resistive when loaded, and if possible,
the indicator does not extinguish with the Engine should be checked by monitoring for a Voltage drop
running, then perform both the Temperature Gauge with the system operational (under load).
Indicates H O T and the O il Pressure indicates Low •CHECK fo r proper in sta lla tio n o f afterm arket
diagnosis. electronic equipment which may effect the integrity of
5. C H E C K for open filaments in inoperative lamps. other systems. See Troubleshooting Procedures.
6. Instrument Cluster gauges are sufficiently accurate to Electrical Diagnosis for the various indications on the
provide reasonable indications for vehicle operation. Instrument Cluster is covered in this and other Sections.
Maintenance measurements are made with test gauges The follow ing table indicates where coverage may be
of greater accuracy. A static error in indication for an found.
DIAGNOSTIC COVERAGE TABLE

IN D IC A TO R SECTION 8A SCHEMATIC DIAGNOSTIC COVERAGE
COVERAGE
O il Gauge (Pressure) 8A-81 8A-81
Temp Gauge (Coolant) 8A-81 8A-81
Fuel Gauge 8A-81 8A-81
Voltmeter 8A-81 8A-81
Tachometer 8A-81 (Gasoline) Engine Controls - Section 6
8A-81 (Gasoline) Engine Controls - Section 6
A ir Bag Lam p 8A-47 9J
Illum ination Lam ps 8A-117 8A-117
Left/Right Turn Lam ps 8A-110 8A-110
Safety Belt Lam p 8A-76 8A-76
H igh Beam Light 8A-102 8A-102
Daytime Running Lights Lam p 8A-102 8A - 102
Electronic Speedometer 8A-81 8A-81
Service Engine Soon Lam p Engine Controls - Section 6 Engine Controls - Section 6
Brake W arning Lam p Hydraulic Brakes - Section 5 Hydraulic Brakes - Section 5
Gen (Battery) Lam p Engine Electrical - Section 6 Engine Electrical - Section 6
Check Gauges Lam p 8A-81 8A-81
Antilock Brakes Lam p A B S Controls - Section 5 A B S Controls - Section 5
Upshift Lam p Engine Controls - Section 6 Engine Controls - Section 6
Service Throttle Soon Lam p Engine Controls - Section 6 Engine Controls - Section 6
Water in Fuel Lam p 8A-81 Engine Controls - Section 6
Low Coolant (Level) Lam p 8A-81 8A-81
Wait to Start Lam p 8A-25 Engine Controls - Section 6
P R N D L (Automatic Transm ission) 8A-81 8A-81
Indicators
INSTRUMENT CLUSTER
FUEL GAUGE IS INACCURATE (SINGLE TANK)

TEST RESULT ACTION
1. D i s c o n n e c t c o n n e c t o r at Fuel Gauge responds correctly. G O to Step 2.
Instrument Cluster. Install a fused Fuel Gauge does not respond correctly. R E P L A C E Instrument Cluster.
j u m p e r w ir e f r o m B + to
Instrument Cluster Pin 22. Install a
fused jumper wire from ground to
In s tru m e n t C lu s t e r P in 31.
Connect one red lead of Tester
J33431-B to Instrum ent Cluster
Pin 16. Connect the other lead to
ground. Set resistance dial to 0
ohms. Fuel Gauge should indicate
E or below. Set resistance dial to
90 ohms. After a short time, Fuel
Gauge should indicate F or above.
2. R E M O V E fused jumper wire from Fuel Gauge responds correctly. G O to Step 3.
b etw e e n B + and In stru m e n t Fuel Gauge does not respond correctly. L O C A T E and R E P A IR high resistance
Cluster. Install a fused jum per in P P L (30) wire between Instrument
w ir e b e tw e e n g r o u n d a n d Cluster and Fuel Gauge Sender (Diesel)
In stru m e n t C lu ste r. C o n n e c t / (Gas) between the Instrument Cluster
Connector at Instrument Cluster. P P L (30) to C l cavity 9 o f the Vehicle
D isc o n n e c t connector at F u e l Control M odule (V C M ), and from C3
Pum p and Sender (Gasoline) or cavity 13 P PL/W H T (1589) of the
F u e l G au ge Se n d e r (D ie se l). V C M to the Fuel Pum p and Sender.
Connect one red test lead of Tester
J33431-B to Fuel Gauge Sender
Connector Cavity B (Diesel) or
Fuel Pump and Sender cavity A
(Gas). Connect the other lead to
ground. Set resistance dial to 0
ohm s and then to 90 ohms and
observe Fuel Gauge response.Fuel
Gauge should indicate empty, then
full after completing its response.
3. Connect Tester J33431-B between Fuel Gauge responds correctly. R E P L A C E Fuel Pum p and Sender
Fuel Gauge Sender Cavity B and (Gasoline) o f Fuel Gauge Sender
C avity A (Diesel) / Fuel Pump (Diesel).
and Sender cavity A and C (Gas). Fuel Gauge does not respond correctly. L O C A T E and R E P A IR high resistance
Set resistance dial at 0 ohms, then in B L K / W H T (451) wire between Fuel
at 90 ohms and observe response. Pump and Sender and Ground.
Fuel Gauge should indicate empty,
then fu ll after com ple tin g its
response.
FUEL GAUGE INDICATES FULL OR ABOVE FULL AT ALL TIMES (SINGLE TANK)
TEST RESULT ACTIO N
1. D i s c o n n e c t c o n n e c t o r at Fuel Gauge indicates full. R E P L A C E Instrument Cluster.
Instrument Cluster. Install a fused Fuel Gauge indicates empty. G O to Step 2.
jum per w ire betw een B + and
Instrument Cluster Pin 22. Install
fu se d ju m p e r w ire b e tw e e n
Instrum ent C luster P in 16 and
engine or chassis ground. Install
fused jumper wire between ground
and Instrum ent C luster P in 31.
Place Ignition Switch in R U N .
2. Rem ove the fused jumper wires Fuel Gauge indicates full. L O C A T E and R E P A IR open in P P L
from the Instrument Cluster and (30) wire between Instrument Cluster
connect the connector. Disconnect and Fuel Pump and Sender (Diesel) or
con n e cto r at F u e l P u m p and Cavity 13 of C3 P P L (1589) o f Vehicle
Sender. Connect a fused jumper Control M odule (Gas). (Gas only)
w ire between F u e l Pum p and L O C A T E and R E P A IR open in P P L
S e n d e r C o n n e c to r C a v it y B (1589) between the Control M odule
(Diesel) or C avity A (G as) and Cavity 13 of Connector C 3 and the
engine or chassis ground. Fuel Pump and Sender Cavity A.
Fuel Gauge indicates empty. G O to Step 3.
3. W h at k in d o f fu e l d oe s th is Gasoline. R E P L A C E Fuel Pump and Sender.
vehicle use? Diesel. G O to Step 4.
4. Install a fused jumper wire at Fuel Fuel Gauge indicates full. L O C A T E and R E P A IR open in
Pump and Sender Connector from B L K / W H T (451) wire between Fuel
Cavity A to Cavity B. Sender and Ground.
Fuel Gauge indicates empty. R E P L A C E Fuel Gauge Sender.
FUEL GAUGE INDICATES EMPTY WHEN THERE IS FUEL IN THE TANK (SINGLE TANK)
TEST RESULT ACTIO N
1. D isc o n n e c t con n e ctor at F u e l Fuel Gauge does not indicate empty. R E P L A C E Fuel Pump and Sender
Pump and Sender (G asoline) or (Gasoline) or Fuel Gauge Sender
Fuel Gauge Sender (Diesel). Place (Diesel).
Ignition Switch in R U N . Fuel Gauge indicates empty. G O to Step 2.
2. Place Ig n itio n Sw itch in O FF. Test lamp lights. (Diesel only) L O C A T E and R E P A IR short to ground
D is c o n n e c t C o n n e c t o r at in P P L (30) wire between Instrument
In stru m e n t C lu ste r. C o n n e c t Cluster and Fuel Gauge Sender.
se lf-p o w e re d test lam p fro m Test lamp does not light. (Diesel only) R E P L A C E Instrument Cluster.
In stru m e n t C lu ste r C o n n e c to r
Cavity 16 to ground. Test lamp lights. (Gasoline only) L O C A T E and R E P A IR the P P L (30)
wire for a shourt to ground between
the Instument Cluster and the Vehicle
Control Module.
Test lamp does not light. (Gasoline) R E P L A C E the Instrument Cluster.
3. Connect a test lamp from Cavity Test lamp lights. (Gasoline only) L O C A T E and R E P A IR PPL/W H T
13 of the Vehicle Control M odule (1589) wire between the Vehicle
Connector C3 to ground. (Gasoline Control M odule and the Fuel Pump
only) and Sender. (Gasoline only)
Test lamp does not light. (Gasoline R E P L A C E Fuel Pum p and Sender.
only)
INSTRUMENT CLUSTER
FUEL GAUGE INDICATES EMPTY AT ALL TIMES (DUAL TANKS)

TEST RESULT ACTION
1. D isc o n n e c t connector at Fu e l Fuel Gauge indicates above empty. G O to Step 3.
P u m p B a la n ce M o d u le . Place Fuel Gauge indicates empty. G O to Step 2.
Ignition Sw itch in R U N . A llow
time to observe response.
2. D i s c o n n e c t c o n n e c t o r at Test lamp lights. L O C A T E and R E P A IR short to ground
Instrument Cluster. Connect test in P P L (30) wire between Fuel Pump
lamp between Instrument Cluster Balance M odule and Instrument
Connector Cavity 16 and ground. Cluster.
Test lamp does not light. R E P L A C E instrument Cluster.
3. Disconnect connector at Balance Test lamp lights. L O C A T E and R E P A IR short to ground
Fuel Gauge Sender. Connect a test in L T G R N (975) wire between Fuel
lamp between Fuel Pump Balance Pump Balance M odule and Balance
M odule Connector Cavity B and Fuel Gauge Sender. G O to Step 4.
b etw een F u e l P u m p B a la n c e Test lamp does not light. L O C A T E and R E P A IR open in L T
M odule Connector Cavity B and G R N (975) wire between Fuel Pum p
B a la n c e F u e l G a u g e S e n d e r Balance M odule and Balance Fuel
Connector Cavity D. Gauge Sender.
B a la n c e F u e l G a u g e S e n d e r Test lamp does not light. L O C A T E and R E P A IR open in
Connector Cavity A and ground. B L K / W H T (451) wire between Balance
Fuel Gauge Sender and Ground.
6. C onnect an ohm m eter between Resistance indication is 110 ohms or G O to Step 7.
Balance Fuel Gauge Sender Pins less.
A and D. Resistance indication is over 100 ohms. R E P L A C E Balance Fuel Gauge Sender.
7. Reconnect connector at Balance Test lamp lights. L O C A T E and R E P A IR short to ground
Fuel G auge Sender. Disconnect in D K B L U A V H T (970) wire between
connector at Fuel Gauge Sender Fuel Pum p Balance M odule and Fuel
(Diesel) or Fuel Pump and Sender Pum p and Sender (Gasoline) or Fuel
(Gasoline). Connect a test lamp Gauge Sender (Diesel).
b etw een F u e l P u m p B a la n c e Test lamp does not light. G O to Step 8.
M odule Connector C avity C to
ground.
8. Connect a test lamp between Fuel Test lamp lights. G O to Step 9.
Pum p Balance M odule connector Test lamp does not light. L O C A T E and R E P A IR open in D K
C a v ity C and Fu e l Pum p and B L U / W H T (970) wire between Fuel
Sender C avity A (G asoline) or Pum p Balance M odule and Fuel Pump
F u e l G a u g e S e n d e r (D ie s e l) and Sender (Gasoline) or Fuel Gauge
Connector Cavity B. Sender (Diesel).
Pum p and Sender (Gasoline) or Test lamp does not ligh t L O C A T E and R E P A IR open in
F u e l G a u g e S e n d e r (D ie s e l) B L K / W H T (451) wire between Fuel
Connector Cavity A and ground. Pum p and Sender (Gasoline) or Fuel
Gauge Sender (Diesel) and Ground.
TEST RESULT ACTION

10. Connect an ohm m eter between Resistance indication is 100 ohm s or G O to Step 11.
Fuel Pump and Sender (Gasoline) less.
or Fuel Gauge Sender (D iesel) Resistance indication is over 100 ohms. R E P L A C E Fuel Pump and Sender
Pins A and D. (Gasoline) or Fuel Gauge Sender
(Diesel).
11. Connect a test lamp between Fuel Test lamp lights. R E P L A C E Fuel Pump Balance Module.
Pum p Balance M odule Connector Test lamp does not light. L O C A T E and R E P A IR open in P N K
Cavity A and ground. (639) wire between Fuel Pump Balance
M odule and Fuse.
FUEL GAUGE INDICATES FULL AT ALL TIMES (DUAL TANKS)

TEST RESULT ACTION
1. D isc o n n e c t the c o n n e c to r at Fuel Gauge indicates full. R E P L A C E Instrument Cluster.
Instrument Cluster. Install a fused Fuel Gauge indicates empty. G O to Step 2.
jumper wire between Instrument
Cluster Pin 31 and ground. Install
a fused jum per w ire betw een
Instrument Cluster Pin 22 and B+.
Install a fused jumper wire from
In stru m e n t C lu ste r P in 16 to
engine or chassis ground.
2. Rem ove the fused jumper wires Fuel Gauge indicates full. L O C A T E and R E P A IR open in P P L
from the In stru m e n t C lu ste r. (30) wire between Instrument Cluster
Connect connector at Instrument and Fuel Pump Balance M odule
Cluster. Disconnect connector at (Diesel) and Vehicle Control M odule
F u e l P u m p B a la n c e M o d u le . Connector C l Cavity 9 (Gasoline).
C on n ect a fused jum per w ire Fuel Gauge indicates empty. C O N N E C T connector at Fuel Pump
betw een F u e l P u m p B a la n c e Balance Module. G O to F U E L
M o d u le C o n n e c to r C a v it y F G A U G E IS IN A C C U R A T E (D U A L
(Diesel)and Connector C 2 Cavity T A N K S ) Diagnosis Chart.
B (Gasoline) and ground.
INSTRUMENT CLUSTER
FUEL GAUGE IS INACCURATE (DUAL TANKS)

TEST RESULT ACTION
N O T E: The follow ing testing requires Fuel Gauge indicates correctly. G O to Step 2.
that a fuel tank be full. It is preferred Fuel Gauge does not indicate correctly. R E P L A C E Instrument Cluster.
that the customer/owner provide the
fuel.
1. D isc o n n e c t the C o n n e c to r at
Instrument Cluster. Install a fused
jumper wire between Instrument
Cluster Pin 31 and ground. Install
a fused jum per w ire between
Instrument Cluster Pin 22 and B+.
Connect one red lead o f Tester
J33431-B to Instrum ent Cluster
Pin 16. Connect the other test lead
to ground. Set resistance dial on
the tester to 1 ohm. The Fuel
Gauge should indicate empty after
a short period o f time. Set the
resistance dial at 45 ohms. The
F u e l G a u g e s h o u ld in d ic a te
half-full after a period of time. Set
the resistance dial to 90 ohms. The
Fuel Gauge should indicate full
after a period of time.
2. Rem ove the tester and the jumper Fuel Gauge indicates 1/2 full G O to Step 3.
wires. Reconnect the Connector at approximately.
Instrument Cluster. Place Ignition Fuel Gauge indicates much more or R E P L A C E Fuel Pump Secondary
S w itc h in R U N . D is c o n n e c t much less than half-full. Module.
co n n e cto r at S e c o n d a ry F u e l
G a u g e S e n d e r. D is c o n n e c t
connector at Fuel Gauge Sender
(Diesel) or Fuel Pump and Sender
(G asoline).C onnect a J3343 1-B
Tester at Secondary Fuel Gauge
Sender Connector C avity D to
ground. Adjust the tester for 45
ohms. Connect a J33431-B Tester
at Fuel Gauge Sender Cavity B
(Diesel) or Fuel Pump and Sender
C avity A (G asoline) to ground.
Adjust the tester for 45 ohms.
3. Ensure that the rear Fuel Tank is 90 Ohms, nominally. R E P L A C E Fuel Pump and Sender
fu ll. C onnect an ohm m eter at (Gasoline) of Fuel Gauge Sender
Se con dary Fu e l G auge Sender (Diesel).
Pins A and D. R E P L A C E Balance Fuel Sender.
M uch less than 90 ohms.
VEHICLE RUNS OUT OF FUEL AT HALF-FULL/REAR TANK IS FULL AT ALL TIMES

(DUAL TANKS)
TEST RESULT ACTION
1. D isc o n n e c t con n e ctor at F u e l Fuel Pump, Secondary runs. G O to Step 2.
Pump, Secondary. Connect a fused Fuel Pump, Secondary does not run. R E P L A C E Fuel Pump, Secondary.
jumper wire between ground and
Secon d a ry F u e l Pum p P in A .
C onnect a fused jum per w ire
betw een B + and F u e l Pum p,
Secondary Pin B.
P u m p , S e c o n d a ry C o n n e c to r Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity A and ground. (150) wire between Fuel Pump,
Secondary and Ground G404.
3. Remove Fuel Pum p Balance Relay Test lamp lights. G O to Step 4.
from its socket. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in L T
lamp between Fuel Pump Balance G R N (1058) wire between Fuel Pump
Relay Socket Cavity 87 and Fuel Balance Relay and Fuel Pump,
P u m p , S e c o n d a ry C o n n e c to r Secondary.
Cavity B.
P u m p B a la n c e R e la y S o c k e t Test lamp does not light. L O C A T E and R E P A IR open in P N K
C a v ity 30 and gro u n d . T u rn (639) wire between Underhood
Ignition ON. Fuse-Relay Center and Fuel Pump
Balance Relay.
5. Rem ove the Fuel Pum p R e lay Test lamp lights. G O to Step 6.
from its socket at the Underhood Test lamp does not light. L O C A T E and R E P A IR open in G R Y
Fuse Relay Center. Connect a test (120) wire between Splice S318 and
lamp between Fuel Pump Balance Fuel Pum p Balance Relay.
Relay Socket Cavity 85 and Fuel
Pum p Relay Socket Cavity A3.
6. D isc o n n e c t con n e ctor at F u e l Test lamp lights. G O to Step 7.
Pum p Balance M odule. Connect Test lamp does not light. L O C A T E and R E P A IR open in L T
test lam p between Fu e l Pum p G R N (497) wire between Fuel Pump
Balance Relay Socket Cavity 86 Balance M odule and Fuel Pump
and Fuel Pump Balance M odule Balance Relay.
Connector Cavity D.
7. Replace Fuel Pum p Balance Relay Test lamp lights. G O to Step 8.
in its Socke t. C on n ect fu sed Test lamp does not light. R E P L A C E Fuel Pump Balance Relay.
jumper wire between Fuel Pump
Balance M odule Connector Cavity
D and ground. Connect a test lamp
at Balance Fuel Pump Connector
Cavity B to ground. Tbm Ignition
O N . N O T E : the circuit w ill be
energized for approx, two seconds.
Pum p Balance M odule Connector
Test lamp does not light. L O C A T E and R E P A IR open in P N K
Cavity A and ground.
(639) wire between Fuel Pump Balance
M odule and Splice S315.
9. Connect a self-powered test lamp Test lamp lights. R E P L A C E Fuel Pump Balance Module.
betw een F u e l P u m p B a la n c e
M odule Connector Cavity E and
B L K / W H T (451) wire between Balance
ground.
Fuel Pump M odule and Ground G104.
INSTRUMENT CLUSTER
FUEL GAUGE DOES NOT CHANGE POSITION ON SCALE (DUAL TANKS)

TEST RESULT ACTION
D isc o n n e c t con n e ctor at F u e l Test lamp does not light. L O C A T E and R E P A IR open in P N K
Pump Balance Module. Connect a (639) wire between Underhood
test lam p between Fu e l Pum p Fuse-Relay Center and Fuel Pump
Balance M odule Connector Cavity Balance Module.
A and ground.
2. Connect test lamp between Fuel Test lamp lights. R E P L A C E Fuel Pum p Balance Module.
Pump Balance M odule Connector Test lamp does not light. L O C A T E and R E P A IR open in
Cavity E and ground. B L K / W H T (451) wire between Fuel
Pump Balance M odule and Ground
G104.
TEMPERATURE GAUGE INDICATES HOT (IN RED ZONE OR CHECK GAUGES LAMP IS
ILLUMINATED) WITH ENGINE COOLANT BELOW NORMAL OPERATING TEMPERATURE
AND IGNITION SWITCH IN RUN
TEST RESULT ACTION
1. Disconnect connector at Engine Temp Gauge indicates cold (at or R E P L A C E Engine Coolant Temperature
Coolant Temperature Sender. Place below 100°F for gasoline engines or at Sender.
Ignition Switch in R U N . or below 160°F for diesel engines).
Temp Gauge does not indicate cold. L O C A T E and R E P A IR short to ground
in D K G R N (35) wire between Engine
Coolant Temperature Sender and
Instrument Cluster. If no short is found,
TEMPERATURE GAUGE INDICATES COLD ALL THE TIME

1. Disconnect connector at Engine Temp Gauge indicates hot. R E P L A C E Engine Coolant Temperature
C o o la n t Tem perature Sender. Sender.
Connect fused jumper wire from Temp Gauge does not indicate hot. L O C A T E and R E P A IR open in D K
E n g in e C o o la n t T em perature G R N (35) wire between Engine
Sender Connector C avity A to Coolant Temperature Sender and
ground. Place Ignition Switch in Instrument Cluster. If wire is good,
RUN. R E P L A C E Instrument Cluster.
TEMPERATURE GAUGE IS NOT ACCURATE

TEST RESULT ACTION
1. Disconnect connector at Engine Temp Gauge indicates correctly. R E P L A C E Engine Coolant Temperature
C o o la n t Tem perature Sender. Gauge Sender.
Connect one red lead from Tester Temp gauges do not indicate correctly. R E P L A C E Instrument Cluster.
J 3 3 4 3 1 -B to E n g in e C o o la n t
Tem perature Sender C onnector
Cavity A . Connect the other lead
to ground. Place Ignition Switch in
R U N . Adjust resistance dial to
1305 ohms and then to 49.5 ohms.
Temp Gauge should indicate cold
(approximately 100°F for gasoline
engine or 160°F for diesel engine)
then hot (approximately 260°F).
OIL PRESSURE GAUGE IS NOT ACCURATE UNDER NORMAL OPERATING CONDITIONS

TEST RESULT ACTION
1. D isc o n n e c t connector at Fu e l O il Gauge indicates correctly. R E P L A C E Fuel Pump O il Presure
Pum p O il Presure Sw itch and Switch and Sender.
Sender. Place Ign itio n Sw itch in O il Gauge does not indicate correctly. L O C A T E and R E P A IR open in T A N
R U N . Connect one red lead of
(31) wire between Fuel Pump O il
Tester J34431-B to Fuel Pump O il
Presure Switch, Sender and Instrument
P re su re S w it c h an d S e n d e r Cluster. If wire is good, R E P L A C E
Connector Cavity A. Connect the
Instrument Cluster.
other lead to ground . A d ju st
resistance dial to 0 ohms and then
to 90 ohms. The O il Gauge should
in d ic a t e low p r e ss u r e
(approxim ately 0) and then high
pressure (approximately 80).
OIL PRESSURE GAUGE INDICATES LOW PRESSURE (IN RED ZONE OR AT 0) WHEN OIL
PRESSURE IS NORMAL
TEST RESULT ACTION
1. D isc o n n e c t con n e ctor at F u e l O il Gauge indicates high pressure R E P L A C E Fuel Pump Fuel O il Presure
Pum p O il Presure Sw itch and (approximately 80 or higher). Switch and Sender.
Sender. Place Ign itio n Sw itch in O il Gauge indicates low or no pressure. L O C A T E and R E P A IR short to ground
RUN. in T A N (31) wire between Fuel Pump
O il Presure Switch, Sender and
Instrument Cluster. If wire is good,
OIL PRESSURE GAUGE INDICATES HIGH PRESSURE (IN RED ZONE OR 80 WITH NO
FLUCTUATION) AT ALL TIMES
TEST RESULT ACTION
1. D isc o n n e c t con n e cto r at Fu e l O il Gauge indicates low pressure. R E P L A C E Fuel Pump O il Presure
Pum p O il Presure Sw itch and Switch and Sender.
Sender. Place Ign itio n Sw itch in O il Gauge indicates high pressure. L O C A T E and R E P A IR open in T A N
R U N . Connect fused jumper wire (31) wire between Fuel Pum p O il
from F u e l Pum p O il P re su re Presure Switch and Sender and
Sw itch and Sen d e r C on n ector Instrument Cluster. If wire is good,
Cavity A to ground. R E P L A C E Instrument Cluster.
VOLTMETER IS NOT ACCURATE

TEST RESULT ACTION
1. Start Engine. Connect voltmeter Measured voltage is approximately the System operating properly.
between p o sitive and negative same as vehicle’s voltage indication.
terminals of the battery. Measured voltage is different from R E P L A C E Instrument Cluster.
vehicle’s voltage indication.
INSTRUMENT CLUSTER
LOW COOLANT LEVEL INDICATOR DOES NOT LIGHT WITH LOW COOLANT LEVEL
(DIESEL ONLY)
TEST RESULT ACTION
1. Ensure that coolant level is good. 10,000 to 50,000 ohms. G O to Step 2.
D isc o n n e c t connector at L o w Less than 10,000 ohms. R E P L A C E Low Coolant Level Sensor.
Coolant Level Sensor. Connect
ohmmeter at Low Coolant Level
Sensor Pins A and B.
2. D isc o n n e c t connector at L o w Test lamp lights. L O C A T E and R E P A IR short to ground
Coolant Level Indicator Module. in L T G R N (1478) wire between Low
C o n n e ct test lam p from L o w Coolant Level Indicator M odule and
Coolant Level Indicator M odule Low Coolant Level Sensor.
Connector Cavity F to ground. Test lamp does not light. G O to Step 3.
3. D i s c o n n e c t c o n n e c t o r at Test lamp does not light. L O C A T E and R E P A IR open in
Instrument Cluster. Connect a test Y E L / B L K (68) wire between
lamp between Instrument Cluster Instrument Cluster and Low Coolant
C onnector C avity 25 and L o w Level Indicator Module.
Coolant Level Indicator M odule Test lamp lights. G O to Step 4.
Connector Cavity E.
4. Reconnect connector at Instrument Low Coolant indicator lights. R E P L A C E Low Coolant Level
Cluster. Place Ignition Switch in Indicator Module.
R U N . Connect fused jumper wire Low Coolant indicator does not light. R E P L A C E Instrument Cluster.
betw een L o w C o o la n t L e v e l
In d ic a to r M o d u le C o n n e c to r
Cavity E and ground.
LOW COOLANT LEVEL INDICATOR LAMP LIGHTS WHEN COOLANT LEVEL IS NOT LOW
(DIESEL ONLY)
TEST RESULT ACTION
1. D isc o n n e c t con n e ctor at L o w Greater than 50,000 ohms. R E P L A C E Low Coolant Level Sensor.
Coolant Level Sensor. Connect an Less than 50,000 ohms. G O to Step 2.
ohm m eter from L o w C o o la n t
Level Sensor Pins A to B.
2. Connect a test lamp between Low Test lamp lights. G O to Step 3.
Coolant Level Sensor Connector Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity B and Ground G105. (150) wire from Low Coolant Level
Sensor to Ground G105.
3. D isc o n n e c t C on n ector at L o w Test lamp lights. G O to Step 4.
Coolant Level Indicator Module. Test lamp does not light. L O C A T E and R E P A IR open in L T
Connect a test lamp between Low G R N (1478) wire between Low
Coolant Level Indicator M odule Coolant Level Indicator M odule and
C o n n e cto r C a v ity F and L o w Low Coolant Level Sensor.
Coolant Level Sensor Connector
Cavity A.
Coolant Level Indicator M odule Test lamp does not light. L O C A T E and R E P A IR open in P N K
Connector Cavity A and ground. (39) wire between IP Fuse Block and
Low Coolant Level Indicator Module.
Coolant Level Indicator M odule Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector Cavity C and ground. 150 wire between Low Coolant Level
Indicator M odule and Ground G200.
TEST RESULT ACTION

Instrument Cluster. Connect a test in Y E L / B L K (68) wire between
lamp between Low Coolant Level Instrument Cluster and Low Coolant
In d ic a to r M o d u le C o n n e c to r Level Indicator Module.
Cavity E and ground. Test lamp does not light. G O to Step 7.
7. Connect connector at Instrument Low Coolant indicator lights. R E P L A C E Instrument Cluster.
Cluster. Place Ignition Sw itch in Low Coolant indicator does not light. R E P L A C E Low Coolant Level
RUN.
Indicator Module.
SPEEDOMETER/ODOMETER INOPERATIVE
TEST RESULT ACTION
1. Perform diagnostic testing as per Problem is resolved. System operating properly.
Antilock Brake Section 5E1 and Problem persists. G O to Step 2.
Engine Controls Sections 6. This
testing w ill identify problems in
the Vehicle Speed Sensor, Vehicle
Speed Sensor Buffer (Diesel) or
the V e h ic le C o n tro l M o d u le
(Gasoline).
2. D i s c o n n e c t c o n n e c t o r at Test lamp does not light. G O to Step 3.
Instrum ent Cluster. D isco n n e ct Test lamp lights. L O C A T E and R E P A IR short to ground
Connector C 4 at Vehicle Control in D K G R N (389) wire between the
M o d u le (G asoline). D iscon n ect Vehicle Control M odule (Gasoline) or
connector at Vehicle Speed Sensor the Vehicle Speed Sensor Buffer
Buffer (D iesel). Connect a test (Diesel).
lam p from In stru m e n t C lu ste r
Connector Cavity 14 to ground.
3. C onnect a test lam p between Test lamp lights. R E P L A C E G o to Step 4.
In stru m e n t C lu ste r C o n n e cto r Test lamp does not light. L O C A T E and R E P A IR open in D K
C a v ity 14 and V e h icle Speed
G R N (389) wire between Instrument
Sensor Buffer Connector Cavity
Cluster and Vehicle Control M odule
15 (D iesel) or Vehicle C ontrol
(Gasoline) or Vehicle Speed Sensor
M odule Connector C 4 Cavity 4
Buffer (Diesel).
(Gasoline).
4. C onnect a test lam p between Test lalmp lights. R E P L A C E Instument Cluster.
Instument Cluster Cavity 14 and
A u d io Alarm M odule C avity B
(389) wire between Instrument Cluster
(Overspeed Sensor).
and A udio Alarm M odule (Overspeed
Sensor). If O K R E P L A C E Audio
Alarm Module.
INSTRUMENT CLUSTER
SPEEDOMETER/ODOMETER IS INACCURATE
TEST RESULT ACTION
1. Ensure that the Vehicle Control Problem persists or is not resolved. G O to Step 2.
M odule (V C M , gasoline engines) Problem does not persist. N o additional action is required.
or the V e h ic le Speed S e n so r
Buffer (diesel engines) is correctly
calibrated for axle ratio and tire
size.
2. Perform a test drive over a known W hile at speed, the scan tool and Speedometer accuracy is within
distance. The distance should be 8 speedometer indications are within 6 tolerance. G O to Step 3.
kilom eters (5 m iles) or more. K P H (4 mph) of each other.
U sin g a scan tool, compare the W hile at speed, the scan tool and R E P L A C E Instrument Cluster.
indicated speed to the speedometer speedometer indicators are discrepant
indication while at speed. Record by more than 6 K P H (4 mph).
the in itia l and fin a l odom eter
readings and the actual distance
driven.
3. D ivid e the actual distance driven Yes. Odometer accuracy is within tolerance.
by the indicated distance driven. Is N o action required.
the calculated result between 0.96 No. R E P L A C E Instrument Cluster.
and 1.04?
TACHOMETER INOPERATIVE (GASOLINE)

TEST RESULT ACTION
1. P e rfo rm D is trib u t o r Ig n it io n Problem does not persist. System operating properly.
S y ste m C h e ck as per E n g in e Problem persists. G O to Step 2.
Controls (Gasoline) Section 6A.
Instrum ent Cluster. D iscon n e ct in W H T (121) wire between Ignition
c o n n e c t o r at I g n i t i o n C o i l . C oil and Instrument Cluster.
C on n ect a test lam p between Test lamp does not light. G O to Step 3.
In stru m e n t C lu ste r C o n n e cto r
C avity 6 and ground.
3. Connect test lamp from Instrument Test lamp lights. R E P L A C E Instrument Cluster.
C lu ste r C onnector C avity 6 to Test lamp does not light. L O C A T E and R E P A IR open in W H T
Ignition C oil Connector Cavity B. (121) wire between Instrument Cluster
and Ignition Coil.
TACHOMETER INOPERATIVE (DIESEL)

TEST RESULT ACTION
1. Disconnect connect at Instrument Test lamp lights. L O C A T E and R E P A IR short to ground
Cluster. Disconnect connector at in W H T (121) wire between Generator
Generator. Connect a test lamp and Instrument Cluster.
betw een G enerator C o n n e cto r Test lamp does not light. G O to Step 2.
In stru m e n t C lu ste r C o n n e cto r Test lamp does not light. L O C A T E and R E P A IR open in W H T
Cavity 6 and Generator Connector (121) wire between Generator and
Cavity A. Instrument Cluster.
TEST RESULT ACTION

3. Connect connector at Generator. Voltage is present. R E P L A C E Instrument Cluster.
S t a r t the e n g i n e . C o n n e c t Voltage is not present. R E P L A C E Generator.
voltmeter or oscilloscope between
In stru m e n t C lu ste r C o n n e c to r
Cavity 6 and ground. Observe for
potentially pulsating voltage at or
below 14 volts.
TACHOMETER IS INACCURATE
TEST RESULT ACTION
1. D isc o n n e c t W H T ( 1 2 1 ) wire Yes. Tachometer accuracy is acceptable. N o
c o n n e c t o r at I g n i t i o n C o i l action is required.
(gasoline engine) or at Generator If no other driveability and em issions
No.
(diesel engine). Start engine and problems are present, R E P L A C E
operate at an indicated 1000 rpm Instrument Cluster.
without racing the engine. Record
tachometer indication. Disconnect
W H T (121) w ire connector at
Ignition coil (gasoline engine) or
at G e n erator (d ie se l e n gin e ).
C onnect hand-held tachom eter,
oscilloscope, or other appropriate
test instrument to the Ignition C oil
(gasoline engine) or Generator
(diesel engine) tachometer output.
Record indicated revolutions per
minute (rpm). Is the rpm indicated
by the test instrument within 250
rpm of the vehicle’s tachometer
indication?
PRNDL INDICATIONS ARE INCORRECT OR NOT PRESENT BUT AUTOMATIC

TRANSMISSION FUNCTIONS NORMALLY
TEST RESULT ACTION
1. Place Automatic Transm ission in N o position indications are illuminated. G O to Step 2.
Park. Start the Engine. Shift the Some position indications are G O to Step 5.
T r a n s m i s s i o n to e a c h g e a r illuminated.
p osition . O b se rve in d ica tio n s.
Place the T ransm ission in Park
and stop the Engine.
2. D i s c o n n e c t c o n n e c t o r at Test lamp lights. G O to Step 3.
Instrument Cluster. Place Ignition Test lamp does not light. L O C A T E and R E P A IR open in P N K
Sw itch in R U N . Connect test a (1020) wire between IP Fuse Block
lam p from In stru m e n t C lu ste r
and Instrument Cluster.
Connector Cavity 7 to ground.
3. C o n n e c t a t e st l a m p f r o m Test lamp lights. G O to Step 4.
In stru m e n t C lu ste r C o n n e c to r Test lamp does not light. L O C A T E and R E P A IR open in
Cavity 4 to ground.
B L K / W H T (451) wire between
Instrument Cluster and ground.
INSTRUMENT CLUSTER
TEST RESULT ACTION

4. D i s c o n n e c t c o n n e c to r C l at Test lamp lights. R E P L A C E Instrument Cluster.
Transm ission Range Switch (part Test lamp does not light. L O C A T E and R E P A IR open in B L K
of Park/Neutral Position Switch). (150) wire between Transm ission Range
C on n ect a test lam p between Switch and Ground G105.
T ra n s m is s io n Range Switch
C o n n e c t o r C l C a v i t y D and
ground.
5. Place Ig n itio n Sw itch in O FF. N o wires are shorted to ground or are G O to Step 6.
D i s c o n n e c t c o n n e c t o r at open.
Transm ission Range Switch (Part One or more wires are open or are L O C A T E and R E P A IR opens/shorts to
o f Park/Neutral Position Switch). shorted to ground. ground in W H T (776), G R Y (773)
D i s c o n n e c t c o n n e c t o r at Y E L (772) and/or B L K / W H T (771)
Instrument Cluster. U sin g a test wires between the Transm ission Range
lamp, check for continuity from Switch and the Instrument Cluster.
cavity to cavity and from cavity to
ground for the follow ing wires:
W H T (776), G R Y (773), Y E L
(772), and B L K / W H T (771).
6. R e c o n n e c t C o n n e c t o r at Indications are not correct as tested. R E P L A C E Instrument Cluster.
Instrument Cluster. Place Ignition Indications are correct as tested. R E P L A C E Park/Neutral Position
Sw itch in R U N . R e fer to the Switch.
follow ing P R N D L M odule Input
Test Table. Connect from two to
four fused jumper wires from the
listed Transm ission Range Switch
connector cavities to ground as
shown by the X . Repeat for each
transm ission range column.
PRNDL MODULE INPUT TEST TABLE

TRANS P R N D D 2 1 INPUT
RANGE
SELECT
CAV/WIRE
C X X X X P A R IT Y
W HT
(776)
B X X X X C
GRY
(773)
D X X X X B
YEL
(772)
A X X X X A
BLK/W H T
(771)
INSTRUMENT CLUSTER
CIRCUIT OPERATION OIL PRESSURE GAUGE

The Engine O il Pressure is displayed by the O il
FUEL GAUGE Gauge. The pointer of the gauge is moved by current flow
The pointer o f the Fuel Gauge is m oved by the through two C oils and is sim ilar in operation to the Fuel
magnetic fields of two coils. The coils are at right angles to Gauge. The Fuel Pump O il Pressure Switch and Sender
each other. Battery voltage is applied to the E-C oil (empty) senses Engine O il Pressure. The O il Sender has a low
and the circuit divides at the opposite end o f the coil. One resistance (approximately 0 ohms) when O il Pressure is
path continues to ground through the F -C o il (full). Another low (0 psi) and a high resistance (approximately 90 ohms)
goes to ground through the variable resistance of the level when O il Pressure is high (80 psi).
sensor in the Fuel Pum p and Sender (Gasoline) or Fuel
Gauge Sender (Diesel) for vehicles with single fuel tanks. TEMPERATURE GAUGE
The Fuel Pump Balance M odule averages the resistance for The Engine coolant temperature is displayed by the
vehicles with two fuel tanks. W hen the tank is low, the Temp Gauge. The pointer of the gauge is moved by current
resistance of the level sensor is low. A large current flow flow through two C oils and is sim ilar in operation to the
passes through the E -C o il and the pointer moves toward E Fuel Gauge. The Engine Coolant Temperature Sender has a
on the Fuel Gauge. W hen the tank is full, the level sensor’s low resistance at higher temperatures. It has a resistance of
resistance is high. Less current passes though the E-C oil approximately 49.5 ohms at 123°C (260°F). Its resistance
and the pointer moves toward F on the scale. W ith two increases at lower temperatures and is approximately 1305
coils operating the pointer, the Fuel Gauge is not affected ohms at 478C (100T ). This causes the current through the
by changes in the system’s battery voltage. For vehicles sensor to increase as the coolant temperature increases and
with single fuel tanks, the level sensor in the Fuel Gauge the Temp Gauge pointer moves toward the hot end of the
Sender produces a resistance of about 4 ohms when the scale.
tank is empty. The resistance is about 90 ohms when the
tank is full. A short to ground in the sender or w iring w ill VOLTMETER
provide a fully empty indication. A n open in the circuit The Voltmeter measures the electrical system ’s voltage
w ill produce a fully-full indication. For vehicles with dual when the Ignition Switch is in R U N or STA R T. It measures
fuel tanks, the Fuel Pump Balance M odule measures the battery voltage as fed to the Instrument Cluster . W ith the
resistance of both Fuel Senders. The module averages the engine running, the normal reading is 14 (12 to 16) volts.
resistance and produces an equivalent resistance reflecting The indication may decrease to 9.5 volts in cold weather
the average level of both fuel tanks. Both power to the with the engine stopped.
module and a change in the input resistance are required to
produce a change in the output resistance to the Fuel LOW ENGINE COOLANT LEVEL
Gauge. The Fuel Pump Balance M odule responds to a very INDICATOR
low resistance (short to ground) in one or both fuel sender The Low Coolant level indicator for Diesel Engines
circuits by considering the affected tank(s) to be empty. A only lights to warn the driver when the radiator has a low
very high resistance (open circuit) in either fuel sender coolant level. Battery voltage is applied to the Low Coolant
circuit w ill cause the Fuel Pum p Balance M odule to Level Indicator M odule when the Ignition Switch is in
produce a zero output (both tanks empty) signal to the Fuel R U N or STA R T. The Low Coolant Level Indicator M odule
Gauge. The Fuel Pump Balance M odule equalizes level in monitors the resistance of the Low Coolant Level Sensor.
the two fuel tanks. Fuel is fed to the Engine from the front The level sensor has a high resistance of 50,000 ohms or
(prim ary) fuel tank. W hen the level in the front tank more when the coolant level is low. This is the setpoint at
decreases to about two gallons less than the level in the which the Low Coolant Level Indicator M odule grounds
rear (secondary) fuel tank, the Fuel Pum p Balance M odule the Y E L / B L K (68) wire to light the Low Coolant lamp. A n
energizes the Fuel Pump Balance Relay. This starts the increasing coolant level can reduce this resistance to less
Fuel Pump, Secondary which transfers fuel from the rear than 10,000 ohm s. The lam p is extinguished below
tank to the front tank. W hen the level in the front tank approximately 50,000 ohms.
increases to about two gallons greater than the rear tank,
the Fuel Pump, Secondary stopped. T his approach tends to
empty the rear tank first.
INSTRUMENT CLUSTER
SPEEDOMETER AND ODOMETER CHECK GAUGES LAMP

The Vehicle Speed Sensor produces voltage pulses of The Check Gauges Lam p lights when either the engine
frequency proportional to vehicle speed. T h is signal is oil pressure is low or the engine coolant temperature is
processed by the Vehicle Speed Sensor Buffer (Diesel) or high. The Instrument Cluster’s Check Gauges Lam p D river
Vehicle Control M odule (Gasoline) to produce a voltage solid state logic monitors the input signals to the O il Gauge
pulse signal to the speedometer and odometer. and the Temp Gauge. W ith the Ignition Switch in R U N or
ST A R T , the Check Gauges Lam p D river grounds the Check
TACHOMETER Gauges lamp when either o f the input signals exceeds its
The Tachometer displays Engine speed in rpm. Voltage setpoint. T h is causes the lam p to light. The lam p is
pulses are taken from the Ig n itio n C ontrol M od ule norm ally illuminated when the Ignition Switch is placed in
(G a so lin e ) or G enerator (D ie se l) and sent to the R U N . It extinguishes when the engine is started and oil
Tachometer. Solid state circuits convert the pulse frequency pressure increases above setpoint.
to drive the pointer of the Tachometer.
PRNDL INDICATOR
The P R N D L Indicator indicates the gear selection for
Automatic Transm issions. The P R N D L Indicator receives
coded input through four wires from the Transm ission
Range Selector (part of the Park/Neutral Position Switch).
Depending upon which combination of the four wires to
the P R N D L Indicator are grounded, a gear selection
indication light emitting diode (L E D ), e.g. Reverse (R), is
illu m in ate d . The in d ica tio n s are separate from the
T ran sm issio n ’s inputs to the Vehicle C ontrol System
(Gasoline) or the Powertrain Control M odule (Diesel).
8A - 8 4 - 0 ELECTRICAL DIAGNOSIS____________________________
ELECTROCHROMATIC REARVIEW MIRROR WITH COMPASS
BACKUP
7 7
LAMP (PART OF PA RK /
SWITCH NEUTRAL POSITION
SWITCH)
.3 5 PNK 39
FOCI
.8 LT GRN I 24 LT GRN J 24
V
.8 LT CRN | 24
.8 LT GRN BACKUP
S160 LAMPS
24 SECTION 8 A -1 I2
.8 LT GRNN I 2
24
03 &
:C l 0 0
.8 LT GRN I 2
24
I
8 0 C27I
I
.8 LT GRN | 24
.3 5 PNK | 39
3. 11
ELECTROCHROMATIC
MIRROR
HEAOLAMP
SENSOR
Z SWITCH REAR VIEW
MIRROR WITH COMPASS
(MIRROR SIOE)
ELECTROCHROMIC MIRROR
CHANGES REFLECTM IY
RESET TO DAYTIME SOLO *V M
COMPASS AND & ACCORDING TO GLARE
HKaH REFLECTMTY STATE
'r 0 “ IN REVERSE
MIRROR C/m T
f» — J
MIRROR
INPUT
^____ DAYTIME-HIGH REFLECTIVITY
LIGHT GLARE-UEOIUM REFLECTMTY
ELIMINATES MILD GLARE
ON TEMPERATURE AND HEAVY GLARE-LOW REFLECTIVITY FOR
INDICATOR MIRROR INPUT MAXIMUM a ARE
GROUNO CONTROL REDUCTION
AMBIENT SENSOR
(WINDSHIELD S O E )
O----
2V
.5 BLK I 150
SEE GROUNO
S 316 m mm m DISTRIBUTION
PAGE 8 A -I4 - 1 3
.8 BLK 1150
cX oti SEE GROUND

DISTRIBUTION
r - < PAGE 8 A -1 4 -3
.8 BLK 1 150
3 BLK 1 150 T
— G 200 P GROUNO

Backup Lam p Switch (MG5)...., L H of Transm ission, below Shift Tow er............................ 2 7 .... 38
Backup Lam p Switch (M W 3 ).... L H top o f Transm ission................................................ . 2 6 .... 36
Convenience Center.............. Under L H of IP, on Bulkhead........................................ 3 3 .... 44
M irror with C om p ass......... , O n top inside o f W indshield center, part of Inside Rearview
M irro r..................................................................... 5 4 .... 69
IP Fuse B lo ck ...................... , L H o f IP, near L F D oor Jamb Sw itch ............................. 3 2 .... 43
Switch, Connector C 2 ......... A t L H center of T ransm ission........................................ 2 3 .... 3 1 .... 202-67
C O N N EC T O R S:

at B ulkhead ............................................................. 4 ...... 8 ...... 202-0
C 2 7 1 .................................. In-line to Spotlamps (Z56, Police Package)....................... ....... 202-16
G R O U N D S:
G 200 .................................. Behind L H of IP, below Fuse Block, on Tie B a r............... 3 2 .... 43
S P L IC E S :
S160 (4.3L) ........................ Engine Harness, approx. 21 cm from E G R Valve Breakout,



S160 (7.4L) ........................ Engine Harness, approx. 28 cm from Fuel Injector Breakout,

Breakout

Breakout
S316 (Suburban/Crew
Cab/Utility).......... Illum inated Vanity M irror Jumper Harness, approx. 11 cm
8A - 8 4 • 2 ELECTRICAL DIAGNOSIS____________________________
ELECTROCHROMATIC REARVIEW MIRROR WITH COMPASS
DIAGNOSIS - ELECTROCHROMATIC MIRROR, ELECTRONIC

COMPASS
TROUBLESHOOTING HINTS: C H E C K with a system disconnected. These circuits
1. C H E C K G A U G E S Fuse 4. If fuse is open, L O C A T E may be intermittent or resistive when loaded, and if
and R E P A IR source o f overload, and R E P L A C E Fuse. possible, should be checked by m onitoring for a
2. C H E C K that ground G 200 is clean and tight. voltage drop with the system operational under load.
• C H E C K for a broken or partially broken wire inside • C H E C K fo r proper in sta lla tio n o f afterm arket
o f the in s u la tio n w h ic h c o u ld cau se syste m electronic equipment which may affect the integrity o f
malfunction but prove G O O D in continuity/voltage other system. See to Troubleshooting Procedures.
SYSTEM CHECK
ACTION NORMAL RESULTS
[1]
• Turn Ignition Switch to ON. Mirror gradually darkens.
• Gear Selector in PARK.
• Cover Ambient Light Sensor (windshield side) with
dark cloth.
• Shine light on Headlamp Sensor (mirror side).
[2] Gear Selector in REVERSE.
Mirror gradually lightens to a clear state.
[3] Gear Selector in PARK.

Mirror gradually darkens.
[4] Remove cloth and light.

ELECTROCHROMATIC MIRROR DOES NOT LIGHTEN OR DARKEN PROPERLY

TEST RESULT ACTION
C on n ect a test lam p between Test lamp does not light. L O C A T E and R E P A IR open in P N K
E le c tro c h ro m a tic R e a r V ie w (39) between Connector C271 and IP
M irror cavity 1 and ground. Fuse Block.
2. Connect a test lamp betweep B + Test lamp lights. R E P L A C E Electrochromatic Rear View
and Electrochrom atic Rear View Mirror.
M irro r cavity 2. Test lamp does not ligh t L O C A T E and R E P A IR open in B L K
(150) between Electrochromatic Rear
View M irro r and G200.
ELECTROCHROMATIC MIRROR/ELECTRONIC COMPASS - INOPERATIVE DISPLAY

TEST RESULT ACTION
1. Disconnect Electrochromatic Rear Test lamp lights. G O to Step 2.
View M irror Connector. Place test
lamp from P N K / B L K (39) wire at P N K / B L K (39) wire between
E le c t r o c h r o m a t ic R e a r V i e w
Electrochromatic Rear View M irror
M irro r C onnector C avity 1 to Connector and C 271or in P N K (39)
ground. Place Ignition Switch in wire between C271 and IP Fuse Block.
RUN.
2. Place test lamp from P N K / B L K Test lamp lights. R E P L A C E Electrochromatic Mirror.
(39) wire Cavity 1 to B L K (150) Test lamp does not light. L O C A T E and R E P A IR open in B L K
wire at Cavity 2 Electrochromatic (150) wire and between
Rear View M irror connector.
connector and ground.
ELECTROCHROMATIC MIRROR INOPERATIVE IN REVERSE

TEST RESULT ACTION
1. D i s c o n n e c t c o n n e c t o r at Test lamp lights. R E P L A C E Electrochromatic Rear View
E l e c t r o c h r o m a t ic R e a r V i e w Mirror.
Mirror. W ith the Ignition in R U N , Test lamp does not light. G O to Step 2.
place the Transm ission in reverse.
C o n n e c t a te s t l a m p f r o m
E l e c t r o c h r o m a t ic R e a r V i e w
M irror cavity 3 to ground.
2. C onnect a test lam p between Test lamp lights. C H E C K for an open in 24 (LT G R N )
cavity C o f C l (A/T) or cavity B between Backup Lam p Switch and
(M/T) at the Backup Lam p Switch cavity 3 o f Electrochromatic Rear View
to ground. Mirror. If O K , R E P L A C E Backup
Lam p Switch.
Test lamp does not light. R E P A IR open in 24 (LT G R N )
between Backup Lam p Switch and IP
Fuse Block.
CIRCUIT OPERATION COMPASS DISPLAY

The Electrochromatic Rear View M irror dim s to a The Com pass D isplay circuitry is entirely contained
level required to m inim ize glare while still maintaining within the Rearview Mirror.
maximum rear vision. The com pass display is located on the mirror. It
The m irror switch has three positions: OFF, M and presents directional displays relative to sym bolic horizon
C/M. The M position energizes the m irror only while the lines and road lines.
C/M position energizes both the m irror and the compass. The electronic compass includes a fluxgate magnetic
W hen a situation requires the electronic module within field sensor and a microprocessor. The m icroprocessor
the mirror assembly reduces the reflectivity o f the Rear receives inputs from the sensor, processes them and
View M irror and automatically dim s the L E D compass provides outputs to the compass display which indicates the
readout. The Autom atic D im m ing function is inhibited vehicle heading, relative to the Earth’s magnetic fields.
while backing up.
For diagnosis o f the Automatic Day-N ight M irrors See SETTING THE COMPASS ZONE
Section 8A-148. Refer to Calibration O f Com pass in W indow s for
Setting and Calibration Procedures.
WIPER/WASHER: PULSE
HOT IN ACCY OR RUN
MNOSMELO
VWPER
MOTOR
MOOULE

IP Fuse B lo ck ................... .... L H of IP, near L F D oor Jamb Sw itch .......................... .... 3 2 .... 43

M o to r........................... ..... A t Washer Reservoir................................................. .... 7 ...... 11

M odule......................... ..... A t center and rear o f Engine Compartment, at Bulkhead....... 4 ..... 8 ...... 202-70
Sw itch.......................... ..... A t Steering Column, part of M ultifunction Lever............ .... 4 7 .... 61
CONNECTORS:
C 1 0 2 ............................... .... Forward Lam ps Harness to IP Harness, L R o f Engine
mounted on Fender................................................ ..... 4 ...... 8 ...... 202-2
C 1 1 6 ............................... .... L F of vehicle, near Core Support................................ .... 7 ..... 11.... 202-49
C 2 6 6 ............................... .... IP Harness to Steering Colum n Harness, L H of Steering

Column, near Bulkhead................................................ 3 2 .... 43 .... 202-14
GROMMETS:
P 1 0 0 ............................... ... L R of Engine Compartment, at Bulkhead above C 1 0 0 .....
P 1 0 1 ............................... ... R R of Engine Compartment, at B ulkhead ...................... .... 7 ..... 12
GROUNDS:
G 113................................ ... O n Radiator Support, near L H Headlam p....................... ... 4 ...... 8
G 200................................ ... Behind L H of IP, below Fuse Block, on lie B a r............ ... 3 2 .... 43
SPLICES:
S 1 2 3 ................................ ... Forward Lam ps Harness, approx. 20 cm from L H Park
S 1 5 8 ................................ ... In Washer Pump Jumper Harness

Breakout
DIAGNOSIS - WIPER/WASHER: PULSE
TROUBLESHOOTING HINTS: These Circuits may be intermittent or resistive when

1. Check condition of F R T W IP E R Fuse #11. If Fuse is loaded, and if p ossib le , should be checked by
open, L O C A T E and R E P A IR source o f overload. m onitoring for a Voltage drop w ith the system
R E P L A C E Fuse. operational (under load).
2. C H E C K Grounds G113 and G 200 are clean and tight. •CH ECK fo r proper in sta lla tio n o f afterm arket
• C H E C K for a broken (or partially broken) wire inside electronic equipment which may affect the integrity of
o f the in s u la tio n w h ic h c o u ld cause sy ste m other systems See Troubleshooting Procedures.
m a lfu n c tio n but prove “ G O O D” in a 3. C H E C K for proper mechanical operation. R E P A IR
Continuity/Voltage Check with a system disconnected. binding linkage prior to electrical diagnosis.
8A - 9 1 - 2 ELECTRICAL DIAGNOSIS________________________
WIPER/WASHER: PULSE
WIPERS INOPERATIVE IN ANY MODE

1. D i s c o n n e c t W i n d s h i e l d Test lamp lights. G O to Step 2.
W iper/W asher Sw itch connector. Test lamp does not light. L O C A T E and R E P A IR open in Y E L
Connect test lamp from Connector (143) wire between W indshield
C266 Cavity E 4 to ground. Place Wiper/Washer Switch Connector and IP
Ignition Switch in R U N . Fuse Block.
2. Connect W indshield Wiper/Washer Battery voltage. G O to Step 3.
Switch connector. Position switch N o voltage. R E P L A C E W indshield Wiper/Washer
in LO . Connect D M M from B R N Switch.
( 9 6 ) w i r e at W i n d s h i e l d
Wiper/Washer Switch connector to
ground.
3. C heck continuity o f B R N (96) Continuity. G O to Step 4.
w i r e b e t w e e n W i n d s h i e l d N o continuity. L O C A T E and R E P A IR open in B R N
W iper/W asher Sw itch connector (96) wire between W indshield
and W in d sh ie ld W ip e r M o t o r Wiper/Washer Switch connector and
M odule connector. W indshield W iper M otor M odule
connector.
4. Check continuity o f B L K (150) Continuity. R E P L A C E W indshield W iper M otor
wire between W indshield W iper Module.
M o t o r M o d u l e con n e ctor and N o continuity. L O C A T E and R E P A IR open in B L K
ground. (150) wire between W indshield W iper
M otor M odule connector and ground.
WIPERS INOPERATIVE AT HIGH SPEED

TEST RESULT ACTIO N
1. D is c o n n e c t W in d sh ie ld W ip e r Test lamp lights. R E P L A C E W indshield W iper M otor
M otor M odule connector. Place Module.
Ig n itio n S w it c h in A C C and Test lamp does not light. G O to Step 2.
W indshield Wiper/Washer Switch
in H I position. Connect test lamp
from P P L (92) wire at W indshield
W iper M otor M odule connector to
ground.
2. Connect test lamp between P P L Test lamp lights. L O C A T E and R E P A IR open in P P L
(92) at W indshield Wiper/Washer (92) wire between W indshield
Switch connector and ground. Wiper/Washer Switch connector and
W indshield W iper M otor M odule
connector.
Test lamp does not light. R E P L A C E W indshield Wiper/Washer
Switch.
WIPERS INOPERATIVE AT LOW SPEED

TEST RESULT ACTION
1. D is c o n n e c t W in d sh ie ld W ip e r Test lamp lights. R E P L A C E W indshield W iper M otor
M otor M odule Connector. Place Module.
Ig n itio n S w it c h in A C C and Test lamp does not light. G O to Step 2.
W indshield Wiper/Washer Switch
in L O position. Connect a test
lam p from B R N (9 6) wire at
W indshield W iper M otor M odule
connector to ground.
2. Connect a test lamp from B R N Test lamp lights. L O C A T E and R E P A IR open in B R N
( 9 6 ) w i r e at W i n d s h i e l d (96) wire between W indshield
Wiper/Washer Switch connector to Wiper/Washer Switch connector and
ground. W indshield W iper M otor M odule
connector.
Test lamp does not light. R E P L A C E W indshield Wiper/Washer
Switch.
NO DELAY IN THE PULSE (DELAY) MODE

TEST RESULT ACTION
1. D i s c o n n e c t W i n d s h i e l d A reading of approximately 680 ohms. G O to Step 2.
Wiper/W asher Sw itch connector. A reading of less than or greater than R E P L A C E W indshield Wiper/Washer
Place W indshield W iper Switch in 680 ohms. Switch.
L O position. Connect a D M M
from B R N (96) wire Terminal to
Y E L (1 4 3 ) w ire T e rm in a l at
W indshield Wiper/Washer Switch.
2. M o ve W indshield Wiper/W asher Readings increase in steps to L O C A T E and R E P A IR open in B R N
Sw itch through delay range to approximately 450 k ohms. (96) wire or Y E L (143) wire between
maximum delay position. Wiper/Washer Switch connector and
W indshield W iper M otor Module. If
wires are good, R E P L A C E W indshield
Wiper/Washer Switch.
Readings are not as specified. R E P L A C E W indshield Wiper/Washer
Switch.
WIPER/WASHER: PULSE
WIPERS WILL NOT SHUT OFF

TEST RESULT ACTION
1. D i s c o n n e c t W i n d s h i e l d Test lamp lights. L O C A T E and R E P A IR a short to
W ip e r/W ash e r M o t o r M o d u l e voltage in B R N (96) wire from
connector. Place Ignition Switch in W indshield W iper M otor M odule
A C C and W i n d s h i e l d Connector to W indshield Wiper/Washer
W ip e r/ W a s h e r S w i t c h in L O Switch connector. If N O short is found,
position. Connect a test lamp from R E P L A C E W indshield Wiper/Washer
B R N (96) w ire at W in d sh ie ld Switch.
W iper M otor M odule connector to Test lamp does not light. G O to Step 2.
ground.
2. M o v e W indshield W iper/W asher Test lamp lights. L O C A T E and R E P A IR a short to
Switch to H I position. Connect a voltage in P P L (92) wire from
test lamp from P P L (92) wire at W indshield W iper M otor M odule
W indshield W iper M otor M odule connector to W indshield Wiper/Washer
connector to ground. Switch connector. If N O short is found,
R E P L A C E W indshield Wiper/Washer
Switch.
3. C on n ect test lam p from Y E L Test lamp lights. R E P L A C E W indshield W iper M otor
(143) wire at W indshield W iper and Module.
M o t o r M o d u l e c o n n e c t o r to Test lamp does not light. L O C A T E and R E P A IR open in Y E L
ground. (143) wire from W indshield W iper
M otor M odule connector to ground.
WASHER NOT OPERATIVE

TEST RESULT ACTIO N
1. D iscon n ect W in d sh ie ld W asher Test lamp lights. G O to Step 2.
Pum p M o t o r connector. Place Test lamp does not light. G O to Step 3.
I g n it i o n S w it c h to A C C and
W iper/Washer Sw itch to W A SH .
Connect a test lamp from R E D
(228) wire at W indshield Washer
Pump M otor connector to ground.
2. C onnect test lam p from R E D Test lamp lights. R E P L A C E W indshield W asher Pump
(228) wire to B L K (150) wire at Motor.
W indshield W asher Pum p M otor Test lamp does not light. L O C A T E and R E P A IR open in B L K
connector. (150) wire from W indshield W asher
Pump M otor connector to ground.
3. Connect test lamp from B R N (96) Test lamp lights. R E P L A C E W indshield W iper M otor
wire at W indshield W iper M otor Module.
M odule connector to ground. Test lamp does not light. L O C A T E and R E P A IR open in B R N
(96) wire from W indshield W iper
M otor M odule connector to W indshield
Wiper/Washer Switch connector. If wire
is good, R E P L A C E Wiper/Washer
Switch.
CIRCUIT OPERATION PULSE

W ith the W indshield Wiper/Washer Switch in P U L S E
WIPERS (PULSE) (D e lay), Voltage is applied to the B R N (96) wire, the
The pulse-type W iper/W asher System includes an W indshield W iper M otor M odule and the solid-state control
operating mode in which the wipers make single strokes board. Battery voltage is supplied to the Park/Run Relay
with an adjustable time interval between strokes. The time C o i l w h i c h i s m o m e n t a r i l y g r o u n d e d b y the
interval is controlled by a Solid-State Pulse/Speed/Wash Pulse/Speed/Wash Control circuit and the relay closes.
Control in the W indshield W iper M otor M odule. The Battery voltage is supplied through the closed contacts of
duration o f the relay interval is determined by the pulse the relay to run the W indshield W iper M otor Module. The
delay resistance in the W indshield Wiper/Washer Switch. relay remains energized as long as the contacts o f the
Park/Run Switch remain closed. W hen the wiper blades
LOW SPEED have reached P A R K , the P ark/R u n S w itc h opens,
In the L O position, the Wiper/Washer Switch supplies de-energizing the Park/Run Relay. The wiper blades remain
b atte ry v o l t a g e to the B R N ( 9 6 ) w ire and the in P A R K until the control board grounds the Park/Relay
Pulse/Speed/Wash Control. The Pulse/Speed/Wash Control C o il to start another sweep. The delay time between
provides ground to the Park/Run Relay which is energized sweeps is controlled by the pulse delay resistors. The delay
and su p p lie s battery voltage to the brushes o f the can be adjusted from 0 to 43 seconds.
W indshield W iper M otor Module. The wipers run at low
speed until they are turned off. WASHER (PULSE WIPER)
W h en the W in d s h ie ld W ip e r/W ash e r S w itch is
HIGH SPEED depressed, voltage is supplied to the solid-state control
W ith die W indshield Wiper/Washer Switch in the H I board. The control board supplies battery voltage to the
position, battery voltage is supplied from the P P L (92) wire W indshield Washer M otor pump through the R E D (228)
directly to a second armature terminal of the W indshield wire. It also starts the wiper cycle through the low speed
W iper M otor Module. The W ipers run at high speed. W hen brushes o f the W indshield W iper M o to r M odule. The
the W indshield Wiper/Washer Switch is turned to OFF, the washer continues to run as long as the switch is held down.
wipers complete die last sweep at low speed and park. The solid-state control board keeps the wipers on for
approximately six seconds after the washer goes off. If the
PARK washer is switched on during the P U L S E operation, the
W hen the wipers are turned off, the W indshield W iper wipers run in low speed for six seconds. The wash cycle is
M otor M odule runs at low speed until the W iper Blades completed before the wipers return to the delayed pulse
reach the P A R K position. A t that time the Park/Run Relay operation.
opens and shunts the W iper M otor to stop it immediately. The W indshield W iper M otor M odule is equipped with
The W iper Blades remain in the P A R K position. a circuit breaker which protects the motor when the wipers
are blocked. The resulting high current w ill open the circuit
MIST breaker which w ill reset upon cooling.
W hen the control is moved to M IS T and released, the
W ipers make one sweep at low speed and return to P A R K .
The Circuit Operation is the same as low speed.
REAR WIPER/WASHER
GROUND LAM P GROUND


Convenience Center.............. Under L H of IP, on Bulkhead..................................... ... 33.... .. 44
IP Fuse B lo ck ...................... L H o f IP, near L F D oor Jamb Sw itch .......................... ... 32.... .. 43
W indow Washer Pump Motor,
R e a r............................... In Washer Reservoir, R F o f vehicle, behind support....... ... 5 .... .. 10
R e a r............................... O n lower Liftgate g la ss............................................ .... 71.... .. 93
R e a r............................... Center of IP, R H of R a d io ............................................. 49.... .. 6 4 ... . 202-69
CONNECTORS:
C 1 0 2 ................................. Forward Lam ps Harness to IP Harness, L R of Engine
mounted on Fender................................................ ... 4 ....... 8 ..... . 202-2
C 1 1 6 ................................. L F o f vehicle, near Core Support................................ ... 7 ....... 11... . 202-49
C 2 2 1 ................................. A t Convenience Center.............................................. ... 4 7 ... .. 6 2 ... . 202-53
C 4 0 2 ................................. Top center rear of vehicle.......................................... ... 41....... 6 7 ... . 202-57
GROUNDS:
G 113.................................. O n Radiator Support, near L H Headlam p...................... .... 4 ..... . 8
G 400 .................................. R H B Pillar, near D oor Striker.................................... .... 5 8 ... . 76
SPLICES:
S 1 2 3 .................................. Forward Lam ps Harness, approx. 20 cm from L H Park
S 1 5 8 .................................. In W asher Pump Jumper Harness
S 2 1 9 .................................. IP Harness, approx. 5 cm from D L C Breakout
S410 (2-Door U tility)............ Front-to-Rear Body Harness, approx. 37 cm from R R D oor

Breakout

REAR WIPER/WASHER
DIAGNOSIS - REAR WIPER/WASHER
TROUBLESHOOTING HINTS: m a lfu n c tio n but prove “ G O O D ” in a

1. C H E C K condition o f R R W P R Fuse. If fuse is open, C o n t i n u i t y / V o l t a g e C H E C K w ith a s y s t e m
L O C A T E and R E P A IR the source o f overload. disconnected. These circuits may be intermittent or
R E P L A C E fuse. resistive when loaded, and if possible, should be
2. C H E C K that Grounds G113 and G 400 are clean and checked by monitoring for a voltage drop with the
tight. system operational (under load).
3. C H E C K for mechanical binding. • C H E C K fo r proper in sta lla tio n o f afterm arket
• Refer to Rear W indow Wiper/Washer System section electronic equipment which may affect the integrity of
for mechanical diagnosis. other systems. See Troubleshooting Procedures.
• C H E C K for a broken (or partially broken) W ire inside
o f the in s u la t io n w h ic h c o u ld cause s y ste m
REAR WIPER INOPERATIVE IN ANY MODE

TEST RESULT ACTIO N
1. D i s c o n n e c t R e a r W i n d o w Test lamp lights. G O to Step 2.
W ip e r / W a s h e r S w i t c h . P lace Test lamp does not light. R E P A IR open in W H T (393) between
Ignition Switch in R U N . Connect the IP Fuse Block and the Rear
a test lam p from term inal A to W indow Wiper/Washer Switch.
ground.
2. C o n n e c t R e a r W i n d o w Test lamp lights. G O to Step 3.
Wiper/Washer Switch. Disconnect Test lamp does not light. L O C A T E and R E P A IR open in G R Y
R e a r W i n d o w W ip e r / W a s h e r (391) between the Rear W indow
M o to r M od ule. Connect a test Wiper/Washer M odule and the Rear
lamp from terminal B to ground. W indow/Wiper W asher Switch. If O K ,
Turn Rear W indow Wiper/Washer R E P L A C E Rear W indow Wiper/Washer
Sw itch to O N. Switch.
3. Connect a self-powered test lamp Test lamp lights. R E P L A C E Rear W indow Wiper/Washer
from Rear W indow Wiper/Washer Module.
M odule terminal A to ground. Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) between the module and the
ground.
REAR WIPER INOPERATIVE IN PULSE SPEED

TEST RESULT ACTIO N
C o n n e c t a test lam p at Rear Test lamp does not light. R E P L A C E Rear W indow Wiper/Washer
W in d o w W iper/W asher Switch Switch.
term inal F, and then from the
m odule term inal D to ground.
M ove switch to D E L A Y .
2. D i s c o n n e c t R e a r W i n d o w Test lamp lights. R E P L A C E Rear W indow Wiper/Washer
Wiper/Washer Module. Connect a Module.
test lam p from terminal D and Test lamp does not light. L O C A T E and R E P A IR open in L T
then from the module terminal B B L U (97) between the Rear W indow
to g r o u n d . M o v e s w i t c h to Wiper/Washer M odule and ground.
D ELA Y.
REAR WIPER INOPERATIVE IN LO SPEED

TEST RESULT ACTIO N
1. Place Ign itio n Switch in R U N . Test lamp lights. G O to Step 2.
Con n ect a test lam p at R e ar Test lamp does not light. R E P L A C E Rear W indow Wiper/Washer
W in d o w W iper/W asher Sw itch
Switch.
terminal D to gro u nd . M o v e
Switch to LO .
test l a m p f r o m the m o d u le
Test lamp does not light. L O C A T E and R E P A IR open in G R Y
terminal B to gro u nd . M o v e (391) between the Rear W indow
switch to LO .
Wiper/Washer M odule and ground.
REAR WIPER WILL NOT TURN OFF OR PARK

TEST RESULT ACTIO N
1. Place ign itio n sw itch in R U N . Test lamp lights. R E P L A C E Rear W indow Wiper/Washer
Con n ect a test lam p at R e ar Switch.
terminal D to ground.
self-powered test lamp from the
module terminal A to ground.
(150) between the Rear W indow
Wiper/Washer M odule and ground.
REAR WASHER INOPERATIVE

TEST RESULT ACTIO N
Con n ect a test lam p at R e ar Test lamp does not light.
R E P L A C E Rear W indow Wiper/Washer
W in d ow W iper/W asher Sw itch
Switch.
terminal B to ground. Press Rear
W indow Wiper/Washer Switch.
2. Disconnect Rear W indow Washer Test lamp lights. G O to Step 3.
Pump M otor Connector. Connect a
test lamp from the motor terminal
G R N (392) between pump and switch.
A to ground. Press Rear W indow
If no open is found, R E P L A C E Rear
W indow Wiper/Washer Switch.
3. Connect test lamp from D K G R N Test lamp lights. R E P L A C E the Rear W indow Washer
(3 9 2 ) to B L K (1 5 0 ) at R e a r Pump Motor.
W in d o w W asher Pum p M o t o r
connector. Press Rear W indow
(150) between the Rear W indow
Washer Pump M otor and ground.
REAR WIPER/WASHER
CIRCUIT OPERATION is supplied to the P ark/R u n R e la y C o i l w hich is

momentarily grounded by the Pulse/Speed/Wash Control
REAR PULSE WIPER/WASHER LT BLU circuit, and the relay closes. Battery voltage is supplied by
SYSTEM L T B L U 97 through the closed contacts of the relay to run
Voltage to the Rear Wiper/Washer is supplied through the Rear W indow Wiper/Washer M otor at L O speed. The
the W H T (393) with the Ignition Switch in A C C or R U N . relay remains energized as long as the contacts o f the
Park/Run Switch rem ain closed. W hen the w iper blade
WIPER reaches P A R K , the Park/Run Switch opens, de-energizing
In a d d itio n to the features o f a conventional the Park/Run Relay. The wiper blade remains in P A R K
(non-pulse) W iper System (M IST , L O and H I speeds), the until the Control Board grounds the Park/Relay C o il to
Rear Pulse Wiper/Washer System includes an operating start another sweep. The delay time between sweeps is
mode in which the wiper makes single strokes with an controlled by the Pulse D elay Resistor. The delay is
adjustable time interval between strokes. The time interval approximately 9 seconds.
is controlled by a Solid-State Pulse/Speed/Wash Control in
the Rear W indow Wiper/Washer Module. The duration of WASHER
the relay interval is determined by the Pulse D elay W hen the Rear W indow W iper/W asher Switch is
Resistance in the Rear W indow Wiper/Washer Switch. pressed, voltage is supplied to the Solid-State Control
In the O N position, the Rear W indow Wiper/Washer Board in the Rear W indow Wiper/Washer Module. The
Switch supplies Voltage to the Pulse/Speed/Wash Control Rear W ind ow W iper/W asher Switch su pp lies battery
through G R Y (391). The Pulse/Speed/W ash C on trol voltage to the Rear W indow W asher Pump M otor through
provides ground to the Park/Run Relay which is energized D K G R N (392). The switch also starts the wiper cycle
and supplies voltage to the Rear W indow Wiper/Washer through the lo speed b rushes o f the R ear W in d ow
M otor Brushes. The wipers run until turned to OFF. Wiper/Washer Motor. The washer continues to run as long
W hen the Rear W indow W iper/W asher Sw itch is as the switch is held down. The Solid-State Control Board
turned to off, the Rear W indow Wiper/Washer M otor runs keeps the wipers on for approximately six seconds after the
at lo speed until the w iper blade reaches the P A R K washer goes off. If the washer is switched on during
position. The Park/Run Relay then opens and shunts the P U L S E operation, the wipers run in low speed for six
Rear W indow Wiper/Washer M otor to stop the wiper blade seconds. W hen the wash cycle is completed the W ipers
im m ediately. The w iper blade rem ains in the P A R K return to the P U L S E operation.
position. The Rear W indow Washer Pum p M otor is equipped
W ith the R ear W ind ow W iper/W asher Switch in with a circuit breaker which protects the motor when the
P U L S E , V oltage is supplied to the R e ar W in d o w wipers are blocked. The resulting high current w ill open
Wiper/Washer M otor M odule through G R Y (391). Voltage the circuit breaker which w ill reset upon cooling.
BLANK
8A - 10 0 • 0
iHotAtAWTImeel m
1 Underhood >
I Power N8
? ! Fuse - Relay o
I CellO
, Distribution UQHT1NQ
Fuse 8 | Center
50 A
I I o
b_ _
5 RED 42
A6 C100 5
ELECTRICAL DIAGNOSIS
Power 5 RED 42
Distribution
5 RED
+ S205
Cell 10 42 3 RED 42
C
r '* * * " » ,
) Breaker And Panel
1 Dimmer '1IP
i Switch ; Switch
^ WghBeam
Indfcator
Inetrument
1j isA
I Cluster
A
GT
1YEL 10
E 1 3 IC 2 6 6
i ► Cluster
C el 81
j
1YEU 10 0.5 BLK/WHT 451

D
u Al
r “ T “ Headlamp
Hea< S215
1Dimmer
Jlo / h i jDimi
qj1Swit
Switch 1 BLK/WHT 451
A C F C200 (Gas)
0.8 TAN 12 K C200 (OteseD
1 LT
GRN 11 Fog Lamp
1 BLK/WHT 451
E12 J[ E11 C266 [ Relay
C el 102 SI 03 Ground
Distribution
PI 02 C el 14
1 LT
GRN 11 1 LT GRN
11 I LT GRN
S125 k :
1 LT II
1 BLK/WHT 451 1 BLK/WHT 451
GRN 11
1 TAN 12
F A C l 02
0.8 TAN/WHT
1 TAN 12
5 5 1 (Diesel Only)
1 LT
GRN 11 A G103 (Gas) «G 104 (Diesel)
(Gas)
v V
To Heedtemps
I w /Q uad H eadtem ps"! I w/o Quad Headtem pel
From Headtem p Dim m er Switch From Headtemp Switch
■A. --------
0.8 TAN
1 TAN
Headlamp,
High/Low
Beam, RH
ELECTRICAL DIAGNOSIS 8A - 100 -

0.8 BLK 150 0.8 BLK 250
S123 Ground
i------- Distribution »S128
Cell 14
2BLK 150 2 BLK 250
LG113 AG112
HEADLIGHTS

Sw itch............................. Low er L H o f IP .......................................................... 3 2 ..... 43 ... . 202-34
Headlam p Sw itch ................. Part o f Multifunction Switch, L H o f Steering C olu m n ........ 3 2 ..... 43... . 202-34

(Com posite)...................... L F o f vehicle.............................................................. 4 .... .. 8

(Com posite)...................... R F of vehicle.............................................................. 4 .... .. 7

L H .................................. L F o f vehicle.............................................................. 4 .... .. 8

R H ................................. R F o f vehicle.............................................................. 4 .... .. 7

(Com posite)...................... L F o f vehicle.............................................................. 4 .... .. 8

(Com posite)...................... R F o f vehicle.............................................................. 4 .... .. 7
Instrument Cluster................. Upper L H end o f IP, above Steering C olu m n.................... 3 2 ... .. 4 3 ... . 202-38
Underhood Fuse-Relay Center.. L R o f Engine Compartment, on Fender............................ 5 .... .. 9
CONNECTORS:
at Bulkhead............................................................. 4 .... .. 8 ..... . 202-0

mounted on Fender.................................................... 4 .....„ 8 ..... . 202-2
C 200 (D ie se l)...................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 ... .. 4 9 ... . 202-11

Colum n, near Bulkhead............... ............................... 3 2 ... „ 43 ... . 202-14
GROMMETS:
P102 (6 J3 ).......................... Near base Steering Colum n at Bulkhead
GROUNDS:
G 103 (G a s)......................... R F o f Engine, near Thermostat H o u sin g .......................... 14... . 18
G 104 (Gas, D ie se l)............... R H top center o f Cylinder H e ad ..................................... 1 6 ... . 20
G 112 .................................. R F of Engine Compartment, at W heelhousing................... 2 ..... . 5
G 113 .................................. O n Radiator Support, near L H Headlam p......................... 4 ..... . 8
SPLICES:
S103 (5.0L - H D , 5.7L - H D).. Engine Harness, approx. 13 cm from E G R Valve Breakout,

Breakout

S I 03 (7.4L - A/T)................. Engine Harness, approx. 34 cm from Fuel Injector Breakout,
512 0 .................................. Forward Lam ps Harness, approx. 22 cm from W indshield

Washer Pump Breakout, toward L H Headlamp
5121 ................................ Forward Lam ps Harness, approx. 12 cm from L H Headlamp

Breakout, toward W indshield W asher Pump
S I 2 3 .................................. Forward Lam ps Harness, approx. 20 cm from L H Park

S I 25 (D iesel)....................... IP Harness, approx. 20 cm from Instrument Cluster

Breakout
S125 (G as).......................... IP Harness, approx. 13 cm from P100, toward Forward

Lam ps Harness
S I 2 8 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp


Breakout
S205 (G as).......................... IP Harness, approx. 12 cm from Steering Colum n Harness

Breakout


DIAGNOSIS - HEADLAMPS
TROUBLESHOOTING HINTS: 6. C H E C K for a broken (or partially broken) wire inside
1. C H E C K condition o f L IG H T IN G Fuse. If Fuse is the insulation which could cause system malfunction
open, L O C A T E and R E P A IR source of overload. but prove G O O D in a continuity/voltage check with a
R E P L A C E Fuse(s). sy ste m discon n e cte d . T h e s e c irc u it s m ay be
2. C H E C K that Grounds G 103 (Gas), G104, G112, and intermittent or resistive when loaded, and, if possible,
G i l 3 are clean and tight. should be checked by m onitoring for a voltage drop
3. C H E C K that Headlamp filaments are not open. with the system operational (under load).
4. C H E C K that the Instrum ent C luster H igh Beam 7. C H E C K fo r proper in sta lla tio n o f afterm arket
Indicator filament is not open. electronic equipment which may affect the integrity of
5. C H E C K that the Headlam p Sw itch 1 7A C ircu it other systems. See Troubleshooting Procedures.
B re ake r is not open. The circu it breaker w ill
automatically reset after cooling down.
HEADLIGHTS
LOW AND HIGH BEAM HEADLAMPS INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t S t e e r in g C o l u m n Test lamp lights. G O to Step 2.
C o n e c t o r C 2 6 6 . C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR open in Y E L
(10) or in T A N (12) in Steering
Connector C266 Cavity E l 3 for Column. If wire is not open,
Y E L (10) and Cavity E l 2 for T A N R E P L A C E Headlamp Switch.
(12). Operate Headlamp Switch at
least twice. The test lamp should
lig h t on alte rn a te s wi t c h
operations.
2. D is c o n n e c t H e a d la m p S w itc h Test lamp lights. G O to Step 3.
Connector. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in Y E L
test lamp between Connector C266
(10) between Headlamp and Panel
Cavity E 13 and Headlam p and
Dim m er Switch and Connector C266.
Panel D im m er Switch Connector
Cavity G for Y E L (10).
3. Connect a test lam p between Test lamp lights. R E P L A C E Headlamp Switch.
H e a d la m p and Panel D i m m e r Test lamp does not light.
Sw itch Connector C avity C for
(42) between Underhood Fuse-Relay
R E D (42) and ground.
Center and Headlamp and Panel
Dim m er Switch.
LOW BEAM HEADLAMPS INOPERATIVE

TEST RESULT ACTION
1. Disconnect C 266 at the Steering Test lamp lights. L O C A T E and R E P A IR open in T A N
Colum n. Connect a self-powered (12) between Connector C 266 and
test lamp between Connector C266 Splice S I 20.
C avity E l 3 for Y E L (10) and
Test lamp does not light. L O C A T E and R E P A IR open in T A N
Cavity E l 2 for T A N (12). Operate
(12) wire in Steering Colum n. If wire
Headlamp Switch at least twice.
is not open, R E P L A C E Headlamp
Select low beam.
Switch.
HIGH BEAM HEADLAMPS INOPERATIVE

TEST RESULT ACTION
1. D iscon n ect C onnector C 2 6 6 at Test lamp lights. L O C A T E and R E P A IR open in L T
S t e e r in g C o lu m n . C o n n e c t a G R N (11) between Connector C 266
self-powered test lam p between and Splice S I 21.
Connector C 266 Cavity E l 3 for Test lamp does not light.
L O C A T E and R E P A IR open in L T
Y E L (10) and Cavity E l l for L T
G R N (11) in Steering Column. If wire
G R N (11). O perate H eadlam p
is not open, R E P L A C E Headlamp
Sw itch at least twice. Select high
Switch.
beam.
LH HEADLAMP HIGH/LOW BEAM INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t L H H e a d l a m p Test lamp lights. G O to Step 2.
Connector. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in B L K
test lamp between L H Headlamp (150) between L H Headlamp and
C onnector C a vity A fo r B L K Ground G i l 3.
(150) and ground.
2. P l a c e H e a d l a m p an d P a n e l Test lamp lights. G O to Step 3.
D im m e r S w itch in H e ad lam p Test lamp does not light. L O C A T E and R E P A IR open in T A N
p o s it io n . O perate H e a d la m p (12) between splice S I 20 and L H
S w i t c h to select lo w beam. Headlamp.
Connect a test lamp between L H
Headlamp Connector Cavity C for
T A N (12) and ground.
3. Connect a test lamp between L H Test lamp lights. R E P L A C E L H Headlamp.
Headlamp Connector Cavity B for Test lamp does not light. L O C A T E and R E P A IR open in L T
L T G R N ( ll) and ground. Operate G R N (11) between Splice S121 and
Headlamp Switch to select high L H Headlamp.
beam.
RH HEADLAMP HIGH/LOW BEAM INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t R H H e a d l a m p Test lamp lights. G O to Step 2.
Connector. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in B L K
test lamp between R H Headlamp (250) between R H Headlamp and
Connector C a v ity A fo r B L K Ground G112.
(250) and ground.
2. P l a c e H e a d l a m p a n d P a n e l Test lamp lights. G O to Step 3.
D im m e r S w ifc h in H e ad lam p Test lamp does not light. L O C A T E and R E P A IR open in T A N
p o s it io n . O perate H e a d la m p (12) between Splice S I 20 and R H
S w i t c h to select lo w beam. Headlamp.
Connect a test lamp between R H
Headlamp Connector Cavity C for
T A N (12) and ground.
3. Connect a test lamp between R H Test lamp lights. R E P L A C E R H Headlamp.
Headlamp Connector Cavity B for Test lamp does not light. L O C A T E and R E P A IR open in L T
L T G R N (11) and ground. Operate G R N (11) between Splice S I 21 and
Headlamp Switch to select high R H Headlamp.
beam.
HEADLIGHTS
LH LOW BEAM HEADLAMP INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t L H L o w B e a m Test lamp lights. G O to Step 2.
Headlam p Connector. Connect a Test lamp does not light. L O C A T E and R E P A IR open in B L K
self-powered test lamp between (150) between L H Low Beam
L H L o w B e a m H e a d la m p Headlamp and Ground G113.
C on n ector C a v ity A fo r B L K
(150) and ground.
2. P l a c e H e a d l a m p a n d P a n e l Test lamp lights. If filament is not open, R E P L A C E L H
D im m e r S w itc h in H eadlam p Low Beam Headlamp socket.
p o s it io n . O p e rate H e a d la m p Test lamp does not light. L O C A T E and R E P A IR open in T A N
S w i t c h to se lect lo w beam. (12) between Splice S I 20 and L H Low
Connect a test lamp between L H Beam Headlamp.
Low Beam Headlamp Connector
C a v i t y C f o r T A N (1 2 ) and
ground.
LH HIGH BEAM HEADLAMP INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t L H H i g h B e a m Test lamp lights. G O to Step 2.
Headlam p Connector. Connect a Test lamp does not light.
L O C A T E and R E P A IR open in D K
B L U (593) between L H H igh Beam
L H H ig h B e a m H e a d la m p Headlamp and Ground G113.
C o n n e c to r C a v it y A fo r B L K
(150) and ground.
2. Place the Headlam p and Panel Test lamp lights. If filament is not open, R E P L A C E L H
D im m e r S w it c h in H e adlam p H igh Beam Headlamp socket.
p o s it io n . O p e rate H e a d la m p Test lamp does not light. L O C A T E and R E P A IR open in L T
S w i t c h to select h ig h beam. G R N (11) between Splice S I 21 and
Connect a test lamp between L H L H H igh Beam Headlamp.
H igh Beam Headlamp Connector
C a v i t y B for G R N (11) and
ground.
RH LOW BEAM HEADLAMP INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t R H L o w B e a m Test lamp lights. G O to Step 2.
Headlam p Connector. Connect a Test lamp does not light. L O C A T E and R E P A IR open in B L K
self-powered test lap between R H (250) between R H Low Beam
Low Beam Headlamp Connector Headlamp and Ground G112.
C a v it y A for B L K (250) and
ground.
2. P l a c e H e a d l a m p a n d P a n e l Test lamp lights. If filament is not open, R E P L A C E R H
D i m m e r S w itc h in Head lam p Low Beam Headlamp socket.
p o s it io n . O p e rate H e a d la m p Test lamp does not light. L O C A T E and R E P A IR open in T A N
S w i t c h to select lo w beam. (12) between Splice S I 20 and R H Low
Connect a test lamp between R H Beam Headlamp.
Low Beam Headlamp Connector
C a v i t y B fo r T A N (12) and
ground.
RH HIGH BEAM HEADLAMP INOPERATIVE

TEST RESULT ACTION
1. D i s c o n n e c t R H H i g h B e a m Test lamp lights. G O to Step 2.
Headlamp Connector. Connect a Test lamp does not light. L O C A T E and R E P A IR open in B L K
self-powered test lam p between (250) between R H H igh Beam
R H H ig h B e a m H e a d la m p Headlamp and Ground G112.
C on n ector C a v ity A fo r B L K
(250) and ground.
2. Place the Headlam p and Panel Test lamp lights. If filament is not open, R E P L A C E R H
D im m e r S w itc h in H e ad lam p H igh Beam Headlamp socket.
P o s it io n . O perate H e a d la m p Test lamp does not light. L O C A T E and R E P A IR open in L T
S w it c h to select h ig h beam. G R N (11) between Splice S121 and
Connect a test lamp between R H R H H igh Beam Headlamp.
H igh Beam Headlamp Connector
Cavity A for L T G R N (11) and
ground.
HIGH BEAM INDICATOR INOPERATIVE BUT HIGH BEAM HEADLAMPS OPERATE

TEST RESULT ACTION
1. P l a c e H e a d l a m p a n d P a n e l Test lamp lights. G O to Step 2.
D im m e r S w itc h in H e ad lam p Test lamp does not light. L O C A T E and R E P A IR open in L T
position. Observe that headlamps G R N (11) between Splice S125 and
are on. Operate Headlamp Dim m er Instrument Cluster.
S w it c h to select h ig h beam.
D iscon n ect In stru m e n t Cluster
Connector. Connect a test lamp
b e tw e e n I n s t r u m e n t C l u s t e r
Connector Cavity 5 for L T G R N
(11) and ground.
2. Connect a self-powered test lamp Test lamp lights. If H igh Beam Indicator bulb is good,
b e tw e e n In s t r u m e n t C l u s t e r R E P L A C E Instrument Cluster.
Connector Cavity 4 for B L K / W H T Test lamp does not light. L O C A T E and R E P A IR open in the
(451) and ground. B L K / W H T (451) between Instrument
Cluster and Ground G 103 or G104.
HIGH BEAM HEADLAMPS REMAIN ON AFTER HEADLAMP SWITCH ACTUATION

TEST RESULT ACTION
1. D isconnect C onnector C 2 6 6 at Headlamps remain on. L O C A T E and R E P A IR short to voltage
Steering Column. on L T G R N (11) between Headlamp
Switch and Headlamps.
Headlamps turn off or remain off. R E P L A C E Headlamp Switch.
LOW BEAM HEADLAMPS REMAIN ON AFTER HEADLAMP SWITCH ACTUATION

TEST RESULT ACTION
1. Disconnect Connector C 266 at the Headlamps remain on. L O C A T E and R E P A IR short to voltage
Steering Column. on T A N (12) between Headlamp
Switch and Headlamps.
Headlamps turn off or remain off. R E P L A C E Headlamp Switch.
HEADLIGHTS
HEADLAMPS REMAIN ON WITH HEADLAMP AND PANEL DIMMER SWITCH OFF

TEST RESULT ACTION
1. Disconnect the Connector at the Test lamp lights. L O C A T E and R E P A IR short to voltage
H e a d la m p and Panel D im m e r on Y E L (10) between Headlamp and
S w i t c h . D i s c o n n e c t C 2 6 6 at Panel Dim m er Switch and Headlamp
Steering Colum n. Connect a test Switch.
lam p between C onnector C 2 6 6 Test lamp does not light. R E P L A C E Headlamp Switch.
Cavity E l 3 for Y E L (10) and
ground.
CIRCUIT OPERATION Headlamps are grounded, current flow s through the low
Voltage is available at all times to the Headlamp beam filaments and light is emitted.
Switch from the L IG H T IN G M a xi Fuse through the R E D • The R H Headlamp is grounded at Ground G112 by
(42) wire. W ithin the Headlamp and Panel Dim m er Switch B L K (250)
is a 17A circuit breaker which resets automatically. The • The L H Low Beam Headlamp is groounded at Ground
circuit breaker opens upon heating due to an overcurrent G113 B L K (150)
condition. W ith the circuit breaker open, current stops and • The R H Low Beam Headlamp is grounded at Ground
the circuit b reaker’s therm al element cools. W h e n G 112 by B L K (250)
sufficiently cooled, the circuit breaker closes. W ith the hight beams selected, voltage is available on
The three position Headlam p Sw itch has an O F F the L T G R N (11) wires to the high beam connector pins or
p o s i t i o n , a P A R K I N G L A M P S p o s i t i o n , and a the the H igh Beam Headlamps (composite). Because the
H E A D L A M P S position. W hen the switch is in the Headlamps are grounded, the lamps operate.
H E A D L A M P S position, voltage is available on the Y E L • The L H Headlamp is grounded at Ground G113 by
(10) wire to the Headlamp Switch. The Headlamp Switch B L K (150)
is part o f the M ultifu n ction Switch on the Steering • The L H H igh Beam Headlamp is grounded at Ground
Column. B y pulling the M ultiFunction Switch Lever up G113 by B L K (150)
along the axis of the Steering Colum n, the switch changes • The R H H igh Beam Headlamp is grounded at Ground
selections. Repeated switch operations alternate between G i l 2 by B L K (250)
the high and the low beam selections. L T G R N (11) also makes high beam voltage available
W ith the low beams selected, voltage is available on at the Instrument Cluster for lighting the blue Headlamp
the T A N (12) wire to the low beam connector pins or to H igh Beam Indicator Lamp. Since the Instrument Cluster’s
the L o w Beam Headlam ps (com posite). Because the lamp circuits are grounded at Grounds G 103 or G 104 by
B L K (451), the lamp lights when voltage is available.
BLANK
HEADLAMPS: DAYTIME RUNNING LAMPS
BASE HEADLAMPS
QUAD HEADLAMPS
“ IP LH FORWARD RH FORWARD
03-26*97
GROUNO LAMP GROUNO LAMP GROUNO 4206W0S88
8A ■ 102 - 4 ELECTRICAL DIAGNOSIS_______
FROM PACE FROM PAGE

8 A -1 0 2 -1 .3 B A -102-0.2
S204
3 8LK
03-26-97
4208W0589

Convenience Center.............. Under L H of IP, on Bulkhead....................................... .. 3 3 .... 44

(D R L ) M o d u le .................. Under L H of IP, taped on IP Harness............................. .. 3 4 .... 4 5 .... 202-61

(D R L ) R e la y ..................... Under L H of IP, at lower center of Convenience Center.... ... 3 3 .... 44
Fog Lam p, L H ..................... A t L H lower edge of Front Bum per and A ir Deflector..... ... 0 ...... 1
Fog Lam p, R H ..................... A t R H lower edge of Front Bum per and A ir Deflector..... .. 0 ...... 1
Fog Lam p Relay................... Under L H end o f IP, on lower L H of Convenience Center.. .. 3 3 .... 44
Fog Lam p Sw itch................. Center of IP, R H of Steering Colum n Shift L e v e r............ .. 4 8 .... 6 3 .... 202-62

Sw itch............................. Low er L H of I P ........................................................ .. 3 2 .... 4 3 .... 202-34
Headlamp Dim m er Sw itch...... . Part o f Multifunction Lever.......................................... .. 3 2 .... 4 3 .... 202-34

(Com posite)...................... , L F of vehicle............................................................ .. 4 ...... 8

(Com posite)...................... , R F of vehicle............................................................ .. 4 ...... 7

L H .................................. . L F of vehicle............................................................ .. 4 ...... 8

R H ................................. . R F o f vehicle............................................................ .. 4 ...... 7

(Com posite)..................... . L F of vehicle............................................................ ... 4 ...... 8

(Com posite)..................... . R F of vehicle............................................................ ... 4 ...... 7
Ignition Sw itch .................... . O n Steering Column, under Lock C ylin d e r..................... .. 4 2 .... 57
Instrument C luster................ . Upper L H end of IP, above Steering C olu m n.................. ... 3 2 .... 4 3 .... 202-38
IP Fuse B lo ck ....................... L H o f IP, near L F D oor Jamb Sw itch ............................... 3 2 .... 43
Park Brake W arning Sw itch ... . Mounted on Park Brake, under L H end of I P ................. ... 3 3 .... 44
CONNECTORS:
C 1 0 2 ................................. . Forward Lam ps Harness to IP Harness, L R o f Engine
mounted on Fender..................................................... 4 ...... 8 ...... 202-2
C 200 (D ie se l)....................... Behind R H of IP, near Heater Motor, in foam w rap............. 3 7 .... 4 9 .... 202-11
C 200 (G a s)......................... . Behind R H of IP, near Heater Motor, in foam w rap......... ... 3 7 .... 4 9 .... 202-10
C 2 6 6 ................................. . IP Harness to Steering Colum n Harness, L H o f Steering

Colum n, near Bulkhead............................................ ... 3 2 .... 4 3 .... 202-14
DIODES:
D 2 0 3 ................................. . IP Harness, at R H of Steering Colum n Support.............. ... 4 1 .... 53
GROMMETS:
P 1 0 0 ............................. . . L R of Engine Compartment, at Bulkhead above C l 0 0 ...... ... 4 ...... 8
8A - 102 ■ 6 ELECTRICAL DIAGNOSIS_______

GROUNDS:
G 103 (G a s)......................... R F of Engine, near Thermostat H o u sin g .......... 14 .... 18
G 104 (Gas, D ie se l)............... R H top center o f Cylinder H e a d ..................... 16 .... 20
G i l 2 .................................. R F of Engine Compartment, at W heelhousing 2 ...... 5
G i l 3 .................................. On Radiator Support, near L H Headlamp.......... 4 ...... 8
G 200.................................. Behind L H of IP, below Fuse Block, on Tie Bar 3 2 .... 43
SPLICES:

Breakout
512 0 ................. ................. Forward Lam ps Harness, approx. 22 cm from W indshield

Washer Pum p Breakout, toward L H Headlamp

Breakout, toward W indshield Washer Pump
S I 2 3 .................................. Forward Lam ps Harness, approx. 20 cm from L H Park

S I 25 (D iesel)....................... IP Harness, approx. 20 cm from Instrument Cluster

Breakout
5125 (G as).......................... IP Harness, approx. 13 cm from P I00, toward Forward

Lam ps Harness
5126 (Pickup O n ly ).............. Forward Lam ps Harness, approx. 5 cm from L H Headlamp

Breakout, toward L H Horn
S I 2 8 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp

S I 6 5 ................................... Engine Compartment, IP Harness, approx. 9 cm from P I00,

toward Forward Lam ps Harness Connector
S 2 0 4 ................................... IP Harness, approx. 10 cm from Steering Colum n Harness

Breakout

Breakout
S210 (G as).......................... IP Harness, approx. 4 cm from Auxiliary Power Outlet

Breakout

Breakout
S215 (D ie sel)....................... IP Harness, approx. 8 cm from Instrument Cluster Breakout,



Breakout

DIAGNOSIS - HEADLAMPS: DAYTIME RUNNING LAMPS

8. C H E C K that Daytim e Running Lam ps (D R L ) Relay is
securely mounted in Convenience Center.
TROUBLESHOOTING HINTS: • C H E C K for a broken (or partially broken) wire inside
1. C H E C K the condition o f the D R L -F O G F U S E 15 and o f the insulation which could cause system failure but
the G A U G E S F U S E 4. If either Fuse is open, prove G O O D in a continuity/voltage check with a
L O C A T E and R E P A IR source of overload. sy ste m d isco n n e cte d . T h e se c irc u it s m ay be
2. C H E C K that Grounds G112, G113 (with Fog Lam ps intermittent or resistive when loaded, and if possible,
or with Q U A D Headlamps) and G 200 are clean and should be checked by monitoring for a voltage drop
tight. with the system operational (under load).
3. C H E C K that the Fog Lam p Relay is securely mounted • C H E C K fo r proper in sta lla tio n o f afterm arket
in the Convenience Center. electronic equipment which may effect the integrity of
4. C H E C K the L H and R H L o w and H igh Beam other systems. See Troubleshooting Procedures.
filaments.
5. C H E C K the H igh Beam Indicator filament.
6. C H E C K the L H and R H Fog Lam p filaments.
7. C H E C K the Daytime Running Lam ps (D R L ) indicator
filament.
LOW AND HIGH BEAM HEADLAMPS ARE INOPERATIVE

TEST RESULT ACTION
1. Turn Headlam p Sw itch to O N . Test lamp does not light. R E P L A C E Headlamp and Panel
Backprobe Headlam p and Panel Dim m er Switch.
Dim m er Switch Connector with a Test lamp lights. G O to Step 2.
test lam p fro m C a v it y G to
ground.
2. D iscon n e ct H eadlam p D im m e r Test lamp does not light. L O C A T E and R E P A IR open in Y E L
Switch Connector. Connect a test (10) wire between Headlamp and Panel
lam p from H eadlam p D im m e r Dim m er Switch.
Sw itch Connector C avity D to Test lamp lights. R E P L A C E Headlamp Dim m er Switch.
ground.
8A ■ 102 ■ 8 ELECTRICAL DIAGNOSIS__________________________
LOW BEAM HEADLAMPS ARE INOPERATIVE

TEST RESULT ACTION
1. H im Headlamp and Panel Dim m er Test lamp does not light. R E P L A C E Headlamp Dim m er Switch.
Sw itch to O N . M ove Headlamp Test lamp lights. G O to Step 2.
Dim m er Switch to L O W position.
B a ckp ro b e H e adlam p D im m e r
Switch Connector with a test lamp
from Cavity A to ground.
2. W ith Headlamp Dim m er Switch in Test lamp does not light. L O C A T E and R E P A IR open in P P L
L O W , R E M O V E D a y t im e (359) wire between Headlamp Dim m er
Running Lam p Relay and connect Switch and Daytim e Running Lam p
a test lam p at C a v ity G 5 to Relay.
ground. Test lamp lights. G O to Step 3.
3. R E - IN S T A L L Daytim e R unning Test Lam p does not light. L O C A T E and R E P A IR open in T A N
Lam p Relay. Backprobe Cavity B (12) wire between Daytim e Running
at H IG H / L O W Beam Headlam p Lam p Relay and H IG H / L O W Beam
with Headlamp Dim m er Switch in Headlamp. If O K , R E P L A C E Daytim e
L O W position. Running Lam p Relay.
Test lamp lights. R E P L A C E H IG H / L O W Beam
Headlamps.
HIGH BEAM HEADLAMPS ARE INOPERATIVE

TEST RESULT ACTION
1. Turn Headlamp and Panel Dim m er Test lamp does not light. R E P L A C E Headlamp Dim m er Switch.
Sw itch to O N . M ove Headlamp Test lamp lights. L O C A T E and R E P A IR open in L T
Dim m er Sw itch to H IG H position. G R N (11) wire between Headlamp
B a ckp ro b e H ead lam p D im m e r Dim m er Switch and Headlamp.
Sw itch Connector with a test lamp
from Cavity C to ground.
ONE LOW BEAM OR HIGH BEAM HEADLAMP INOPERATIVE

TEST RESULT ACTION
1. Connect a test lamp from LH /R H Test lamp does not light. L O C A T E and R E P A IR open in the
H eadlam p C onnector C a vity B w iring between affected Headlamp and
(Q U A D Headlam ps) or Cavity A ground.
(B A S E Headlam ps) to B+. Test lamp lights. C H E C K for an open in the w iring
between affected Headlamp and Splice
S I 20 (for inoperative low beam) or
Splice S I 21 (for inoperative high
beam). If O K , R E P L A C E affected
Headlamp.
HIGH BEAM INDICATOR INOPERATIVE

TEST RESULT ACTION
1. D isco n n e c t In stru m e n t C lu ste r Test lamp does not light. L O C A T E and R E P A IR open in
connector. Connect a test lamp B L K / W H T (451) wire between
from Instrument Cluster Connector Instrument Cluster Connector and
Cavity 4 to B+. Ground G103 (Gas), G 104
(Gas,Diesel).
2. W ith Instrument Cluster Connector Test lamp does not light. L O C A T E and R E P A IR open in L T
disconnected and Headlamp and G R N (11) wire between Instrument
Panel Dim m er Switch O N. M ove Cluster Connector and Splice S I 25.
H e ad lam p D im m e r S w itc h to
H IG H . Connect a test lamp from
the Instrument Cluster Connector
Cavity 5 to ground.
Test lamp lights. C H E C K for inoperative H IG H Beam
Indicator Beam bulb. If O K ,
HIGH BEAM HEADLAMPS ON WITH HEADLAMP AND PANEL DIMMER SWITCH OFF
TEST RESULT ACTION
1. D isco n n e ct H eadlam p D im m e r H igh Beam Headlamps turn OFF. G O to Step 2.
Switch Connector. H igh Beam Headlamps remain O N. L O C A T E and R E P A IR short to Voltage
in L T G R N (11) wire between
Headlamp Dim m er Switch and L H
H igh Beam Headlamp and/or R H H igh
Beam Headlamp.
2. R e con n e ct H e ad lam p D im m e r H igh Beam Headlamps turn OFF. R E P L A C E Headlamp and Panel
Sw itch C onnector. D isc o n n e c t Dim m er Switch.
H e ad lam p and P an e l D im m e r H igh Beam Headlamps remain O N. L O C A T E and R E P A IR short to voltage
Switch Connector. in Y E L (10) wire between Headlamp
and Panel Dim m er Switch and
Headlamp Dim m er Switch.
FOG LAMPS ARE INOPERATIVE

TEST RESULT ACTION
1. Rem ove Fog Lam p R elay from Less than 10.0 volts. G O to Step 2.
Convenience Center. T\im Ignition M ore than 10.0 volts. G O to Step 6.
Switch to R U N . Press Park Lam p
Sw itch to O N . Turn F o g Lam p
Switch to O N . Connect a D M M
from Fog Lam p Relay Cavity G1
to ground. Measure voltage.
2. B a ck p ro b e F o g L a m p S w itc h M ore than 10.0 volts L O C A T E and R E P A IR open in Y E L
C onnector w ith a D M M from (317) wire between Fog Lam p Switch
C a v ity A to ground. M easu re and Convenience Center.
voltage. G O to Step 3.
Less than 10.0 volts.
3. B a ckp ro b e F o g L a m p S w itc h M ore than 10.0 volts G O to Step 4.
C onnector w ith a D M M from
Less than 10.0 volts. G O to Step 5.
C a v ity C to ground. M e a su re
voltage.
TEST RESULT ACTION

4. B a ck p ro b e F o g L a m p Sw itch Test lamp lights. R E P L A C E Fog Lam p Switch.
Connector with a test lamp from Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity C to E. (150) wire between Splice S218 and
Fog Lam p Switch.
5. Backprobe Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR open in B R N
Dim m er Switch Connector with a (9) wire between Fog Lam p Switch
test lamp from Cavity S to ground. and Headlamp and Panel Dim m er
Switch.
Test lamp does not light. R E P L A C E Headlamp and Panel
Dim m er Switch.
6. Connect a test lam p from Fog Test lamp does not light. L O C A T E and R E P A IR open in L T
Lam p Relay Cavity G1 to H3. G R N (11) wire between Instrument
Cluster and Convenience Center and
S125.
7. Connect a test lam p from Fog Test lamp does not light. L O C A T E and R E P A IR open in O R N
Lam p Relay Cavity H I to ground. (340) wire between IP Fuse Block and
Convenience Center.
8. Connect a Fused Jumper from Fog Fog Lam ps light. R E P L A C E Fog Lam p Relay.
Lam p Relay Cavities H I to G3. Fog Lam ps do not light. L O C A T E and R E P A IR open in P P L
(34) wire between Convenience Center
and Splice S I 26.
ONE FOG LAMP INOPERATIVE

TEST RESULT ACTION
1. C o n n e c t a te st la m p fro m Test lamp does not light. L O C A T E and R E P A IR open in B L K
inoperative Fog Lam p Connector (150/LH, 250/RH) wire between ground
Cavity A to B+. (G113/LH, G112/RH) and inoperative
Fog Lamp.
Test lamp lights. C H E C K for an open in P P L (34) wire
between Splice S I 26 and affected Fog
Lamp. If O K , R E P L A C E inoperative
Fog Lamp.
FOG LAMP INDICATOR INOPERATIVE

TEST RESULT ACTION
1. D isc o n n e c t F o g L am p Sw itch Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connector. Connect a test lamp (150) wire between Fog Lam p Switch
from Fog Lam p Switch Connector and G200.
C avity E to B +. Test lamp lights. C H E C K for an open in P P L (34) wire
between Fog Lam p Switch and S165.
If O K , R E P L A C E Fog Lam p Switch.
FOG LAMPS REMAIN LIT WITH FOG LAMP SWITCH OFF

TEST RESULT ACTION
1. Remove Fog Lam p Relay. D o Fog No. L O C A T E and R E P A IR short to voltage
Lam ps turn O F F ? in P P L (34) wire between Fog Lam p
Switch, L H Fog Lamp, R H Fog Lam p
and Convenience Center.
Yes. G O to Step 2.
2. D isco n n e c t F o g Lam p Sw itch Yes. R E P L A C E Fog Lam p Switch.
Connector. D o Fog Lam ps turn No. L O C A T E and R E P A IR short to voltage
O FF? in Y E L (317) wire between Fog Lam p
Switch and Convenience Center.
DAYTIME RUNNING LAMPS (DRL) ARE INOPERATIVE

TEST RESULT ACTION
1. Insure Park Brake is OFF. Turn Yes. R E F E R to A B S C O N T R O L S for
Ig n it io n S w itc h to R U N . Is diagnosis of the Brake W arning
B R A K E Indicator lit? System.
No. G O to Step 2.
2. T\im Ignition Switch to L O C K . Test lamp does not light. L O C A T E and R E P A IR open in P N K
D isc o n n e c t D a ytim e R u n n in g (39) wire between IP Fuse Block and
Lam ps (D R L ) M odule Connector. D R L Module.
Turn Ig n itio n Sw itch to R U N . Test lamp lights. G O to Step 3.
Connect a test lamp from D R L
M odule Connector C avity C to
ground.
3. Connect a test lamp from D R L Test lamp does not light. L O C A T E and R E P A IR open in B L K
M odule Connector Cavity C to H. (150) wire between D R L M odule and
G200.
4. Remove Daytime Running Lam ps Test lamp does not light. C H E C K for an open in O R N (340)
(D R L ) Relay from Convenience wire between IP Fuse B lo ck and Diode
Center. Connect a test lamp from 203. If O K , C H E C K for an open in
D R L Relay Cavity G 6 to ground. Y E L (634) wire between Diode 203
and Convenience Center. If O K ,
L O C A T E and R E P L A C E Diode 203.
5. Connect a test lamp from D R L Test lamp does not light. L O C A T E and R E P A IR open in P N K
Relay Cavity G 4 to ground. (39) wire between S213 and
Convenience Center.
6. Turn Ignition Sw itch to L O C K . N o C H E C K for a poor connection or
R e c o n n e c t D R L M o d u le damaged terminals at D R L M odule
Connector. Turn Ignition Switch to Connector. If O K , R E P L A C E D R L
R U N . Is Daytime Running Lam ps Module.
(D R L ) Indicator lit? Yes G O to Step 7.
7. Connect a D M M from D R L Relay Less than 10.0 volts. L O C A T E and R E P A IR open in L T
C a v it y H 6 to B + . M e a s u re G R N / B L K (592) wire between D R L
voltage. M odule and Convenience Center.
M ore than 10.0 volts. G O to Step 8.
8. Connect a Fused Jum per from Low Beam Headlamps light at low R E P L A C E D R L Relay.
D R L Relay Cavity G 6 to H4. intensity.
Low beam Headlamps do not light. G O to Step 9.
TEST RESULT ACTION

9. R e -in s t a ll D R L R e la y . T u rn Test lamp does not light. L O C A T E and R E P A IR open in T A N
Ig n it io n S w itc h to R U N and (12) wire between D R L Relay and L H
disconnect a Headlamp Connector. H IG H /LO W Beam Headlamps.
Connect a test lamp from Cavity Test lamp lights. G O to Step 10.
C to ground.
10. U sin g a self-powered test lamp, Test lamp does not light. L O C A T E and R E P A IR open in B L K
Connect between C avity A and (150) wire between L H H IG H /LO W
ground. Beam Headlamp and G113 and/or
(250) wire between R H H IG H /LO W
Beam Headlamp and ground G112.
Test lamp lights. R E P L A C E L H and/or R H H IG H /LO W
Beam Headlamp.
DAYTIME RUNNING LAMPS (DRL) DO NOT DISABLE WITH PARKING BRAKE ENGAGED
TEST RESULT ACTION
1. Turn Ig n itio n Sw itch to R U N . No. Refer to A B S C O N T R O L S for
E n g a g e P a rk in g B ra k e . D o e s diagnosis of the Brake W arning
B R A K E Indicator light? System.
Yes. G O to Step 2.
2. Turn Ignition Sw itch to L O C K . Test lamp lights. R E P L A C E D R L module.
D isc o n n e c t D a y tim e R u n n in g Test lamp does not light. L O C A T E and R E P A IR open in L T
Lam ps (D R L ) M odule Connector. B L U (1134) wire between Park Brake
Connect a test lamp from D R L Switch and D R L Module.
M odule Connector C avity A to
B+.
DAYTIME RUNNING LAMPS (DRL) ARE OPERATIONAL AT ALL TIMES

TEST RESULT ACTION
1. Turn Ignition Switch to R U N . Is Yes. G O to Step 2.
Daytim e R unning Lam ps (D R L ) No. G O to Step 4.
Indicator lit?
2. D isc o n n e c t D a y tim e R u n n in g No. R E P L A C E D R L Module.
Lam ps (D R L ) M odule. Is D R L Yes. G O to Step 3.
Indicator lit?
3. D isc o n n e c t In stru m e n t C lu ste r Yes. R E P L A C E Instrument Cluster.
Connector. D oes D R L disable? No. L O C A T E and R E P A IR short to ground
in L T G R N / B L K (592) wire between
Instrument Cluster and Convenience
Center.
4. Rem ove Daytim e Running Lam ps Yes. R E P L A C E D R L Relay.
(D R L ) R elay from Convenience No. L O C A T E and R E P A IR short to voltage
Center. Does D R L disable? in T A N (12) wire between Convenience
Center and L H H IG H / L O W Beam
Headlamp (B A S E Headlamps) and L H
H igh Beam Headlamp (Q U A D
Headlamps).
DAYTIME RUNNING LAMPS (DRL) INDICATOR IS INOPERATIVE

TEST RESULT ACTION
1. Turn Ignition Switch to L O C K . Test lamp does not light. L O C A T E and R E P A IR open in B L K
D isco n n e c t Instrum ent C lu ste r (150) wire between Instrument Cluster
Connector. Connect a test lamp and Splice S204.
from Instrument Cluster Connector Test lamp lights. G O to Step 2.
Cavity 4 to B+.
2. Turn Ig n itio n Sw itch to R U N . Test lamp does not light. L O C A T E and R E P A IR open in L T
C o n n e c t a te st la m p fro m G R N / B L K (592) wire between
In stru m e n t C lu ste r C o n n e cto r Instrument Cluster and Daytime
Cavity 17 to ground. Running Lam ps (D R L ) Module.
Test lamp lights. Replace Instrument Cluster.
CIRCUIT OPERATION position, voltage is supplied to die H igh Beam Indicator.

Since the H igh Beam Indicator is supplied with a ground
HEADLAMPS from Ground G103 (Gas) and G104 (Gas, Diesel) it lights.
Voltage is supplied to the Headlam p and Panel Ground is supplied from G112 for the R H H igh Beam
Dim m er Switch at all times. The Headlamp and Panel Headlamp. Ground is supplied from G113 to the L H High
Dim m er Sw itch includes a Self-Resetting Circuit Breaker. Beam Headlamp. With both power and ground applied to the
The Circuit Breaker opens when the Headlamp and Panel H igh Beam Headlamps, they light at full intensity.
Dim m er Switch draws too much current. W hen the Circuit
Breaker opens, it interrupts the current flow. W ith no FOG LAMPS
current flow, the Circuit Breaker cools off and resets Fog Lam p operation is possible with the Headlamp and
automatically. W hen the Headlam p and Panel Dim m er Panel Dim m er Switch in the P A R K or H E A D position, but
Switch is in the H E A D position, the Headlamp and Panel if the Headlamp and Panel Dim m er Switch is in the H E A D
Dim m er Switch directs voltage to either the Low Beam or position, the F o g Lam ps are on ly operational if the
H igh Beam Headlamps (depending on Headlamp and Panel Headlamp Dim m er Switch is in the L O W position.
Dim m er Switch position). W hen the Headlamp and Panel W ith the Headlamp and Panel Dim m er Switch in the
Dim m er Switch is in the H E A D position, not only is P A R K or H E A D position (if in the H E A D position,
Voltage supplied for the Headlam ps, but the Daytim e Headlamp Dim m er Sw itch must be in L O W position),
Running Lam ps (D R L ) M odule receives a “Headlamps voltage is applied through the closed contacts o f the Park
O N ” signal. W hen the D R L M odule receives this signal, it Lam p Switch to the Fog Lam p Switch. W ith the Fog Lam p
disables D R L operation (if Ignition Switch is in R U N , Switch in the O N position, voltage is applied through the
B U L B T E S T or S T A R T positions). closed contacts of the Fog Lam p Switch to the C o il (power
W hen the Headlamp and Panel Dim m er Switch is in side) of the Fog Lam p Relay. Voltage is applied to the
the H E A D position and the Headlamp and Panel Dim m er contact side o f the relay through the D R L -F O G F U S E 15.
Switch is in the L O W position, voltage is applied through Ground is supplied from the Daytim e Running Lam ps
the closed contacts of the Headlamp and Panel Dim m er (D R L ) M odule to the C oil (ground side) of the Fog Lam p
Switch and the Headlamp Dim m er Switch to the L H and Relay (provided that the Headlamp Dim m er Switch is in
R H L o w Beam Headlam ps. G round is supplied from the L O W position if the Headlamp and Panel Dim m er
Ground G112 to the R H Low Beam Headlamp, and G113 Switch is O N). W ith both power and ground applied to the
to the L H Low Beam Headlamp (B A S E Headlamps) and coil o f the Fog Lam p Relay, the relay energizes and voltage
the L H Low Beam Headlamp (Q U A D Headlamps). Since is applied through the closed contacts of the relay to the
both power and ground are applied to the Low Beam Fog Lam p O N Indicator, the L H Fog Lam p and the R H
Headlamps, they light. Fog Lamp. W ith both power and ground applied to the Fog
W hen the Headlamp Dimmer Switch is moved to the Lam p O N Indicator, the L H Fog Lam p and the R H Fog
H IG H position with the Headlamp and Panel Dimmer Switch Lam p, they light. If the Headlamp Dim m er Switch is
in the H E A D position, voltage is applied through the closed switched to the H IG H position when the Headlamp and
contacts of the Headlamp and Panel Dim m er Switch and the Panel Dim m er Switch is in H E A D and the Fog Lam p
Headlamp and Panel Dim m er Switch to the D R L Module, Switch O N , then the D R L M odule receives a H igh Beam
L H H igh Beam Headlamp and the R H H igh Beam Headlamp. Headlamp operation signal and disables the Fog Lamp
W ith the H e ad lam p D im m e r S w itc h in the H IG H Relay, turning the Fog Lam ps OFF.
DAYTIME RUNNING LAMPS (DRL) through the D R L -F O G F U S E 15 and the closed contacts of
Daytim e Running Lam p (D R L ) operation is automatic, the D R L Relay to the L H and R H L O W Beam Headlamps.
provided that the Ignition Switch is in the R U N , B U L B W hen D R L is operating, the D R L M odule w ill also supply
T E S T or S T A R T position, the Parking Brake is disengaged ground to the Daytime Running Lam ps (D R L ) Indicator.
and the Headlamp and Panel Dim m er Switch is in OFF. Voltage is applied through the G A U G E S F U S E 4 with the
W hen D R L is operating, the L O W Beam Headlamps are Ignition Sw itch in the R U N , B U L B T E S T or S T A R T
on. position to the D R L Indicator. W ith both power and ground
Voltage is supplied through the G A U G E S F U S E 4 applied to the D R L Indicator, it lights. If the Parking Brake
when the Ignition Switch is in the R U N , B U L B T E S T or is engaged, a ground signal is sensed at the D R L Module.
S T A R T position to the Daytime Running Lam ps (D R L ) W hen the D R L M odule receives this signal, it disables
M odule and to the C o il (power side) o f the Daytim e D R L operation by removing ground from the C oil of the
Running Lam ps (D R L ) Relay. If the Parking Brake is D R L Relay. The D R L M odule w ill also disable D R L
disengaged and the Headlamp and Panel Dim m er Switch is operation if the Headlamp and Panel Dim m er Switch is O N
in the O F F position, then the D R L M odule supplies ground or the Ignition Switch is turned to the O FF, L O C K or
to the C o il (ground side) of the D R L Relay. W ith both A C C Y positions (also, by rem oving the ground from the
power and ground applied to the C o il of the D R L Relay, it coil of the D R L Relay).
energizes, and the contacts close. Voltage is applied
EXTERIOR LAMPS
FRONT MARKER, PARK/TURN, AND TAIUSTOP - TURN LAMPS
EXTERIOR LAMPS
FRONT MARKER, PARK/TURN, AND TAIUSTOP - TURN LAMPS
EXTERIOR LAMPS
ROOF MARKER LAMPS
1
I
1
SEE GR0UN0
DISTRIBUTION
03-11-97
420SW0666
EXTERIOR LAMPS
CLEARANCE AND ENDGATE MARKER LAMPS (PICKUP W / DUAL REAR WHEELS)
HOT AT ALL TIMES
]
EXTERIOR LAMPS
CHMSL (SUBURBANAJTILITY)
GROUND
04-15-97
4208W 0668
EXTERIOR LAMPS
REAR PARK/MARKER (PART OF LH/RH TAIUSTOP-TURN LAMPS) AND LICENSE LAMPS
I F6 ^ PARKLPS I E iS
I r FUSE 9 | BLOCK
I S 20 A I
L t- J
.8 ORN I 2 4 0
H /*\
EXTERIOR LAMPS
TRAILER TOW
LICENSE s to p la m p sto p la m p
LAMPS
03-11-07
4208W 0670
EXTERIOR LAMPS
CARGO/CHMSL LAMPS (EXCEPT SUBURBAN/UTILITY)
CARGO
LAMP
CR0SSB00Y
03-11-97
GROUND 4208W0671
EXTERIOR LAMPS

Backup Lam p Switch, (M G5)... L H of Transmission, below Shift Tower........................... 2 7 .... 38
Backup Lam p Switch, (M W 3).. L H top of Transm ission..................................... ........... 2 6 .... 36
Cargo Lam p (Pickup)............. Rear center o f cab, above Rear Window, part o f C H M S L ... 6 9 .... 90
Cargo Lam p Switch (Pickup).... Center o f IP, center L H of R ad io.................................... 4 8 .... 63

(C H M S L , Pickup).............. A t top rear center of cab............................................... 6 9 .... 9 0 .... 202-64

(C H M S L , Suburban/Utility)... A t top rear center of vehicle, part of R o o f....................... 7 0 .... 9 2 .... 202-64
Clearance Lam p, L F .............. Front of L R Fender...................................................... 6 9 .... 89
Clearance Lam p, L R .............. Rear o f L R Fender....................................................... 6 9 .... 89
Clearance Lam p, R F .............. Front of R R Fender..................................................... 6 9 .... 89
Clearance Lamp, R R ............. Rear of R R Fender......................................... ............. 6 9 .... 89
Convenience Center.............. Under L H o f IP, on Bulkhead ........................................ 3 3 .... 44
Endgate M arker Lam ps.......... O n center and bottom o f Endgate................................... 7 1 .... 94
Headlam p and Panel Dim m er

Sw itch............................. Low er L H of I P .......................................................... 3 2 .... 43.... 202-34
Instrument Cluster................. Upper L H end of IP, above Steering C olum n.................... 3 2 .... 43 .... 202-38
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. 3 2 .... 43
License Lam ps, L H / R H .......... Rear of vehicle, at License H older.................................. 7 4 .... 98
M arker Lam ps, Front............. Across top front o f vehicle............................................ 4 ...... 7
M arker Lam ps, R o o f.............. Across top front o f ro o f...................... ......................... 3 ...... 6
Park and Turn Lam p, L F ....... A t L F comer o f vehicle............................... ................. 4 ...... 8
Park and Tbm Lam p, R F ....... A t R F comer o f vehicle................................................ 4 ...... 8
Stoplamp R e la y .................... In Underhood Fuse-Relay Center, L R o f Engine

Tail/Stop-Tum Lam p, L R
Cab/Chassis...................... L R comer of vehicle.................................................... 7 3 .... 9 7 .... 202-66
Pickup/Utility.................... L R comer of vehicle.................................................... 7 4 .... 99 .... 202-66
Tail/Stop-l\im Lam p, R R
Cab/Chassis...................... R R comer of ve h icle .................................................... 7 3 .... 9 7 .... 202-66
Tail/Stop-Tlim Lam p, R R
Pickup/Utility.................... L R comer o f vehicle.................................................... 7 4 .... 9 9 .... 202-66
Stoplamp Sw itch .................. Top of Brake Pedal........ .............................................. 44.... 5 7 .... 202-70
Tum/Hazard Flasher.............. Mounted to Convenience Center, under L H o f IP, L H of

Steering Colum n, on Bulkhead..................................... 3 3 .... 44.... 202-56
Tum/Hazard Sw itch............... Part of M ultifunction Switch, upper L H o f Steering Colum n. 4 7 .... 61
Underhood Fuse-Relay Center.. L R o f Engine Compartment, on Fender............................ 5 ...... 9

C O N N EC T O R S:
C 1 0 0 .............................. ... Engine Harness to IP Harness, L R of Engine Compartment,

at Bulkhead ...................................... ...................... . 4 ...... 8 ...... 202-0
C 1 0 2 .............................. ... Forward Lam ps Harness to IP Harness, L R o f Engine

mounted on Fender................................................... . 4 ...... 8 ...... 202-2
C 1 0 3 .............................. ... Engine Harness to Fuel Pump Motor, L R of Engine

C 1 0 4 .............................. ... IP Harness to Front-to-Rear Harness, L R o f Engine

C 200 (D ie se l).................. ... Behind R H o f IP, near Heater Motor, in foam w rap.......... . 3 7 .... 49 .... 202-11
C 200 (G a s)..................... ... Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-10

Colum n, near Bulkhead............................................. . 3 2 .... 4 3 .... 202-14
C 2 9 8 .............................. 202-17,
Behind L H o f IP, near Convenience Center...................... . 3 2 .... 4 3 .... 18
C 3 0 1 .............................. ... A t L F K ic k Panel........................................................ . 4 7 .... 6 2 .... 202-20,

56
C 4 0 7 .............................. ... Beneath L R edge of b e d ....................... ....................... . 7 4 .... 9 9 .... 202-57
C408 (Pickup/Cab)............ ... Beneath center rear edge of bed..................................... . 7 4 .... 9 9 .... 202-57
C408 (Suburban/Utility)...... ... Low er center outside of Endgate.................................... . 7 4 .... 9 9 .... 202-57
C 4 0 9 .............................. ... Beneath rear center o f bed, near Bum per......................... . 7 4 .... 9 9 .... 202-58
C 4 1 1 .............................. ... A t L R o f cab............................................................. . 7 0 .... 9 1 .... 202-58
G R O U N D S:
G103 (G a s)..................... ... R F o f Engine, near Thermostat H o u sin g .......................... . 1 4 .... 18
G 104 (Gas, D ie se l)........... ... R H top center of Cylinder Head......................... ........... . 1 6 .... 20
G 105.............................. ... R F of Engine block..................................................... . 1 3 .... 17
G 112.............................. ... R F of Engine Compartment, at W heelhousing.................. . 2 ..... 5
G 113 .............................. ... O n Radiator Support, near L H Headlam p......................... . 4 ...... 8

G 200.............................. ... Behind L H o f IP, below Fuse Block, on H e B a r.............. . 3 2 .... 43
G 202.............................. ... R H o f IP, mounted to H V A C Plenum Bracket.................. . 5 0 .... 65
G 400.............................. ... R H B Pillar, near D oor Striker...................................... . 5 8 .... 76
G 401.............................. ... Rear o f L H Frame Rail, behind Bum per.......................... . 7 3 .... 96
G 403.............................. ... Rear o f L H Frame Rail, behind Bum per.......................... . 7 3 .... 96
G R O M M ETS:
P 1 0 0 .............................. ... L R o f Engine Compartment, at Bulkhead above C 100
P 1 0 1 .............................. ... R R o f Engine Compartment, at Bulkhead........................ . 7 ...... 12

EXTERIOR LAMPS

S P L IC E S :
S103 (5.0L - H D , 5.7L - H D).. Engine Harness, approx. 13 cm from E G R Valve Breakout,

Breakout

S107 (5.0L, 5.7L) ................ Engine Harness, approx. 35 cm from E G R Valve Breakout,
S107 (6.5L, H D ) .................. Engine Harness, approx. 30 cm from E B C M Breakout,

S107 (6.5L, LD )................... Engine Harness, approx. 24 cm from E B C M Breakout,


S I 1 9 .................................. Forward Lam ps Harness, approx. 16 cm from W indshield

Washer Pum p Breakout, toward L H Headlamp
512 2 ................................ Forward Lam ps Harness, approx. 7 cm from L H Headlamp

Breakout, toward W indshield Washer Pum p
512 3 ................................ Forward Lam ps Harness, approx. 20 cm from L H Park

512 7 ................................ Forward Lam ps Harness, approx. 5 cm from R H Headlamp

Breakout, toward R H Horn
512 8 ................................ Forward Lam ps Harness, approx. 5 cm from R H Headlamp




Breakout





Breakout

Breakout
S210 (G as).......................... IP Harness, approx. 4 cm from A uxiliary Power Outlet

Breakout
5 2 1 4 .................................. IP Harness, approx. 9 cm from Instrument Cluster Breakout
5215 (D iesel)....................... IP Harness, approx. 8 cm from Instrument Cluster Breakout,



Breakout


Breakout


toward C299
S 2 6 7 .................................. IP Harness, approx. 4 cm from Instrument Cluster Breakout

S316 (Suburban/Crew
S322 (Suburban/Crew
Cab/Utility)....................... Dom e Lam p Harness, approx. 25 cm from C411, toward
Dom e Lam p

w/Overhead C on sole ).......... Dom e Lam p Harness, approx. 15 cm from C H M S L

w/o Overhead Console)....... Dom e Lam p Harness, approx. 9 cm from C H M S L Breakout,
toward C411
S410 (2-Door Utility)........... Front-to-Rear Body Harness, approx. 37 cm from R R D oor

Breakout
J410 (4-Door Utility/

EXTERIOR LAMPS

S411 (Chassis C ab ).............. Taillamp Harness, approx. 33 cm from Taillamp Extension
Harness Breakout

5411 (Suburban/Utility).......... Taillamp Harness, approx. 7 cm from Taillamp Trailer Tow

5412 (Chassis C ab)............... Taillamp Harness, approx. 23 cm from Taillamp Extension


5412 (Fleetside/Stepside
w/Dual Rear W heels).......... Taillamp Harness, approx. 23 cm from Taillamp Extension
5413 (Fleetside/Stepside)........ Taillamp Harness, approx. 27 cm from Trailer Harness

Breakout, toward R H Taillamp

S414 (Chassis Cab, H D ) ........ Taillamp Harness, approx. 15 cm from Taillamp Extension
5414 (Fleetside/Stepside)........ Taillamp Harness, approx. 10 cm from Taillamp Extension

5415 ................................ License Lam ps Harness, approx. 14 cm from L H License

Lam p, toward Taillamp Harness Breakout
5416 ................................ License Lam ps Harness, approx. 4 cm from Taillamp

S419 (2-Door U tility )............ Front-to-Rear Body Harness, approx. 20 cm from C H M S L

Breakout

Suburban)............................ Front-to-Rear Body Harness, approx. 5 cm from C H M S L
Breakout
S421 (Chassis C ab)............... Taillamp Harness, approx. 7 cm from Taillamp Extension


S421 (Suburban/Utility).......... Taillamp Harness, approx. 20 cm from Taillamp Extension

S424 (2- D oor U tility)........... Front-to-Rear Body Harness, approx. 15 cm from C H M S L

Breakout

Suburban)............................ Front-to-Rear Body Harness, approx. 10 cm from C H M S L
Breakout
DIAGNOSIS - EXTERIOR LIGHTS

•CH ECK fo r proper in sta lla tio n o f afterm arket
TROUBLESHOOTING HINTS: other systems. See Troubleshooting Procedures.
EXTERIOR LAMPS CARGO LAMPS

1. C H E C K for an open or shorted filament within the 1. C H E C K condition o f C T S Y Fuse. If fuse is open,
inoperative bulb(s). L O C A T E and R E P A IR source of overload. R E P L A C E
2. Rear Lam p system s (Taillam ps, Clearance Lam ps, fuse.
Endgate Lam ps and License Lam ps) all receive 2. C H E C K operation of Dom e and Courtesy Lamps. If
voltage from the same B R N (9) wire and share the inoperative, R E P A IR before proceeding with Cargo
same G round G 401. If on ly one system is not Lam ps diagnosis.
working, L O C A T E and R E P A IR open in w iring bulbs
• C H E C K for a broken (or partially broken) wire
that pertain to that system.
inside of the insulation which could cause system
3. C H E C K co n d itio n o f S T O P / H A Z , P A R K L P S ,
m a lf u n c t io n but p ro ve GOOD in a
T U R N -B /U and Fuse 2 (Pickup) Fuse(s). If fuse(s) is
c o n t in u it y / v o lt a g e c h e c k w ith a s y ste m
open, L O C A T E and R E P A IR source o f overload.
R E P L A C E fuse(s). disconnected. These circuits may be intermittent or
• C H E C K for a broken (or partially broken) wire inside resistive when loaded, and if possible, should be
of the insulation that could cause system malfunction checked by m onitoring for a voltage drop with the
but prove good in a continuity/voltage check with a system operational (under load).
syste m d isco n n e cte d . T h e se c irc u its m ay be • C H E C K for proper installation o f aftermarket
intermittent or resistive when loaded, and if possible, electronic equipm ent w hich m ay affect the
should be checked by monitoring for a voltage drop integrity o f other systems. See Troubleshooting
with the system operational (under load). Procedures.
TAIUSTOP-TURN LAMPS INOPERATIVE (SUBURBAN/UTILITY)

TEST RESULT ACTION
1. C onnect test lam p from O R N Test lamp lights. G O to Step 3.
(1 4 0 ) w ire at T C C / S to p la m p Test lamp does not light. G O to Step 2.
Switch Connector to ground.
2. 'D im Hazard Flasher Switch to O N Hazard Flashers operate. L O C A T E and R E P A IR open in O R N
position. (140) wire between Splice S299 and
TCC/Stoplam p Switch Connector.
Hazard Flashers do not operate. L O C A T E and R E P A IR open in O R N
Splice S299.
3. Connect test lamp from W H T (17) Test lamp lights. G O to Step 4.
w ire at T C C /Stoplam p Sw itch Test lamp does not light. R E P L A C E TCC/Stoplamp Switch.
C on n ector to ground. Actuate
Brake Pedal.
wire at Connector C 266 to ground. Test lamp does not light. L O C A T E and R E P A IR open in W H T
Actuate Brake Pedal.
(17) wire between TCC/Stoplamp
Switch Connector and Connector C266.
5. Connect test lamp from Y E L (18) Test lamp lights. G O to Step 6.
o r D K G R N ( 1 9 ) w ir e at
Test lamp does not light. R E P L A C E Tum/Hazard Switch.
C o n n e c t o r C 2 6 6 to g ro u n d .
EXTERIOR LAMPS
TEST RESULT ACTIO N

6. Connect a self-powered test lamp Test lamp lights V E R IF Y condition of Connectors C l 04
to T e r m i n a l A o f L R / R R and C409. If O K , L O C A T E and
Tail/Stop-Tum Lam p Connector. R E P A IR open in Y E L (18) and D K
G R N (19) wires between Connector
C266 and lamp connector.
Test lamp does not light. L O C A T E and R E P A IR open B L K
(150) wire between lamp connector and
ground.
TAIL/STOP-TURN LAMPS INOPERATIVE (PICKUP)

TEST RESULT ACTIO N
1. C onnect test lam p from O R N Test lamp lights. G O to Step 2.
(1 4 0 ) w ire at T C C / S to p la m p Test lamp does not light. L O C A T E and R E P A IR open in O R N
Switch Connector to ground. (140) wire between IP Fuse Block and
TCC/Stoplam p Switch.
w ire at T C C /Sto p lam p Sw itch Test lamp does not light. R E P L A C E TCC/Stoplam p Switch.
Connector and ground. Actuate
Brake Pedal.
3. Connect a test lamp from L T B L U Test lamp lights. R E P L A C E Tum/Hazard Switch.
(2 0) w ire at C onnector C 2 6 6 Test lamp does not light. G O to Step 4.
Terminal E 2 and ground. Actuate
Brake Pedal.
4. Rem ove Stoplamp Relay. Connect Test lamp lights. G O to Step 5.
test lam p from Term inal E 7 at Test lamp does not light. L O C A T E and R E P A IR open in R E D
Stoplamp Relay and ground. (642) wire between M a xi Fuse 2 and
Stoplamp Relay.
5. Connect test lamp from Terminals Test lamp lights. G O to Step 6.
E 7 - E 9 at Stoplamp Relay. Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire between Stoplamp Relay
and Ground G105.
6. Connect test lamp from Terminal Test lamp lights. G O to Step 7.
D 7 at Stoplamp Relay to ground. Test lamp does not light. L O C A T E and R E P A IR open in W H T
Actuate Brake Pedal. (17) wire between TCC/Stoplamp
Switch and Stoplamp Relay.
7. C onnect a Fused Jum per wire Test lamp lights. R E P L A C E Stoplamp Relay.
between Terminal E 7 and D 9 at Test lamp does not light. L O C A T E and R E P A IR open in L T
Stoplamp Relay. Connect test lamp B L U (20) wire between Stoplamp
fro m L T B L U (2 0 ) w ire at Relay and Connector C266.
Connector C 266 Terminal E 2 to
ground.
TAIL/STOP-TURN LAMPS INOPERATIVE ON ONE SIDE

TEST RESULT ACTION
1. Connect test lamp from Y E L (18) Test lamp lights. G O to Step 4.
or D K G R N (19) wire at affected Test lamp does not light. G O to Step 2.
Tail/Stop-Tum Lam p Connector to
ground. Actuate Brake Pedal.
2. Connect test lamp from Y E L (18) Test lamp lights. L O C A T E and R E P A IR open in Y E L
o r D K G R N ( 1 9 ) w ir e at (18) or D K G R N (19) wire between
C o n n e c t o r C 4 0 9 to g ro u n d . Connector C409 and affected Stoplamp.
TEST RESULT ACTION

3. Connect test lamp from Y E L (18) Test lamp lights. L O C A T E and R E P A IR open in Y E L
o r D K G R N ( 1 9 ) w ir e at (18) or D K G R N (19) wire between
C o n n e c t o r C 1 0 4 to g ro u n d . Connector C l 04 and Connector C409.
Actuate Brake Pedal. Test lamp does not light. L O C A T E and R E P A IR open in Y E L
(18) or D K G R N (19) wire between
Connector C l 04 and Connector C266.
If no open is found, R E P L A C E
Tum/Hazard Switch.
4. Connect self-powered test lam p Test lamp lights. R E P L A C E lamp.
from B L K (150) wire at affected Test lamp does not light. L O C A T E and R E P A IR open in B L K
Tail/Stop-T\im Lam p to ground. (150) wire between lamp and Splice
S411.
PARK/TURN LAMPS INOPERATIVE

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Lam ps operate. G O to Step 3.
Dim m er Switch in P A R K . Observe Lam ps do not operate. G O to Step 2.
F ro n t P a rk / T u rn and M a r k e r
Lamps.
2. Connect test lam p From O R N Test lamp lights. L O C A T E and R E P A IR open in B R N
(2 4 0 ) w ire at T e rm in al H o f (9) wire between Splice S210 and
H e ad lam p and P an e l D im m e r Headlamp and Panel Dim m er Switch
Switch to ground. Connector. If no open is found,
R E P L A C E Headlamp and Panel
Dim m er Switch.
Test lamps does not light. L O C A T E and R E P A IR open in O R N
Headlamp and Panel Dim m er Switch.
3. Connect test lamp from B R N (9) Test lamp lights. L O C A T E and R E P A IR open in B L K
wire at L H Tail/Stop-Tum Lam p (150) wire between Splice S411 and
Connector to ground. Ground G401.
4. Connect test lamp from B R N (9) Test lamp lights. L O C A T E and R E P A IR open in B R N
wire at Connector C 409 to ground. (9) wire between Connector C 409 and
Splice S412.
5. Connect test lamp from B R N (9) Test lamp lights. L O C A T E and R E P A IR open in B R N
wire at Connector C l 04 to ground. (9) wire between Connectors C l 04 and
C409.
Connector C l 04.
TURN SIGNALS/HAZARD FLASHERS INOPERATIVE

TEST RESULT ACTION
1. Turn Ignition Switch to the R U N Turn Signal operates. G O to Step 7.
position. T\im Turn Signal O N. I\im Signal does not operate. G O to Step 2.
EXTERIOR LAMPS
TEST RESULT ACTIO N

2. Connect a test lamp from P N K Test lamp lights. G O to Step 3.
(139) wire at Connector C 266 Test lamp does not light. L O C A T E and R E P A IR open in P N K
Terminal A 2 and ground. (139) wire between IP Fuse B lo ck and
Connector C266.
3. Ensure that Turn Signal is O N. Test lamp does not light. R E P L A C E Tum/Hazard Switch.
Connect a test lamp from L T B L U Test lamp lights. G O to Step 4.
(1508) wire at Connector C 266
Terminal A 3 and ground.
4. Connect a test lamp from L T B L U Test lamp lights. G O to Step 6.
(1508) and B L K (150) wires at Test lamp does not light. G O to Step 5.
Tum/Hazard Flasher Terminals H 9
and G8.
5. E n s u r e T u rn S ig n a l is O N . Test lamp lights. L O C A T E and R E P A IR open in B L K
Connect a test lamp from L T B L U (150) wire between Tum/Hazard
(1 5 0 8 ) w ire at T u rn / H a z a rd Flasher and Ground 200.
Flasher Terminal H 9 and ground. Test lamp does not light. L O C A T E and R E P A IR open in L T
B L U (1508) wire between Tum/Hazard
Flasher and Ground 200.
6. Turn Turn Signal OFF. Connect a Test lamp lights. G O to Step 10.
self-powered test lamp from P P L Test lamp does not light. L O C A T E and R E P A IR open in P P L
(1 697) wire from Turn/Hazard (1697) wire between Turn/Hazard
F la s h e r T e r m in a l H 7 and Flasher and Connector C266.
Connector C266 Terminal E9.
7. Connect a test lamp from O R N Test lamp does not light. L O C A T E and R E P A IR open in O R N
(140) w ire at Connector C 2 6 6 (139) wire between Connector C 266
Terminal E8 and ground. and IP Fuse Block.
8. Turn Hazard Switch O N. Connect Test lamp does not light. R E P L A C E Tum/Hazard Switch.
a test lamp from G R Y (1696) wire Test lamp lights. G O to Step 9.
at Connector C 266 Terminal E l
and ground.
9. Connect a test lamp from G R Y Test lamp lights. R E P L A C E Tum/Hazard Flasher.
( 1 6 9 6 ) w ire at T u rn / H a z a rd Test lamp does not light. L O C A T E and R E P A IR open in G R Y
Flasher Terminal H 8 and ground. (1696) wire between Tum/Hazard
Flasher and Connector C266.
10. T u r n H a z a r d S w i t c h O N . Test lamp lights. R E P L A C E Tum/Hazard Switch.
Reconnect Tum /Hazard Flasher. Test lamp does not lig h t R E P L A C E Tum/Hazard Flasher.
Connect a test lam p from P P L
(1697) wire at Connector C 266
Terminal E 9 and ground.
TURN SIGNALS INOPERATIVE ON ONE SIDE

TEST RESULT ACTION
1. Turn Hazard Flasher Switch O N. A ll lights flash. G O to Step 2.
O b s e r v e l i g h t s o n s i d e A ll lights do not flash. G O to Step 3.
malfunctioning.
2. Turn Hazard Flasher Switch OFF. Test lamp lights. System O K.
Place Ignition Switch in R U N and Test lamp does not light. R E P L A C E Tum/Hazard Switch.
Tum/Hazard Sw itch to side that
does not work. Connect test lamp
from L T B L U (14) or D K B L U
(15) wire at Connector C 266 to
ground.
3. Connect test lamp from L T B L U Test lamp lights. G O to Step 4.
(14) or D K B L U (15) wire at Test lamp does not light. L O C A T E and R E P A IR open in L T
P ark / T u rn or M a rk e r La m p B L U (14) or D K B L U (15) wire
Connector to ground. between affected Park/Tum or M arker
Lam p and Connector C l 02 or between
Connectors C l 02 and C266.
4. Connect test lamp from L T B L U Test lamp lights. C H E C K condition of bulb sockets.
(14) or D K B L U (15) wire to Repair as necessary.
B L K (1 5 0 o r 2 5 0 ) w ire at Test lamp does not light. L O C A T E and R E P A IR open in B L K
Park/Turn or M arker Lamp.
(150 or 250) or B R N (9) wire between
affected Park/Tum or M arker Lam p and
Ground G113 or G112.
ROOF MARKER LAMPS INOPERATIVE

TEST RESULT ACTION
1. Remove each R o o f M arker Lamp, Test lamp lights. G O to Step 2.
o n e at a tim e . C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR the open in the
self-powered test lamp between B L K (250) wire between the
Cavity B for the B L K (250) wire m alfunctioning lamp and Ground G200.
and ground.
2. Connect test lamp between Cavity Test lamp lights. R E P L A C E the malfunctioning bulb.
A for the B R N (9) wire at each Test lamp does not light. L O C A T E and R E P A IR the open in the
R oof M arker Lam p and ground. B R N (9) wire between Splice S210 and
Place the Headlam p and Panel the lamps.
Dim m er Switch in the Park Lam ps
position.
3. Connect an test lam p between Test lamp lights. G O to Step 4.
H e ad lam p and P an e l D im m e r Test lamp does not light. L O C A T E and R E P A IR the open in the
Switch Connector Cavity H for the
B R N (240) wire between the IP Fuse
B R N (240) wire and ground.
B lo ck and the Headlamp and Panel
Dim m er Switch.
4. Place the Headlamp Switch in the Test lamp lights. L O C A T E and R E P A IR the open in the
Park Lam ps position. Connect test B R N (9) wire between the Headlamp
lamp between the Headlamp and and Panel Dim m er Switch and Splice
Panel Dim m er Sw itch Connector S225.
Cavity S and ground.
Test lamp does not light. R E P L A C E the Headlamp and Panel
Dim m er Switch.
8A - 110 - 18 ELECTRICAL DIAGNOSIS___________________________
EXTERIOR LAMPS
CLEARANCE/ENDMARKER LAMPS INOPERATIVE

TEST RESULT ACTION
1. One at a time, remove the bulb Test lamp lights. G O to Step 2.
from each Clearance/Endm arker Test lamp does not light. L O C A T E and R E P A IR the open in the
Lamp. Connect a self-powered test B L K (150) wire between the lamp and
lamp between C avity A for the Ground G401.
B L K (150) wire and ground.
2. Connect test lamp between Cavity Test lamp lights. R E P L A C E the License Lam p bulb.
B for the B R N (9) wire at each Test lamp does not light. L O C A T E and R E P A IR the open in the
la m p and gro u n d . P la ce the B R N (9) wire between Splice S412 and
H e ad lam p and Panel D im m e r the lamp.
Sw itch in the Clearance Lam ps
position.
3. C onnect an test lam p between Test lamp lights. G O to Step 4.
H e ad lam p and Panel D im m e r Test lamp does not light. L O C A T E and R E P A IR the open in the
Sw itch Connector Cavity H for the B R N (240) wire between the IP Fuse
B R N (240) wire and ground. Block and the Headlamp and Panel
Dim m er Switch.
4. Place the Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR the open in the
Dim m er Switch in die Clearance B R N (9) wire between the Headlamp
Lam ps position. Connect test lamp and Panel Dim m er Switch and Splice
between the Headlamp and Panel S210.
Dim m er Switch Connector Cavity Test lamp does not light. R E P L A C E the Headlamp and Panel
S and ground. Dim m er Switch.
ONE LICENSE LAMP INOPERATIVE

TEST RESULT ACTION
1. Rem ove the bulb from the License Test lamp lights. G O to Step 2.
L a m p C o n n e c to r. C o n n e c t a Test lamp does not light. L O C A T E and R E P A IR the open in the
self-powered test lam p between B L K (150) wire between the License
License Lam p Connector Cavity A Lam p Connector and Ground G401.
fo r the B L K (1 5 0 ) w ire and
ground.
2. C o n n e c t te st la m p b e tw e e n Test lamp lights. R E P L A C E the License Lam p bulb.
License Lam p Connector Cavity B Test lamp does not light. L O C A T E and R E P A IR the open in the
for the B R N (9) wire and ground. B R N (9) wire between Splice S415 and
Place the Headlam p and Panel the License Lam p Connector.
position.
BOTH LICENSE LAMPS INOPERATIVE

TEST RESULT ACTIO N
H e ad lam p and P an e l D im m e r Test lamp does not light. L O C A T E and R E P A IR the open in the
Switch Connector Cavity H for the B R N (240) wire between the IP Fuse
B R N (240) wire and ground. Block and the Headlamp and Panel
Dim m er Switch.
2. Place the Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR the oen in the
Dim m er Switch in the Park Lam ps B R N (9) wire between the Headlamp
p o sitio n . C o n n e c t test la m p and Panel Dim m er Switch and Splice
between the Headlamp and Panel S210.
Dim m er Switch Connector Cavity Test lamp does not light. R E P L A C E the Headlamp and Panel
S and ground. Dim m er Switch.
LH CENTER HIGH MOUNTED STOPLAMP (CHMSL) INOPERATIVE

TEST RESULT ACTION
1. Remove the L H C H M S L . Connect Test lamp lights. G O to Step 2.
a self-powered test lamp between Test lamp does not light. L O C A T E and R E P A IR the open in the
the L H C H M S L Connector Cavity B L K (150) wire between the L H
B for the B L K (150) wire and C H M S L Connector and Splice S421.
ground.
2. Connect test lamp between the L H Test lamp lights. R E P L A C E the L H C H M S L bulb.
C H M S L Connector Cavity A for Test lamp does not light.
L O C A T E and R E P A IR the open in the
the W H T (17) wire and ground. W H T (17) wire between Splice S422
Actuate the Brake Pedal. and the L H C H M S L connector.
RH CENTER HIGH MOUNTED STOPLAMP (CHMSL) INOPERATIVE

TEST RESULT ACTION
1. Remove the R H C H M S L . Connect Test lamp lights. G O to Step 2.
a self-powered test lamp between Test lamp does not light. L O C A T E and R E P A IR the open in the
the R H C H M S L Connector Cavity B L K (150) wire between the R H
B for the B L K (150) wire and C H M S L connector and Splice S421.
ground.
2. Connect test lamp between the R H Test lamp lights. R E P L A C E the R H C H M S L bulb.
C H M S L Connector Cavity A for
Test lamp does not light. L O C A T E and R E P A IR the open in the
the W H T (17) wire and ground.
W H T (17) wire between Splice S422
Actuate the Brake Pedal. and the R H C H M S L connector.
CENTER HIGH MOUNTED STOPLAMPS (CHMSL) INOPERATIVE

TEST RESULT ACTIO N
1. Remove the L H C H M S L . Connect Test lamp lights. L O C A T E and R E P A IR the open in the
a self-powered test lamp between B L K (150) wire between Splice S421
the L H C H M S L Cavity A for the and Ground G400.
W H T (17) wire and ground.
Test lamp does not light. L O C A T E and R E P A IR the open in the
W H T (17) wire between Splices S410
and S422.
8A ■ 110 - 20 ELECTRICAL DIAGNOSIS_______________________________ _
EXTERIOR LAMPS
CHMSL LAMPS ARE ON WITH BRAKE PEDAL RELEASED

TEST RESULT ACTIO N
1. Disconnect the Connector at the Test lamp lights. A D J U S T or R E P L A C E the
TCC/Stoplam p Sw itch. Connect TCC/Stoplamp Switch.
test lamp between TCC/Stoplamp Test lamp does not light. L O C A T E and R E P A IR the short to
Switch Connector Cavity F for the voltage on the W H T (17) wire between
W H T (17) wire and ground. Place the TCC/Stoplam p Switch and C H M S L
the Ignition Switch in R U N . Lamps.
LH TURN SIGNAL INDICATOR INOPERATIVE

TEST RESULT ACTIO N
1. Disconnect Connector C 266 at the Test lamp lights. If the L H Turn Signal Indicator bulb is
Steering Column. Disconnect the good, R E P L A C E the Instrument
C o n n e c to r at the In stru m e n t Cluster.
Cluster. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR the open in the
test lamp between Connector C266 L T B L U (14) wire between Splice
Cavity A 7 and Instrument Cluster S267 and the Instrument Cluster.
Connector C avity 3 for the L T
B L U (14) wire.
RH TURN SIGNAL INDICATOR INOPERATIVE

TEST RESULT ACTIO N
1. Disconnect Connector C266 at the Test lamp lights. If the R H Turn Signal Indicator bulb is
Steering Column. Disconnect the good, R E P L A C E the Instrument
C o n n e c to r at the In stru m e n t Cluster.
Cluster. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR the open in the
test lamp between Connector C266 D K B L U (15) wire between Splice
Cavity A 6 and Instrument Cluster S214 and the Instrument Cluster.
Connector Cavity 32 for the D K
B L U (15) wire.
CARGO LAMPS INOPERATIVE

TEST RESULT ACTIO N
1. Turn Cargo/Dome Lam p Switches Test lamp lights. G O to Step 2.
to O N. Connect test lamp from Test lamp does not light. G O to Step 3.
D K B L U / W H T (1 4 9 ) w ire at
Cargo Lam p Connector to ground.
2. C o n n e c t test lam p fro m D K Test lamp lights. R E P L A C E bulb.
B L U / W H T (149) wire to W H T Test lamp does not light. L O C A T E and R E P A IR open in W H T
(1 5 6 ) w ire at C a r g o L a m p (156) wire from Cargo Lam p to Splice
Connector. S322.
3. Connect test lamp from O R N (40) Test lamp lights. G O to Step 4.
w ire at C a rg o L a m p S w itc h Test lamp does not light. L O C A T E and R E P A IR open in O R N
Connector to ground. (40) wire between Cargo Lam p Switch
Connector and Splice S242.
4. C o n n e c t test lam p fro m D K Test lamp lights. L O C A T E and R E P A IR open in D K
B L U / W H T (149) wire at Cargo B LU /W H T (149) wire from Cargo
L a m p S w it c h C o n n e c to r to Lam p Switch Connector to Cargo
ground. Lam p Connector.
Test lamp does not light. R E P L A C E Cargo Lam p Switch.
SPOTLAMP(S) INOPERATIVE
TEST RESULT ACTIO N
1. Connect a test lamp from O R N Test lamp lights. R E P L A C E Spotlamp light bulb.
(940) wire at cavity J1 of the IP Test lamp does not light. L O C A T E and R E P A IR the open in
Fuse B lo c k and ground o f the O R N (940) wire between IP Fuse
inoperative spotlamp. Block and Spotlamp.
CIRCUIT OPERATION S I 22 and the many lamps connected in parallel to ground.

These lamps provide low resistance paths to ground. The
TAIUSTOP-TURN, MARKER, ENDGATE M arker Lam p w ill flash with the Turn Lam ps. The lamps
CLEARANCE, PARK/TURN AND LICENSE used for the ground path w ill not flash, however, since the
LAMPS voltage drop across the M arker Lam p is much higher than
Voltage is supplied through the P A R K L P Fuse to the that across the other lamps.
Headlamp and Panel Dim m er Switch at all times, when the W hen the Headlamp and Panel Dim m er Switch is in
Headlamp and Panel Dim m er Switch is in the P A R K or either P A R K or H E A D , voltage is supplied through the
H E A D position, voltage is supplied to the Tail/Stop-Tum, P A R K L P Fuse, Headlamp and Panel Dim m er Switch and
Marker, Endgate Clearance, Park/Tum and License Lamps. Sp lice 122 to the M a rk e r and P ark Lam ps. If the
Tum/Hazard Switch is in T U R N LE FT , the L F M arker
STOPLAMPS Lam p w ill have voltage at both connections and w ill go
Voltage is supplied at all times through the ST O P /H A Z out. W hen the flasher removes voltage to the Tumlamp, the
Fuse to the TCC/Stoplamp Switch. W hen the Brake Pedal M arker Lam p w ill be grounded through the Tumlamp and
is depressed, the contacts in the TCC/Stoplamp Switch w ill go on. In this way, the L F M arker Lam p w ill flash on
close. Voltage is supplied (from the Stoplamp Relay on when the L F Park/Tumlamp goes off, and off when the
Pickups, the TCC/Stoplamp Switch on all except Pickups) Tumlamp goes on.
through the Tum /Hazard Sw itch to the L H and R H W ith the Tum /Hazard Sw itch in T U R N R IG H T ,
Stoplamps, and the Stoplamp lights. If a Turn Signal is on, voltage w ill be supplied to the R H lamps in the same way.
the Stoplamp on that side w ill flash as a Turn Signal. The
other Stoplamp w ill serve as a Stoplamp. HAZARD LAMPS
V o ltage is su p p lie d at a ll tim es, th ro u gh the
TURN SIGNAL LAMPS ST O P / H A Z Fuse and the Tum /Hazard Flasher to the
W ith the Ignition Switch in R U N or STA R T, voltage is normally open contact of the Hazard Flasher Switch in the
supplied through the T U R N -B /U Fuse and Tum/Hazard Tum/Hazard Switch. W ith the Hazard Switch in H A Z A R D
Flasher to the norm ally closed contact o f the Hazard F L A S H , voltage is supplied to both Front and Rear
Flasher Switch in the Tum/Hazard Switch. Tumlamps. A ll of the Tumlamps and Turn Indicators flash
With the Turn Signal Switch in L H Thm position, on and off.
voltage is supplied to both the L H Turn Indicator and the The Front M arker Lam ps flash in H A Z A R D F L A S H
L F Park/Tum Lam p L T B L U (14) wire. Voltage is supplied just as they did in T U R N R IG H T and T U R N LEFT . If the
to the L R Turn Lam p Y E L (18) wire. Headlamp and Panel Dim m er Switch is in “O F F ” , they
The lamps go on immediately. They begin to flash Flash on when the Hazard Lam ps are on. If the Headlamp
when the current flow heats up the tim ing element in the and Panel Dim m er Switch is in either the P A R K or H E A D
flasher and it repeatedly opens and closes the circuit. position, they flash on when the Hazard Lam ps are off and
The voltage supplied to the L F Park/Tum Lam p w ill off when the Hazard Lam ps are on.
also be supplied to the L F M arker Lamp. If the Headlamp In H A Z A R D , the circuit is alw ays open, and the
and Panel Dim m er Switch is in the O F F position, the L F Tum/Hazard Rasher controls the lamps.
M arker Lam p w ill find a path to ground through Splice
EXTERIOR LAMPS
CARGO LAMPS ROOF WIRING

Voltage is supplied at all times through the C T S Y Fuse If the vehicle is equipped with option 6F5 as part o f
3 to the Cargo Lam p Switch. W hen the Cargo Lam p the police package Z56, there w ill be an extra w iring
Sw itch is turned O N , voltage flow s through the switch to harness provided fo r any ro o f m ounted afterm arket
the lamp. G round is supplied b y the Courtesy Lam p accessories. The harness begins under the R H side o f the
Switch, (part o f the Headlamp and Panel Dim m er Switch), IP, coiled on the floor. The harness is then routed under the
Illum inated Entry M odule, or the Remote Keyless Entry R H Front D oor S ill Plate, up the R H B Pillar, across the
M odule through the Power D oo r Jamb Sw itches). roof bow, and looped 32 inches rearward o f W indshield
centerline.
SPOT LAMPS
GRILLE LAMPS
If die vehicle is equipped with either option 7 X 6 or
A s part o f the police package Z 56 there w ill be an
7 X 7 as part o f the police package Z56, there w ill be either
extra w iring harness and relay provided for any aftermarket
one or two Spot Lam ps mounted on the A Pillar. Voltage is
accessories, which would include grille lights and grille
applied at all times from Fuse B L A N C through B L K (940)
speaker. The harness starts under the R H side o f the IP,
w ire to the Sp o t L a m p (s). The Sp o t L a m p (s) are
coiled on the floor. The harness is then routed through a
perm anently case grounded. W h en the Sp o t Lam p
grommet in the Bulkhead, down the R H side o f the Engine
thumbswitch (located on the inside end o f the Spotlamp Compartment, and looped behind the R H side of the Grille.
assem bly) is moved, the circuit is now complete.
BLANK
BACKUP LIGHTS
I 1
HOT IN RUN OR START
T
.8 IT GRN | 24
.8 LT GRN
(EXCEPT
03H-97
4208W0560
ELECTRICAL DIAGNOSIS 8A - 1 1 2 - 1

Backup Lamp, L H Cab Chassis Rear of vehicle............................................................ 73.... .. 97
Backup Lamp, L H
Pickup/Utility.................... Rear of vehicle............................................................ 74.... .. 99
Backup Lamp, R H Cab

C h assis............................. Rear of vehicle............................................................ 7 3 ..... 97
Backup Lamp, R H
Pickup/Utility.................... Rear of vehicle............................................................ 74....,.. 99
Backup Lam p Switch (MG5).... L H o f Transmission, below Shift Tow er........................... 27.... .. 38
Backup Lam p Switch (M W 3 )... L H top of Transm ission................................................ 2 6 ..... 36
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. 3 2 ..... 43
C O N N EC T O R S:

at Bulkhead............................................................. 4 ....... 8 ..... . 202-0
C 1 0 3 .................................. Engine Harness to Fuel Pum p Motor, L R of Engine

Compartment, under Brake Master C ylinder................... 1 4 ... . 18... . 202-49
C 2 6 6 .................................. IP Harness to Steering Colum n Harness, L H of Steering
Colum n, near Bulkhead.............................................. 3 2 ... , 4 3 ... . 202-14
:2 71.................................. In-line to Spotlamps (Z56, Police Package)....................... . 202-16
J 4 0 9 .................................. Beneath rear center o f bed, near Bum per......................... 7 4 ... . 9 9 ... . 202-58
G R O U N D S:
G 401.................................. Rear of L H Frame Rail, behind Bum per.......................... 7 3 ... . 96

S P L IC E S :



S160 (7.4L) ........................ Engine Harness, approx. 28 cm from Fuel Injector Breakout,
S411 (Chassis C ab )............... Taillamp Harness, approx. 33 cm from Taillamp Extension

Harness Breakout

S411 (Suburban/Utility)......... Taillamp Harness, approx. 7 cm from Taillamp Trailer Tow

S414 (Chassis C ab )....... ........ Taillamp Harness, approx. 5 cm from Taillamp Extension
BACKUP LIGHTS


DIAGNOSIS - BACKUP LIGHTS
TROUBLESHOOTING HINTS: • R E F E R to M anual Transm ission section for Backup

lamp Switch access.
(P erfo rm b efo re beginnin g S ystem D iag n o sis) • C H E C K for a broken (or partially broken) wire inside
1. C H E C K condition of T U R N B/U Fuse 16. If fuse is of the insulation which could cause system failure but
open, L O C A T E and R E P A IR source o f overload and prove “G O O D ” in a continuity/voltage C H E C K with
R E P L A C E fuse. a system disconnected. These c irc u its m ay be
2. C H E C K Back up Lam ps for damage to filament or intermittent or resistive when loaded, and if possible,
corrosion between bulb and socket. should be checked by monitoring fuse voltage drop
3. C H E C K adjustment of Back up Lam p Switch. with the system operational (under load).
4. C H E C K that Ground G401 is clean and tight. • C H E C K fo r proper in sta lla tio n o f afterm arket
• R E F E R to Lighting System s section for Back up electronic equipment which may affect the integrity o f
Lam p access. other systems. See Troubleshooting Procedures.
• R E F E R to Autom atic T ra n sm issio n section for
Park/Neutral Position Backup Lam p Switch access.
LH AND RH BACK UP LAMPS ARE INOPERATIVE

TEST RESULT ACTION
1. Disconnect Backup Lam p Switch Test lamp does not ligh t L O C A T E and R E P A IR open in P N K
Connector. Place Ignition Switch (139) wire between IP Fuse B lo ck and
in R U N . Connect a test lamp from Backup Lam p Switch.
Terminal C (A/T) or Terminal B Test lamp lights. G O to Step 2.
(M /T) to ground.
2. Connect a test lamp from Backup Backup Lam p Lights. R E P L A C E Backup Lam p Switch (M/T)
Lam p Switch Connector Terminal or Park/Neutral Position Switch and
F (A/T) or Terminal A (M/T) to Backup Lam p Switch (A/T).
B +. Backup Lam p does not light. L O C A T E and R E P A IR open in L T
G R N (24) wire between Backup Lam p
Switch and Backup Lamps. If O K ,
(150) wire between Backup Lam ps and
Ground G401.
CIRCUIT OPERATION applied to the L H and R H Backup Lam ps, which are
permanently grounded. W hen voltage is applied to L T G R N
BACKUP LAMPS (24), the Backup Lam ps are on. L T G R N (24) also supplies
W hen the Ignition Sw itch is in R U N , voltage is input to the Electrochromatic Rearview M irror Dim m ing
applied through the T U R N B/U Fuse to the Backup Lam p function. Connection is also provided for the Trailer-Tow
Sw itch. W ith the Transaxle in R E V E R S E , voltage is capability.
INTERIOR LAMPS
REGJEXTENDED CAB LAMPS
INTERIOR LAMPS
POWER WINDOW SWITCH ILLUMINATION
■— " 1 IP FUSE
PARK LPS | BLOCK
FUSE 9 |
20 A |
_______I
.8 240
ORN
Hr \
r — p r --------- n headlamp
I \ K2p I ano_panel
I \ SWITCH | DIUMEB
l * > isassM
INTERIOR LAMPS
SUBURBAN/UTILITY/CREW CAB BASE
TO PAGE
8 A -1 1 4 -8
4208W0576
INTERIOR LAMPS
SUBURBAN UTILITY/CREW CAB WITH AUXILIARY UGHTING
INTERIOR LAMPS
OVERHEAD CONSOLE
INTERIOR LAMPS OVERHEAD CONSOLE

FROM PAGE 8 A -I1 4 - 5
A \
BODY
GRODNO
03-10-
4206W0879
INTERIOR LAMPS
UNDERHOOD AND REEL LAMP/CIGAR UGHTER/AUXIUARY POWER FEED
HOT AT ALL TIMES I
ENGINE IP
GROUND GROUNO
03-20-97
4208W 0580
INTERIOR LAMPS
W/INTERIOR LAMP CONTROL MODULE
HOT IN RUN. BULB TEST OR START
03-10-97
4208W0581
INTERIOR LAMPS
ILLUMINATED VANITY MIRRORS
HOT AT ALL TIMES
03*10-97
4206W0582
8A - 1 1 4 - 1 0 ELECTRICAL DIAGNOSIS
INTERIOR LAMPS

A sh Tray L am p .................... In Ash Tray Housing.............................................................. 4 9 .... .. 64
Cigar Ligh te r....................... Lower RH center of IP, LH of Ash Tray........................... 4 9 .... .. 64
Convenience Center.............. Under LH of IP, on Bulkhead.............................................. 3 3 .... .. 44
Courtesy Lam p, L H IP .......... Under LH of IP........................................................................ 4 2 .... .. 54
Courtesy Lam p, R H IP .......... Under RH of IP ....................................................................... 4 2 .... .. 54
Courtesy Lamp, L F Door........ LH of LF Door, midway u p ................................................. 6 1 .... .. 79
Courtesy Lamp, L R D o o r....... LH of LR Door Trim, midway u p ....................................... 6 2 .... .. 80
Courtesy Lam p, R F D o o r....... RH of R F Door, midway up................................................. . 6 1 .... .. 79
Courtesy Lam p, R R D o o r...... RH of RR Door Trim, midway up........................................ 6 2 ....... 80
Package, Z 5 6 )................... Approx. 22 cm from Windshield centerline, in Headliner. 6 0 ....... 78
Dom e Lam p, Rear (Police
Package, Z 5 6 )................... Approx. 22 cm from Windshield centerline, in Headliner. 5 9 ....... 77
D oor Jamb Switch, C a rgo ...... Rear Body Opening, part of RR Cargo Door Contactor... 7 6 .....,. 102
D oor Jamb Switch, L F .......... At LH end of IP........................................................................ 4 5 ....... 59
D oor Jamb Switch, L R .......... Center inside edge of LH B Pillar....................................... 6 8 .....„ 88
D oor Jamb Switch, R F .......... At RH end of IP ...................................................................... 4 5 .....„ 59
D oor Jamb Switch, R R .......... Center inside edge of RH B Pillar........................................ 6 8 ..... . 88
Sw itch............................. Lower LH of IP ........................................................................ 3 2 ..... . 43 ....... 202-34
M o d u le ............................ Under center of IP ................................................................... 3 8 ..... . 50 ...... 202-66
Illuminated Vanity M irror,
LH................................... Part of LH Sunvisor................................................................. 5 5 ..... . 70
Illuminated Vanity M irror,
R H .................................. Part of RH Sunvisor................................................................ 5 5 ..... . 70
IP Compartment B o x Lam p .... In IP Compartment Box
IP Fuse B lo ck ...................... LH of IP, near LF Door Jamb Switch................................. 3 2 ..... . 43
Overhead C on sole ................. At top center of Windshield Centerline............................... 5 3 ..... . 68
Switch, M aster................... On LF Door, near center of A Pillar
Sw itch............... .............. On LF Door, below Inside Door Handle............................. 6 1 ..... 7 9 ... . 202-37,
68

Receiver........................... Under center of IP, R H of Knee Bolster 2 7 ..... 43 ... . 202-45

M irror Sw itch.................... On L F Door, below Inside D oor Handle
Underhood Fuse-Relay Center.. L R of Engine Compartment, on Fender............................ 5 ...... 9


Underhood Lam p.................. Under R H of H o o d ...................................................... 7 ..... 12

R e a r................................ L F Door, below Inside D oor Handle, part of Power W indow
Master Sw itch .......................................................... 6 1 .... 7 9 .... 202-69
CONNECTORS:
C 2 0 6 .................................. Inside lower L H A Pillar............................................... 6 1 .... 7 9 .... 202-50,
51
C 2 1 5 .................................. Inside lower R H A P illa r.............................................. 6 1 .... 7 9 .... 202-52
C 2 9 8 .................................. Behind L H o f IP, near Convenience Center...................... 3 2 .... 4 3 .... 202-17,

18
C 2 9 9 .................................. Behind R H of IP, above H V A C Evaporator H o u sin g.......... 4 3 .... 5 6 .... 202-19
C 3 0 1 .................................. A t L F K ic k Panel........................................................ 4 7 .... 6 2 .... 202-20,

56
C 3 0 2 .................................. A t L F K ick Panel........................................................ 4 7 .... 6 2 .... 202-56
C 4 1 1 .................................. A t L R of cab.............................................................. 7 0 .... 9 1 .... 202-58
C 4 9 6 .................................. In R H B Pillar............................................................ 6 2 .... 80.... 202-58
C 4 9 8 .................................. L H B P illar............................................. ................... 6 2 .... 8 0 .... 202-59
GROUNDS:
G 105 .................................. R F of Engine block...................................................... 1 3 .... 17
G 200 .................................. Behind L H of IP, below Fuse Block, on Tie B a r............... 3 2 .... 43
G 202 .................................. R H of IP, mounted to H V A C Plenum Bracket................... 5 0 .... 65
G 400 .................................. R H B Pillar, near Door Striker....................................... 5 8 .... 76
SPLICES:
S 113................................... Engine Harness, approx. 19 cm from E B C M Breakout



Breakout
S162 (4.3L, 5.0L, 5.7L - LD)... Engine Harness, approx. 17 cm from Starter Solenoid
S I 62 (5.0L -H D, 5.7L - HD).... Engine Harness, approx. 43 cm from L H Oxygen Sensor

INTERIOR LAMPS

S I 62 (7.4L - A/T)............... .. Engine Harness, approx. 40 cm from L H O xygen Sensor
S I 62 (7.4L - M /T ).............. .. Engine Harness, approx. 15 cm from R H Bank O xygen

S 2 0 4 ................................. .. IP Harness, approx. 10 cm from Steering Colum n Harness

Breakout
S 2 0 8 ................................. .. IP Harness, approx. 6 cm from IP Compartment B ox Lam p

Breakout
S 2 0 9 ................................. .. IP Harness, approx. 13 cm from IP Compartment B ox

Lam p Breakout
S210 (D iesel)...................... ,. IP Harness, approx. 14 cm from Steering Colum n Harness

Breakout
S210 (G as)......................... ,. IP Harness, approx. 4 cm from Auxiliary Power Outlet

Breakout
S 2 1 3 ................................. . IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
S 2 1 8 ................................. . IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S 2 4 2 ................................. . IP Harness, approx. 12 cm from Inflatable Restraint Switch

Breakout
S 2 4 6 ................................. . Crossbody Harness, approx. 22 cm from L F D oor Harness

Breakout
S 2 4 7 .................................. . Crossbody Harness, approx. 6 cm into L H D oor Harness

Breakout
S 2 4 8 ................................. . Crossbody Harness, approx. 10 cm from L F D oor Harness

Breakout
S 2 5 1 ................................. . Crossbody Harness, approx. 13 cm right of L F D oor

S 2 5 9 ................................. . Crossbody Harness, approx. 7 cm into Seat Belt Switch,

toward C299
S262 (Crew C a b )................. . Crossbody Harness, approx. 19 cm from Seat Belt Switch
Breakout, toward IP Harness Breakout
S262 (Suburban/Utility)......... . Crossbody Harness, approx, 25 cm from Seat Belt Switch


U tility)............................ .. IP Harness, approx. 4 cm from Instrument Cluster Breakout,
S264 (Gas, Suburban/Utility)..... IP Harness, approx. 8 cm from Instrument Cluster Breakout,

S 3 1 2 .................................. . Illuminated Vanity M irror Jumper Harness, approx. 4 cm


S316 (Suburban/Crew
S 3 2 0 .................................. Dom e Lam p Harness, approx. 11.5 cm from C411, toward

Dom e Lam p
S320 (Crew C a b ).................. Dom e Lam p Harness, approx. 10 cm from C411, toward
Dom e Lam p
S 3 2 1 .................................. Dom e Lam p Harness
S322 (Suburban/Crew
Cab/Utility)....................... Dom e Lam p Harness, approx. 25 cm from C411, toward
Dom e Lam p

w/Overhead C on sole ).......... Dom e Lam p Harness, approx. 15 cm from C H M S L

w/o Overhead Console)....... Dom e Lam p Harness, approx. 9 cm from C H M S L Breakout,
toward C411
S410 (2-Door Utility)............. Front-to-Rear Body Harness, approx. 37 cm from R R D oor

Breakout
S410 (4-Door U tility/

S417 (2-Door Utility)............. Front-to-Rear Body Harness, approx. 34 cm from Front

Dom e Lam p Breakout, toward C301 Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 20 cm into Crossbody
Harness Breakout
S426 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 13 cm from Front



w/Overhead C o n so le ).......... Dom e Lam p Harness, approx. 13 cm from C H M S L

w/o Overhead C onsole)....... Dom e Lam p Harness, approx. 22 cm from C H M S L

w/E55 w/o C 6 9 )................ Front-to-Rear Body Harness, approx. 12 cm from Rear
Breakout
INTERIOR LAMPS

S 5 0 0 ................. Inside L F D oor Harness, approx. 8 cm from Tweeter
Speaker Breakout, toward L F W indow Regulator............ 61 79
S 5 0 2 ................. Inside L F D oor Harness, approx. 4 cm from Tweeter

Speaker Breakout, toward L F W indow Regulator............ 61 79
DIAGNOSIS - INTERIOR LAMPS
TROUBLESHOOTING HINTS: • C H E C K for a broken (or partially broken) wire inside

1. C H E C K the condition of the C IG L T R Fuse 13, o f the in su la tio n w h ich c o u ld cau se syste m
G A U G E S Fuse 4, C T S Y Fuse 3, H O R N Fuse, and malfunction but prove G O O D in a continuity/voltage
P A R K L P S Fuse 9. If any fuse(s) is open, L O C A T E check with a system disconnected. These circuits may
and R E P A IR source of overload. R E P L A C E fuse(s). be intermittent or resistive when loaded, and if
2. C H E C K that Grounds G105, G200, G202, and G400 possible, should be checked by m onitoring for a
are clean and tight. voltage drop with the system operational (under load).
3. C H E C K for open filaments in inoperative lamps. If IP • C H E C K fo r proper in sta lla tio n o f afterm arket
Compartment B o x Lam p remains O N with the switch electronic equipment which may affect the integrity of
O FF, R E P L A C E the IP Compartment B o x Lamp. If other systems. See Troubleshooting Procedures.
Underhood Reel Lam p remains O N with the switch
O FF, R E P L A C E the Underhood Reel Lamp.
OVERHEAD CONSOLE/COURTESY/DOME LAMP(S) INOPERATIVE

TEST RESULT ACTION
1. M ove Courtesy Lam p Switch to Lam ps light. V G O to Step 2.
the O N position. Lam ps do not light. G O to Step 3.
One or more lamps do not light. C H E C K for an open in O R N (40) wire
between splice and affected lamp(s) or
in W H T (156) wire between splice and
affected lamp(s) or in B L K (150)
between affected lamp and Ground
G400. If only one lamp is inoperative
and w iring is good, R E P L A C E lamp.
2. M ove Courtesy Lam p Switch to Lam ps light. System O K.
the O F F position. M ake sure that Lam ps do not light. G O to Step 5.
the Dom e Lam p Defeat Switch is
off. Open and close each door and Lam ps inoperative through one or more C H E C K for an open in P P L (328) wire
note whether or not the lamp(s) o f the D oor Jamb Switches. between Splice and affected D oor Jamb
light. Switch(es). If O K , R E P L A C E affected
D oor Jamb Switch.
3. B a ckp ro b e F ro n t D om e Lam p Test lamp does not light. L O C A T E and R E P A IR open in O R N
Connector with a test lamp from (40) wire between Splice S242 and IP
O R N (40) wire to ground. Fuse Block.
TEST RESULT ACTION

4. Backprobe Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR open in W H T
Dim m er Switch Connector with a (156) wire between Headlamp and
test lamp from Cavity M to B+. Panel Dim m er Switch and Splice S209.
Test lamp does not light. C H E C K for an open in B L K (150)
wire between Headlamp and Panel
Dim m er Switch and Ground G200. If
O K , R E P L A C E Headlamp and Panel
Dim m er Switch.
5. W ith d o o r op e n , d isc o n n e c t Test lamp lights. G O to Step 8.
Interior Lam p C ontrol M od ule Test lamp does not light. G O to Step 6.
Connector. Connect a self-powered
test lam p from In te rior Lam p
B to ground (ensure that the Dom e
Lam p Defeat Switch is O FF).
6. Disconnect Headlam p and Panel Test lamp lights. G O to Step 7.
D im m e r S w it c h C o n n e c to r. Test lamp does not light. L O C A T E and R E P A IR open in G R Y
Connect a self-powered test lamp (157) wire between Headlamp and
from Headlamp and Panel Dim m er Panel Dim m er Switch and Interior
Switch Cavity B to Interior Lam p Lam p Control Module.
B.
7. Reconnect Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR open in B L K
Dim m er Switch Connector. U sing (150) wire between Headlamp and
a s e lf - p o w e r e d te st la m p , Panel Dim m er Switch and Ground
backprobe Cavities B to L. G200.
Test lamp does not light. R E P L A C E Headlamp and Panel
Dim m er Switch.
8. W ith In t e rio r L a m p C o n tro l Test lamp lights. G O to Step 9.
M odule Connector disconnected, Test lamp does not light. L O C A T E and R E P A IR open in W H T
connect a test lamp from Cavity E (156) wire between Interior Lam p
to ground. Control M odule and Splice S246.
Interior Lam p C on trol M od ule Test lamp does not light. L O C A T E and R E P A IR open in O R N
Cavity C and ground. (40) wire between Interior Lam p
Control M odule and Splice S248.
10. Connect a self-powered test lamp Test lamp lights. R E P L A C E Interior Lam p Control
between Interior Lam p Control Module.
M odule Cavity D and ground. Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire between Interior Lam p
Control M odule and Ground G202.
OVERHEAD CONSOLE/COURTESY/ DOME LAMP(S) REMAIN ON

TEST RESULT ACTION
1. Disconnect Headlam p and Panel Lam ps remain O N. L O C A T E and R E P A IR short to ground
Dim m er Switch Connector. in W H T (156) wire.
Lam ps turn OFF. G O to Step 2.
2. Reconnect Headlam p and Panel Lam ps remain O N. R E P L A C E Headlamp and Panel
Dim m er Switch Connector. M ove Dim m er Switch.
Dotne Lam p Defeat Switch to ON. Lam ps turn OFF. G O to Step 3.
INTERIOR LAMPS
TEST RESULT ACTION

3. M ove Dom e Lam p Defeat Switch Lam ps turn O F F with one of the Door R E P L A C E affected D oor Jamb Switch.
to O FF. D isconnect each D oo r Jamb Switches disconnected.
Jamb Switch one at a time and Lam ps remain O N after all of the D oor G O to Step 4.
note if the lamps turn O F F as each Jamb Switches are disconnected.
one is disconnected.
4. U sin g a self-powered test lamp, Test lamp lights. L O C A T E and R E P A IR short to ground
backprobe Cavity B of the Interior in G R Y (157) wire between Interior
Lam p Control M odule to ground. Lam p Control M odule and Headlamp
Ensure D o o r Jamb Switches are and Panel Dim m er Switch.
disconnected. Test lamp does not light. R E P L A C E Interior Lam p Control
Module.
ILLUMINATED ENTRY SYSTEM INOPERATIVE (DOME LAMPS OPERATIVE)

TEST RESULT ACTION
1. W ith doors closed and Ignition Test lamp lights. L O C A T E and R E P A IR short to power
Sw itch in O F F position, backprobe in P N K (39) wire to IP Fuse Block.
C avity A o f die Interior Lam p Test lamp does not light. R E P L A C E Interior Lam p Control
Control M odule using a test lamp. Module.
ILLUMINATED VANITY MIRROR INOPERATIVE

TEST RESULT ACTION
1. Connect a test lamp from O R N Test lamp lights. G O to Step 2.
(40) wire from LH /R H Illuminated Test lamp does not light. L O C A T E and R E P A IR open in O R N
V a n ity M ir r o r C o n n e c to r to (40) wire from LH /R H Illuminated
ground. Vanity M irror to IP Fuse Block.
2. D iscon n e ct L H / R H Illum inated Test lamp lights. R E P L A C E bulb.
Vanity M irro r Connector. Connect Test lamp does not light. L O C A T E and R E P A IR open in B L K
a self-pow ered test lam p from (150) wire from Illuminated Vanity
Cavity B to ground. M irror to Ground G200.
CIGAR LIGHTER INOPERATIVE

TEST RESULT ACTION
1. D is c o n n e c t C ig a r L ig h t e r Test lamp does not light. L O C A T E and R E P A IR open in O R N
Connector. Connect a test lamp (640) wire between IP Fuse Block and
from C ig a r L ig h te r C onnector Cigar Lighter.
Cavity A to ground. Test lamp lights. C H E C K for an open in B L K (150)
wire between C igar Lighter and Ground
G200. If O K , R E P L A C E C igar Lighter.
IP COMPARTMENT BOX LAMP INOPERATIVE

TEST RESULT ACTION
1. Disconnect IP Compartment B ox Test lamp lights. C H E C K for an open in O R N (40) wire
Lam p Connector. Connect a test between IP Compartment B ox Lam p
lamp from IP Compartment B ox and IP Fuse Block. If O K , R E P L A C E
Lam p Connector Cavity A to B+. IP Compartment B o x Lamp.
(150) wire between IP Compartment
B o x Lam p and G200.
UNDERHOOD (REEL) LAMP OPERATIVE

TEST RESULT ACTION
1. D isc o n n e c t U n d e rh o o d (R e e l) Test lamp does not light. L O C A T E and R E P A IR open in O R N
Lam p Connector. Connect a test (740) wire between Underhood Reel
lamp from Underhood Reel Lam p Lam p and Underhood Fuse-Relay
Connector Cavity A to ground. Center.
Test lamp lights. C H E C K for an open in B L K (150)
wire between Underhood (Reel) Lam p
and G105. If O K , R E P L A C E
Underhood (Reel) Lamp.
COMPONENT ILLUMINATION LAMPS INOPERATIVE

TEST RESULT ACTION
1. Turn Headlamp and Panel Dim m er A ll Component Illum ination Lam ps are G O to Step 2.
Switch to the P A R K position. inoperative.
One or more Component Illum ination C H E C K for an open in B R N (9) or
Lam p(s) is inoperative. B L K (150) wire between splice and
affected lamp(s). If O K , R E P L A C E
affected lamp(s).
2. D is c o n n e c t A s h T ra y L a m p Test lamp lights. L O C A T E and R E P A IR open in B L K
Connector. Connect a test Lam p (150) wire between Lam p and Ground
from A sh Tray Lam p Connector G 200 or G202.
Cavity A to ground. Test lamp does not light. L O C A T E and R E P A IR open in B R N
(9) wire between Headlamp and Panel
Dim m er Switch and lamp.
CIRCUIT OPERATION COMPONENT ILLUMINATION LAMPS

Voltage is supplied at all times from the C T S Y Fuse 3 W hen the Headlam p and Panel Dim m er Switch is
to the Courtesy Lam ps, Dom e and Reading Lam ps, and IP turned to the P A R K or H E A D position, voltage is applied
Compartment B o x Lam p. The Courtesy and Dom e and through the P A R K L P S Fuse 9 and the closed contacts of
Reading Lam ps turn on when a ground path is provided by the Headlamp and Panel Dim m er Switch to the Component
the Headlamp and Panel Dim m er Switch or one o f the Illu m in a tio n L a m p s. S in c e a ll o f the C om p on e nt
D oor Jamb Switches. Illum ination Lam ps are grounded through Ground G200,
The IP Compartment B o x Lam p and Vanity Lam ps the lamps light.
have switches that provide ground paths when the switches
close. ILLUMINATED ENTRY
W hen a door is opened, the Illuminated Entry System
UNDERHOOD REEL LAMP is activated. After the last door is closed, the Dom e and
Voltage is supplied at all times to the Underhood Reel Reading Lam ps w ill remain illuminated for 20 seconds or
Lam p from the H O R N Fuse. W hen the switch is closed, a until the Ignition Switch is turned on. Voltage is supplied
ground path is provided. to the module at all times through C T S Y Fuse 3. The
ground path is provided by C K T 150 to Ground G200. The
module senses a ground signal from C K T 157 when a door
is opened. The module then provides a ground path to
C K T 156 which allows the lamps to light.
INSTRUMENT PANEL DIMMING
0 1 0 4 (DIESEL)
ENGINE (GAS)
GROUND 03*25*97
4208W0972
|Z56 ONLTl
DAYTIME RUNNING
LAMPS ( D R L ) /
RADIO SWITCH
Audio Alarm M odule............. Under L H o f IP, at R H of Convenience Center............... .... 3 3 .... 44

Select Switch, Connector 1.... A t center rear of IP, near Remote Control D oor Lock
Receiver............................................................... ... 4 8 .... 6 3 .... 202-59

Receiver............................................................... ... 4 8 .... 6 3 .... 202-60
A u xiliary H V A C Control Lamp,

F ro n t............................... Front o f Overhead Console, part o f H V A C Controls......... ... 5 3 .... 68
A u xiliary H V A C Control Lamp,

R e a r.................. ............. Rear of Overhead Console M olding, in Headliner, part of
H V A C Controls...................................................... ... 5 3 .... 68
A u xiliary Heater Control

M odule, R e a r.................... L H o f IP, R H o f Steering C olum n................................ ... 5 3 .... 6 8 .... 202-26
Cargo T S w itrh .............. 202-61
Daytim e Running Lam ps

(D R L)/R adio Override
Sw itch ............................. Center o f IP, L H of R a d io .......................................... ... 4 9 .... 6 4 .... 202-61
Fog Lam p Sw itch.................. Center o f IP, R H o f Steering Colum n Shift L e v e r........... ... 4 8 .... 6 3 .... 202-62
Headlam p and Panel Dim m er

Sw itch............................. Low er L H o f I P ........................................................... 3 2 .... 4 3 .... 202-34
H V A C Control Lam p............. Part o f Heater Controls, center o f IP, under R adio........... ... 5 3 .... 68

Sw itch (P ickup )................. Center o f IP ............................................................. ... 4 8 .... 6 3 .... 202-65
Instrument Cluster................. Upper L H end o f IP, above Steering C olu m n ................. ... 3 2 .... 43 .... 202-38
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ........................... ... 3 2 .... 43
Liftgate Release Sw itch.......... Center o f IP, L H of Radio
Radio, Connector C l ............. Center o f IP ............................................................. ... 3 5 .... 4 6 .... 202-43
Radio, Connector C 2 ............. Center o f IP ............................................................. ... 3 5 .... 4 6 .... 202-44
Transfer Case Select Sw itch.... Center o f IP, R H o f Steering Colum n Shift L e ve r........... ... 4 8 .... 6 3 .... 202-48
Transfer Case Shift

Illum ination L am p .............. Part o f Transfer Case Selector L e ve r............................. ... 5 2 .... 67

R e a r................................ Center o f IP, R H o f R a d io .......................................... ... 4 9 .... 6 4 .... 202-69
C O N N EC T O R S:
C 200 (D ie se l)...................... Behind R H o f IP, near Heater Motor, in foam w rap......... ... 3 7 .... 4 9 .... 202-11
C 200 (G a s).......................... Behind R H o f IP, near Heater Motor, in foam w rap......... ... 3 7 .... 4 9 .... 202-10
C 2 9 8 .................................. Behind L H o f IP, near Convenience Center.................... ... 3 2 .... 43...... 202-17,
18
C 3 0 0 .................................. In Overhead Console.................................................. ... 3 6 .... 6 1 .... 202-55
C 3 0 2 .................................. A t L F K ic k Panel.......................................................... 4 7 .... 6 2 .... 202-56


G R O U N D S:
G103 (G a s)......................... R F of Engine, near Thermostat H o u sin g .......... 1 4 .... 18
G 104 (Gas, D ie se l)............... R H top center of Cylinder Head...................... 1 6 .... 20
G 200 .................................. Behind L H of IP, below Fuse Block, on Tie Bar 3 2 .... 43
G 202 .................................. R H o f IP, mounted to H V A C Plenum Bracket 5 0 .... 65
G400.................. ................. R H B Pillar, near D oor Striker....................... 5 8 .... 76
S P L IC E S :

Breakout

Breakout
S215 (D iesel).. ................... IP Harness, approx. 8 cm from Instrument Cluster Breakout,

5215 (G as).......................... IP Harness, approx. 12 cm from Instrument Cluster

5216 (Diesel and U p le ve l)...... IP Harness, approx. 12 cm from Instrument Cluster

5216 (Gas, A ll Except IP Harness, approx. 16 cm from Instrument Cluster

Uplevel)........................... Breakout, toward Radio Connectors Breakout
5 2 1 7 ................................ IP Harness, approx. 16 cm from Instrument Cluster Harness

5 2 1 8 ................................ IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S253 (Suburban/Utility).......... Crossbody Harness, approx. 6 cm from IP Harness

Breakout, toward D oor L o ck Relay Breakout

toward C299



S410 (2-Door U tility )............ Front-to-Rear Body Harness, approx. 37 cm from R R D oor
Breakout
S410 (4-Door Utility/ Front-to-Rear Body Harness, approx. 12 cm from R R D oor

Suburban)......................... Speaker Breakout, toward R R D oor Jamb Breakout
DIAGNOSIS - INSTRUMENT PANEL DIMMING

• C H E C K for a broken (or partially broken) wire inside
o f the in su la tio n w h ic h c o u ld cau se syste m
TROUBLESHOOTING HINTS: malfunction but prove G O O D in a continuity/voltage
1. C H E C K the condition o f the P A R K L P S Fuse 9 and check with a system disconnected. These circuits may
the IL L U M Fu se 14. If either Fu se is open, then be intermittent or resistive when loaded, and if
L O C A T E and R E P A IR source o f overload and possible, should be checked by m onitoring for a
R E P L A C E Fuse. voltage drop with the system operational (under load).
2. C H E C K that Grounds G103, G104, G200, and G 400 • C H E C K fo r proper in sta lla tio n o f afterm arket
are clean and tight. electronic equipment which may affect the integrity of
3. C H E C K for open filaments in any inoperative lamps. other systems. See Troubleshooting Procedures.
If Radio illum ination is inoperative, remove Radio for
Repair. If Instrument Cluster illum ination lamps are
inoperative and the w iring is O K , R E P L A C E the
Instrument Cluster.
INSTRUMENT PANEL LAMP(S) ARE INOPERATIVE

TEST RESULTS ACTION
1. Turn Headlamp and Panel Dim m er A ll Instrument Cluster Illum ination G O to Step 2.
Sw itch to the P A R K p osition. Lam ps are inoperative.
M ove switch from the dimmest Instrument Cluster Illum ination Lam ps R E P L A C E Headlamp and Panel
position to the brightest position.
are lit, but intensity is not adjustable Dim m er Switch.
with the switch.
One or more Instrument Cluster C H E C K for an open in G R Y (8 ) wire
Illum ination Lam p is inoperative. between Splice (S217) and affected
lamp(s) or in B L K (150) wire between
Splice and affected lamp(s). If O K ,
R E P L A C E affected lamp(s).
2. Turn Headlamp and Panel Dim m er Less than 10.0 volts. C H E C K for an open or high resistance
Sw itch to the brightest position. in D K G R N (44) or G R Y (8) wire
U s in g a D M M , m e asu re the between Headlamp and Panel Dim m er
voltage from Cavity D 4 o f the IP Switch and Splice S217. If O K ,
Fuse Block, the E L L U M Fuse 14, R E P L A C E Headlamp and Panel
to ground. Dim m er Switch.
M ore than 10.0 Volts. L O C A T E and R E P A IR open in B L K
(451) wire and Grounds G 103 or G104.
INSTRUMENT PANEL LAMPS REMAIN LIT WITH HEADLAMP AND PANEL DIMMER
SWITCH IN THE OFF POSITION
TEST RESULTS ACTION
1. Disconnect Headlam p and Panel Instrument Cluster Illum ination Panel R E P L A C E Headlamp and Panel
Dim m er Switch Connector. Lam ps turn OFF. Dim m er Switch.
Instrument Cluster Illum ination Lam ps L O C A T E and R E P A IR short to voltage
remain lit. in G R Y (8) or D K G R N (44) wire
between Headlamp and Panel Dim m er
Switch and Instrument Cluster
Illum ination Lam ps.
RADIO ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E Radio.
Dim m er Switch in the Park Lam ps N o voltage indicated. L O C A T E and R E P A IR open in G R Y
position. Observe that Park Lam ps (8) wire between Splice S217 and
are operating. Adjust Headlam p Radio.
and Dim m er Switch to midrange
p o s it io n . D is c o n n e c t R a d io
Connector C l. Connect a D M M
betw een R a d io C o n n e c to r C l
Cavity 7 for the G R Y (8) wire and
ground.
REAR WINDOW WIPER/WASHER SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E Rear W indow Wiper/Washer
Dim m er Switch in the Park Lam ps Switch.
position. Observe that Park Lam ps N o voltage indicated. L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p (8) wire between Splice S217 and Rear
and Dim m er Switch to midrange W indow Wiper/Washer Switch.
position. Disconnect Rear W indow
Wiper/Washer Sw itch Connector.
Connect a D M M between Rear
Connector Cavity E for the G R Y
LIFTGATE RELEASE SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E Liftgate Release Switch.
Dim m er Switch in the Park Lam ps L O C A T E and R E P A IR open in G R Y
N o Voltage indicated.
are operating. Adjust Headlam p Liftgate Release Switch.
p o stio n . D is c o n n e c t L iftg a te
R e le a s e S w it c h C o n n e c to r.
Connect a D M M between Liftgate
Release Switch Connector Cavity
A for G R Y (8) wire and ground.
8A - 117 - 6 ELECTRICAL DIAGNOSIS_______________________________
CARGO LAMP SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E Cargo Lam p Switch.
position. Observe that Park Lam ps
are operating. Adjust Headlam p Cargo Lam p Switch.
position. Disconnect Cargo Lam p
S w itc h C on n ector. C on n ect a
D M M b e tw e e n C a rg o L a m p
Sw itch Cavity A for G R Y (8) wire
and ground.
FOG LAMP SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E the Fog Lam p Switch.
Dim m er Switch in the Park Lam ps N o voltage indicated. L O C A T E and R E P A IR the open in the
position. Observe that the Park G R Y (8) wire between Splice S217 and
Lam ps are operating. Adjust the Fog Lam p Switch.
Headlamp and Dim m er Switch to
a m idrange position. Disconnect
the Fog Lam p Switch Connector.
C onnect a D M M between F o g
Lam p Sw itch C avity A for the
G R Y (8) wire and ground.
AUDIO ALARM MODULE ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E Audio Alarm Module.
are operating. Adjust Headlam p Audio Alarm Module.
position. Disconnect Audio Alarm
M o d u le C onnector. C onnect a
D M M betw een A u d io A la rm
M odule Cavity J1 for G R Y (8)
wire and ground.
TRANSFER CASE SELECT SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E Transfer Case Select
position. Observe that Park Lam ps N o voltage indicated. L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p (8) wire between Splice S217 and
and Dim m er Switch to midrange Transfer Case Select Switch.
position. Disconnect Transfer Case
Select Switch Connector. Connect
a D M M between Transfer Case
Select Switch Cavity J for G R Y
INFLATABLE RESTRAINT IP MODULE ENABLE SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E Inflatable Restraint IP
Dim m er Switch in the Park Lam ps M odule Enable Switch.
position. Observe that Park Lam ps N o voltage indicated. L O C A T E and R E P A IR open in
are operating. Adjust Headlam p G R Y (8) wire between Splice S217 and
and Dim m er Switch to midrange Inflatable Restraint IP M odule Enable
p osition. D isco n n e ct Inflatable Switch.
R e stra in t IP M o d u le E n a b le
S w itc h C onnector. C o n n e ct a
D M M between Inflatable Restraint
IP M odule Enable Switch Cavity
D for G R Y (8) wire and ground.
DRL/RADIO OVERRIDE SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E DRL/Radio Override
and Dim m er Switch to midrange D RL/Radio Override Switch.
position. Disconnect D R L/R a d io
O v e rrid e S w itc h C o n n e c to r.
C o n n e c t a D M M D R L / R a d io
O verride Sw itch C a vity A for
G R Y (8) wire and ground.
AUTOMATIC TRANSFER CASE SELECT SWITCH ILLUMINATION DOES NOT DIM

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E Active Transfer Case Select
and Dim m er Switch to a midrange Active Transfer Case Select Switch.
p o s itio n . D is c o n n e c t A c t iv e
T ra n sfe r C a se S e le c t S w itc h
C o n n e c to r. C o n n e c t a D M M
between A ctive T ransfer C ase
Select Switch Cavity H for G R Y
8A - 117 - 8 ELECTRICAL DIAGNOSIS__________________________________________
FRONT/REAR AUXILIARY HVAC CONTROL LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Test lamp lights. G O to Step 2.
Dim m er Sw itch in the Park Lam ps Test lamp does not light. L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p Front/Rear A uxiliary H V A C Control
and Panel D im m e r Sw itch to Lamp.
m idrange p osition . D isco n n e ct
A u x ilia ry H V A C C ontrol Lam p
Connector C3. Connect a test lamp
betw een Fro n t/R e ar A u x ilia ry
H V A C Control Lam p Connector
ground.
2. C on n ect a test lam p between Test lamp lights. R E P L A C E Front/Rear A uxiliary H V A C
F ro n t/ R e a r A u x ilia r y H V A C Control Lamp.
Control Lam p Connector Cavity B Test lamp does not light. L O C A T E and R E P A IR open in B L K
for B L K (150) wire and Ground (150) wire between Front/Rear
G400. Auxiliary H V A C Control Lam p and
Ground G400.
TRANSFER CASE MODE SELECTOR LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
Dim m er Sw itch in the Park Lam ps Test lamp does not light. L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p Transfer Case M ode Selector Lamp.
and P an e l D im m e r Sw itc h to
T ra n sfe r C a se M o d e Se le cto r
Lam p Connector. Connect a test
lamp between Transfer Case M ode
Selector Lam p Connector Cavity
B for G R Y (8) wire and Ground
G202.
2. C on n ect a test lam p between Test lamp lights. R E P L A C E Transfer Case M ode
T ra n sfe r C a se M o d e Se le cto r Selector Lamp.
Lam p C onnector C a vity A for Test lamp does not light. L O C A T E and R E P A IR open in B L K
B L K (1 5 0 ) w ire and G ro u n d (150) wire between Transfer Case
G202. M ode Selector Lam p and Ground
G202.
HVAC CONTROL SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
Dim m er Switch in the Park Lam ps Test lamp does not light. L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p H V A C Control Switch.
and P an e l D im m e r Sw itch to
m idrange p osition. D iscon n e ct
H V A C Control Switch Connector
C3. Connect a test lamp between
H V A C Control Switch Connector
C 3 Cavity 1 for G R Y (8) wire and
Ground G200.
2. C on n ect a test lam p between Test lamp lights. R E P L A C E H V A C Control Switch.
H V A C Control Switch Cavity C Test lamp does not light. L O C A T E and R E P A IR open in B L K
for B L K (150) wire and Ground (150) wire between H V A C Control
G200. Switch and Ground G200.
REAR AUXILIARY HEATER SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
position. Observe that Park Lam ps (8) wire between Splice S217 and Rear
are operating. Adjust Headlam p A uxiliary Heater Switch.
and P anel D im m e r Sw itch to
m idrange position . D isco n n e ct
R e a r A u x ilia ry H eater Sw itch
between Rear A u x ilia ry Heater
Sw itch Connector C avity 1 for
G R Y (8) wire and Ground G200.
2. Connect a test lamp between Rear Test lamp lights. R E P L A C E Rear Auxiliary Heater
A u x i l i a r y H e a t e r S w it c h Switch.
C on n ector C a v ity B fo r B L K Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire and Ground G200. (150) wire between Rear Auxiliary
Heater Switch and Ground G200.
REAR WINDOW WIPER/WASHER SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
position. Observe that Park Lam ps (8) wire between Splice S217 and Rear
are operating. Adjust Headlam p W indow Wiper/Washer Switch.
and P anel D im m e r Sw itch to
m idrange p osition. D isco n n e ct
R e a r W in d o w W ip e r/ W a sh e r
Switch Connector. Connect a test
la m p b etw een R e a r W in d o w
W iper/W asher Sw itch Connector
Cavity E for G R Y (8) wire and
Ground 200.
TEST RESULT ACTION

2. Connect a test lamp between Rear Test lamp lights. R E P L A C E Rear W indow Wiper/Washer
W in d o w W iper/W asher Sw itch Switch.
C on n ector C a v ity H fo r B L K Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire and Ground G200. (150) wire between Rear W indow
Wiper/Washer Switch and Ground
G200.
RADIO LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Test lamp lights. G O to Step 2.
are operating. Adjust Headlam p Radio.
R adio Connector C l. Connect a
t e s t la m p b e t w e e n R a d io
Connector C l Cavity 7 for G R Y
(8) wire and Ground G200.
2. C on n ect a test lam p between Test lamp lights. R E P L A C E Radio.
Radio Connector C l Cavity 5 for Test lamp does not light.
B L K (1 5 0 ) w ire and G ro u n d (150) wire between Radio and Ground
G200.
G200.
UFTGATE RELEASE SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
Dim m er Switch in the Park Lam ps Test lamp does not light.
L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p Liftgate Release Switch.
and Panel D im m e r Sw itch to
m idrange p o sitio n . D isco n n e ct
Liftgate Release Switch. Connect a
test lamp between Liftgate Release
Sw itch Connector C avity A for
2. C o n n e ct a test lam p betw een Test lamp lights. R E P L A C E Liftgate Release Switch.
Liftgate Release Sw itch Connector
C avity B for B L K (150) wire and (150) wire between Liftgate Release
Ground G200.
Switch and Ground G200.
CARGO LAMP SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
are operating. Adjust Headlam p Cargo Lam p Switch.
m idrange position . D iscon n e ct
C argo Lam p Sw itch Connector.
C argo Lam p Sw itch Connector
Ground G200.
2. C onnect a test lam p between Test lamp lights. R E P L A C E Cargo Lam p Switch.
C argo Lam p Sw itch Connector Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity B for B L K (150) wire and (150) wire between Cargo Lam p
Ground G200. Switch and Ground G200.
FOG LAMP SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
position. Observe that Park Lam ps (8) wire between Splice S217 and Fog
are operating. Adjust Headlam p Lam p Switch.
midrange position. Disconnect Fog
Lam p Switch Connector. Connect
a test lamp between Fog Lam p
Sw itch Connector C avity F for
2. Connect a test lamp between Fog Test lamp lights. R E P L A C E F o g Lam p Switch.
Lam p Switch Connector Cavity E Test lamp does not light. L O C A T E and R E P A IR open in B L K
for B L K (150) wire and Ground (150) wire between Fog Lam p Switch
G200. and Ground G200.
AUDIO ALARM MODULE LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
are operating. Adjust Headlam p A ud io Alarm Module.
A u d io Alarm M odule Connector.
A u d io Alarm M odule Connector
Cavity J1 for G R Y (8) wire and
Ground G200.
2. C on n ect a test lam p between Test lamp lights. R E P L A C E A udio Alarm Module.
A u d io Alarm M odule Connector Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity for B L K (150) wire and (150) wire between Audio Alarm
Ground G200. M odule and Ground G200.
8A - 117 - 12 ELECTRICAL DIAGNOSIS_____________________________________
TRANSFER CASE SELECT SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
are operating. Adjust Headlam p Transfer Case Select Switch.
betw een T ran sfe r C ase Select
Sw itch Connector C avity J for
2. C o n n e ct a test lam p betw een Test lamp lights. R E P L A C E Transfer Case Select
T ra n sfe r C a se S e le c t S w itc h Switch.
C o n n e cto r C a v ity H fo r B L K Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire and Ground G200.
(150) wire between Transfer Case
Select Switch and Ground G200.
INFLATABLE RESTRAINT IP MODULE ENABLE SWITCH LAMP ILLUMINATION

INOPERATIVE
TEST RESULT ACTION
Dim m er Switch in the Park Lam ps Test lamp does not light.
L O C A T E and R E P A IR open in G R Y
are operating. Adjust Headlam p Inflatable Restraint IP M odule Enable
and Panel D im m e r Sw itc h to Switch.
In flatab le restraint IP M o d u le
Enable Switch Connector. Connect
a test lam p between Inflatable
R e st ra in t IP M o d u le E n a b le
Sw itch Connector C avity D for
2. C o n n e ct a test lam p between Test lamp lights. R E P L A C E Inflatable Restraint IP
Inflatable Restraint IP M od u le M odule Enable Switch.
Enable Switch Connector Cavity F Test lamp does not light. L O C A T E and R E P A IR open in B L K
for B L K (150) wire and Ground (150) wire Inflatable Restraint IP
G200. M odule Enable Switch and Ground
G200.
ACTIVE TRANSFER CASE SELECT SWITCH LAMP ILLUMINATION INOPERATIVE

TEST RESULT ACTION
are operating. Adjust Headlam p Active Transfer Case Select Switch.
A c tiv e T ra n sfe r C a se S e le c t
Switch Connector. Connect a test
lam p between A c tiv e T ransfer
C ase Select Sw itch C onnector
Cavity D for G R Y (8) wire and
Ground G200.
2. C onnect a test lam p between Test lamp lights. R E P L A C E Active Transfer Case Select
A c t iv e T ra n sfe r C a se S e le c t Switch.
Sw itch Connector C avity F for Test lamp does not light. L O C A T E and R E P A IR open in B L K
B L K (1 5 0 ) w ire and G ro u n d (150) wire between Active Transfer
G200. Case Select Switch and Ground G200.
DRL/RADIO OVERRIDE SWITCH (POLICE PACKAGE, Z56) LAMP ILLUMINATION

INOPERATIVE
TEST RESULT ACTION
are operating. Adjust Headlam p D RL/Radio Override Switch.
D R L / R a d io O v e rrid e S w itc h
betw een D R L / R a d io O ve rrid e
Sw itch Connector C avity A for
2. C on n ect a test lam p between Test lamp lights. R E P L A C E D R L/R adio Override
D R L / R a d io O v e rrid e S w itc h Switch.
C on n ector C a v ity B fo r B L K Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire and Ground G200. (150) wire between D RL/Radio
Override Switch and Ground G200.
RADIO, PRNDL, INFLATABLE RESTRAINT IP MODULE ENABLE, TRANSFER CASE

SELECT SWITCH, AND DRL/RADIO OVERRIDE ILLUMINATION LAMPS DO NOT GO
BRIGHT IN PARADE MODE
TEST RESULT ACTION
1. Disconnect Headlam p and Panel Test lamp lights. L O C A T E and R E P A IR open in
Dim m er Switch Connector. Place P PL/W H T (1382) wire between
H e ad lam p and P an e l D im m e r Headlamp and Panel Dim m er Switch
S w it c h in the P a rk L a m p s and Splice S216.
position. Adjust Headlam p and Test lamp does not light. R E P L A C E Headlamp and Panel
Panel Dim m er Switch to Parade Dim m er Switch.
M ode detent position. Connect a
H e ad lam p and P an e l D im m e r
S w itc h C o n n e cto r C a v itie s H
and N.
RADIO ILLUMINATION DOES NOT GO BRIGHT IN PARADE MODE

TEST RESULT ACTION
1. C h e ck that R a d io is operable. Voltage indicated. R E P L A C E Radio.
P la c e H e a d la m p a n d P a n e l N o voltage indicated. L O C A T E and R E P A IR open in
PPL/W H T (1382) wire between Splice
S216 and Radio.
are operating. Adjust Headlam p
Parade M o d e detent p o sitio n .
Disconnect Radio Connector C l.
Connect a D M M between Radio
C o n n e c to r C l C a v it y 6 fo r
P P L / W H T ( 1 3 8 2 ) w ir e
and ground.
PRNDL ILLUMINATION DOES NOT GO BRIGHT IN PARADE MODE

TEST RESULT ACTION
1. Check that voltmeter is operable. Voltage indicated. R E P L A C E Instrument Cluster.
P la c e H e a d la m p a n d P a n e l N o voltage indicated. L O C A T E and R E P A IR open in
Dim m er Switch in the Park Lam ps PPL/W H T (1382) wire between Splice
position. Observe that Park Lam ps S216 and Instrument Cluster.
are operating. Adjust Headlam p
and Panel D im m e r Sw itc h to
D isc o n n e c t Instrum ent C lu ste r
b e tw e e n In stru m e n t C lu s t e r
C o n n e c t o r C a v it y B 1 2 fo r
P P L / W H T (1 3 8 2 ) w ire an d
ground.
INFLATABLE RESTRAINT IP MODULE ENABLE SWITCH ILLUMINATION DOES NOT GO

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E Inflatable Restraint IP
Dim m er Switch in the Park Lam ps M odule Enable Switch.
position. Observe that the Park N o voltage indicated. L O C A T E and R E P A IR open in
L a m p s are o p e ratin g. A d ju st P PL/W H T (1382) wire between Splice
H ead lam p and P an e l D im m e r S216 and Inflatable Restraint IP
Sw itch to Parade M o d e detent M odule Enable Switch.
position. D isco n n e ct Inflatable
R e stra in t IP M o d u le E n a b le
Sw itch C onnector. C o n n e ct a
D M M between Inflatable Restraint
IP M o d u le E n a b le S w it c h
Connector Cavity C for P P L/W H Y
TRANSFER CASE SELECT SWITCH ILLUMINATION DOES NOT GO BRIGHT IN PARADE

MODE
TEST RESULT ACTION
1. P la c e H e a d la m p an d P a n e l Voltage indicated. R E P L A C E Transfer Case Select
are operating. Adjust Headlam p P PL/W H T (1382) wire between Splice
and Panel D im m e r Sw itc h to S216 and Transfer Case Select Switch.
Parade M o d e detent p osition .
betw een T ran sfer C ase Select
Sw itch Connector C avity B for
P P L / W H T (1 3 8 2 ) w ire and
ground.
DRL/RADIO OVERRIDE SWITCH (POLICE PACKAGE, Z56) ILLUMINATION DOES NOT GO

TEST RESULT ACTION
1. P la c e H e a d la m p a n d P a n e l Voltage indicated. R E P L A C E D R L/R adio Override
are operating. Adjust Headlam p PPL/W H T (1382) wire between Splice
and Panel D im m e r Sw itch to S216 and D R L/R adio Override Switch.
Disconnect D R L / R a d io Override
S w itch C on n ector. C o n n e ct a
D M M b e tw e e n D R L / R a d io
Override Switch Connector Cavity
C for PPL/W H T (1382) wire and
ground.
CIRCUIT OPERATION
INTERIOR LAMPS DIMMING

W ith the Headlam p and Panel Dim m er Sw itch in
P A R K or H E A D , voltage is supplied to the Instrument
Panel Dim m er Switch. T h is voltage goes through the
IL L U M Fuse 14 to the illu m in atio n lam ps. A ll o f the
lam ps are perm anently grounded, so they light. The
intensity o f the illum ination lamps is controllable via the
Headlamp and Panel Dim m er Switch. The rheostat in the
Headlamp and Panel Dim m er Switch varies voltage to the
lamps, which in turn, also varies lamp intensity.
BLANK
POWER WINDOWS
4 DOOR (CREW CAB/SUBURBAN/UTILITY)
HOT AT ALL TIMES HOT IN RUN

1
--------------IIP
F6 . PWR WDO | FUSE
PK LPS A2<
CIRCUIT * BLOCK
FUSE 9
BBEAKER
I 'l 20 A
1 G5 30 A I
L_ J
.8 ORN | 240
H
T — I— T HEADLAMP
SEE INTERIOR
LAMPS I T I AND PANEL
SECTION 8A -114 I \ I DIMMER
j |L _ > | SWITCH
POWER
WINDOW _ .8 BRnY ^ .8 BRN
k a B *A S 2 1 0 C298
MASTER • 8 BRN | .8 BRN 9
SWITCH ....... 9 .)>
J S L il 9 .8 BRN
2 LT GRN
170
.8 BLK
2 PPL
171 2 DKBLU
1307
2 DKBLU
1307 2 DK GRN
168
2 PPL
169
2 BLK 150
S2S9
.8 BLK ,
150
2 LT 8LU
166
2 TAN
167 5 BLK 150
± V
£222
" cross
BOOT
GROUND
POWER
WINDOW
MOTOR
1307
03-11-97
4206W0747
RR
WINDOW
SWITCH
RR
POWER
WINDOW
MOTOR
03-10-97
4208W0748
POWER WINDOWS
2 DOOR (PICKUP/UTILITY)
ELECTRICAL DIAGNOSIS 8A -120-3
Convenience Center............ Under L H of IP, on Bulkhead........................................ 3 3 ..... 44

Sw itch........................... Low er L H of I P .......................................................... 32 .... 4 3 .... 202-34
IP Fuse B lo ck .................... L H o f IP, near L F Door Jamb Sw itch ............................. 3 2 ..... 43

Sw itch........................... O n L F Door, below Inside D oor H andle......................... 6 1 ..... 7 9 .... 202-37,
68
Power W indow Motor, L F ... In L F Door, near Speaker.................................. 6 1 ..... 79
Power W indow Motor, L R ... In L R Door, near Speaker............................................ 6 2 ..... 80
Power W indow Motor, R F ... In R F Door, near Speaker............................................ 6 1 ..... 79
Power W indow Motor, R R ... In R R Door, near Speaker............................................ 6 2 ..... 80
Power W indow Switch, LF.... O n L F D oor Trim Panel, below Inside D oor H andle......... 6 1 ..... 7 9 .... 202-30
Power W indow Switch, LR.... L R Door, below Inside D oor H andle.............................. 6 2 ..... 8 0 .... 202-69
Power W indow Switch, RF.... O n R F D oor Trim Panel, below Inside D oor handle.......... 6 1 ..... 7 9 .... 202-31
Power W indow Switch, R R ... R R Door, below Inside D oor H andle.............................. 6 2 ..... 8 0 .... 202-69
CONNECTORS:
C 2 0 6 ................................ Inside lower L H A Pillar.............................................. 6 1 ..... 7 9 .... 202-50,
51
C 2 0 8 ................................ Inside lower L H A Pillar.............................................. 6 1 ..... 7 9 .... 202-51
C 2 0 9 ............................... Inside lower L H A Pillar.......... 6 1 ..... 7 9 .... 202-51
C 2 1 0 ................................ A t Convenience Center................................................. 3 3 ..... 44.... 202-51
C 2 1 3 ................................ Inside lower R H A P illa r............................................. 6 1 ..... 7 9 .... 202-52
C 2 1 5 ................................ Inside lower R H A P illa r............................................. 6 1 ..... 7 9 .... 202-52
C 2 4 3 ................................ Crossbody H arness....................................................... 60 .... 79...... 202-55
C 2 9 8 ................................ Behind L H of IP, near Convenience Center...................... 3 2 ..... 4 3 .... 202-17,

18
C 4 9 6 ................................ In R H B Pillar...................... 6 2 ..... 8 0 .... 202-58
C 4 9 7 ................................ R H B Pillar................................................................ 6 2 ..... 8 0 .... 202-59
C 4 9 8 ................................ L H B P illar............................................................... 6 2 ..... 8 0 .... 202-59
C 4 9 9 ................................ L H B P illar............................................................... 6 2 ..... 80.... 202-59
GROUNDS:
G 202................................ R H of IP, mounted to H V A C Plenum Bracket.................. 5 0 ..... 65
SPLICES:
S210 (D iesel).................... IP Harness, approx. 14 cm from Steering Colum n Harness
Breakout
S210 (G as)........................ IP Harness, approx. 4 cm from Auxiliary Power Outlet

Breakout
8A - 1 2 0 - 4 ELECTRICAL DIAGNOSIS
POWER WINDOWS

S 2 4 7 ......................... ......... Crossbody Harness, approx. 6 cm into L H D oor Harness
Breakout


toward C 299
S263 (4-Door
Utility/Suburban/Crew Cab)... Crossbody Harness, approx. 32 cm from Seat Belt Switch
S 5 0 0 ................................... Inside left front D oor Harness, near Tweeter................... ... 3 7 .... 62

Regulator................................. ................. ............ .. 61...... 79
Speaker Breakout, toward L F W indow Regulator.......... .. 61...... 79
DIAGNOSIS - POWER WINDOW
TROUBLESHOOTING HINTS: check with a system disconnected. These Circuits may

1. C H E C K condition o f Power W indow Circuit Breaker. be intermittent or resistive when loaded, and if
If C ircu it Breaker is in good condition, use the possible, should be checked by m onitoring for a
follow ing diagnostic procedures. voltage drop with the system operational (under load).
2. C H E C K condition o f Park Lam p Fuse. If Fuse is • C H E C K fo r proper in sta lla tio n o f afterm arket
open, L O C A T E and R E P A IR source o f overload. electronic equipment which may affect the integrity of
R E P L A C E Fuse. other system. See Troubleshooting Procedures.
• C H E C K for a broken (or partially broken) wire inside 3. C H E C K for mechanical failures or binding.
o f the in s u la tio n w h ich c o u ld cau se syste m 4. If the Auto D ow n feature does not operate, R E P L A C E
malfunction but prove G O O D in a Continuity/Voltage the L H W indow Master Switch.
DIAGNOSIS - POWER WINDOWS (2 DOOR)

BOTH POWER WINDOWS INOPERATIVE
TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N Test lamp lights. G O to step 2.
position. Connect a test lamp from Test lamp does not light. R E P A IR open in Y E L (343) wire from
Y E L (343) wire at the L H Power L H Power W indow Master Switch
W indow Master Switch Connector Connector to the IP Fuse Block.
C l Cavity L to ground.
2. Connect a test lamp from Y E L Test lamp lights. C H E C K L H Master W indow Switch
(3 4 3 ) w ire at the L H P o w e r for a poor connection. If O K ,
W indow Master Switch Connector R E P L A C E the L H Power W indow
C l Cavity L to B L K (150) wire at Master Switch.
the L H Pow er W indow Sw itch Test lamp does not light. R E P A IR open in B L K (150) wire from
Connector Cavity C. the L H Power W indow Master Switch
Connector C l Cavity L to ground.
LH WINDOW INOPERATIVE; RH WINDOW OPERATES NORMALLY

TEST RESULT ACTION
1. Place the Ignition Switch in the Test lamp lights in both positions. G O to step 2.
R U N position. Connect a test lamp Test lamp does not light in both C H E C K the L H W indow Switch
between D K B L U (164) wire and positions. Connector for poor connections. If O K,
B R N (165) wire at the L H Power R E P L A C E the L H Power W indow
W in d o w S w it c h C o n n e c t o r Switch.
C a v itie s A and E . P re ss the
window switch U p and Down.
2. Connect a test lamp between D K Test lamp lights in both positions. C H E C K the L H Power W indow M otor
B L U (164) wire and B R N (165) connector for poor connections. If O K,
wire at the L H Power W indow R E P L A C E the L H W indow Motor.
Motor. Press the switch U p and Test lamp does not light in both Repair open between the L H W indow
Down. positions. Switch Connector and L F W indow
M otor connector in D K B L U (164)
wire or B R N (165) wire.
8A - 12 0 - 6 ELECTRICAL DIAGNOSIS_____________________________________________
POWER WINDOWS
RH WINDOW IS INOPERATIVE FROM INDIVIDUAL WINDOW SWITCH, BUT OPERATES

NORMALLY FROM THE LH WINDOW SWITCH
TEST RESULT ACTION
1. Place the Ignition Switch in the Test lamp lights. G O to step 2.
R U N position. Connect a test lamp Test lamp does not light. R E P A IR open in Y E L (343) wire
between Y E L (343) wire at the
between Convenience Center Cavity D
R H P o w e r W in d o w S w it c h
and R H Power W indow Switch.
C o n n e c to r C l C a v ity L and
ground.
2. Connect a test lamp at the R H Test lamp lights in both positions. G O to step 3.
Power W indow Switch Connector Test lamp does not light in both
C H E C K inoperative window switch for
C l Cavity B and D between wire positions. a poor connection. If O K , R E P L A C E
L T B L U (166) w ire and T A N the R H Power W indow Switch.
(1 67) w ire. Pre ss the w indow
switch U p and Down.
3. Connect a test lamp between D K Test lamp lights in both positions. C H E C K the R F Power W indow M otor
B L U (666) wire and B R N (667) for a poor connection. If O K ,
wire at the R F Pow er W indow R E P L A C E the R F Power W indow
M o t o r c o n n e c to r. P r e s s the Motor.
w indow switch U p and Dow n. Test lamp does not light in both R E P A IR open in D K B L U (666) wire
positions. or B R N (667) wire between the Power
W indow Switch and R F Power
W indow Motor.
RH WINDOW IS INOPERATIVE FROM BOTH THE LH WINDOW SWITCH AND THE RH

WINDOW SWITCH; LH WINDOW OPERATES NORMALLY
TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N Test lamp lights in both positions. C H E C K the R F Power W indow M otor
p osition . C onnect a test lam p for a poor connection. If O K ,
between terminals A and B o f the R E P L A C E the R F Power W indow
R H P ow er W in d o w R e gu la to r Regulator Motor.
M o t o r c o n n e c to r. P r e s s the Test lamp does not light in both G O to step 2.
window switch U p and Down. positions.
2. Connect a test lamp at the R H Test lamp lights in both positions. G O to step 3.
Power W indow Switch Connector Test lamp does not light in both G O to step 4.
C 2 between term inals J and L. positions.
P re ss the R H Pow er W in d ow
Switch U p and Down.
3. Connect a test lamp at the R H Test lamp lights in both positions. R E P A IR open in D K B L U (666) wire
Power W indow Switch Connector or B R N (667) wire between the R H
between terminals G and K . Press Power W indow Switch and the R F
the R H Power W indow Switch Up Power W indow Motor.
and Dow n. Test lamp does not light in both C H E C K the R H Power W indow Switch
positions. Connector for a poor connection. If
O K , R E P L A C E the R H Power W indow
Switch.
4. Connect a test lamp at the L H Test lamp lights in both positions. R E P A IR loose connections or opens in
Pow er W indow Switch Connector C K T 167 or C K T 166 between the L H
between terminals B and D. Press D oor Lock and Side W indow Switch
the Power W indow Switch (at the and the R H D oor Lock and Side
D o o r L o c k and Sid e W in d ow W indow Switch.
Switch). Test lamp does not light in both Replace the L H D oor Lock and Side
positions. W indow Switch.
DIAGNOSIS - POWER WINDOWS (4 DOOR)

ALL POWER WINDOWS INOPERATIVE
TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N Test lamp lights. G O to step 2.
position. Connect a test lamp from Test lamp does not light. R E P A IR open in Y E L (343) wire from
Y E L (3 43) w ire at L F Pow er L F Power W indow Master Switch
W indow Master Switch Connector Connector C 2 Cavity L to the IP Fuse
C 2 Cavity L to ground. Block.
2. Connect a test lamp from Y E L Test lamp lights. C H E C K L F Power W indow Switch
(343) wire to B L K (150) wire at Connector C 2 for a poor connection. If
L F P o w e r W in d o w S w it c h O K , R E P L A C E the L F Power W indow
Connector C 2 at Cavity L and C. Master Switch.
Test lamp does not light. R E P A IR open in B L K (150) wire from
L F Power W indow Switch Connector
C 2 Cavity L to ground.
LF WINDOW INOPERATIVE; ALL OTHERS OPERATE NORMALLY

TEST RESULT ACTION
1. Place the Ignition Switch in the Test lamp lights in both positions. G O to step 2.
R U N position. Connect a test lamp Test lamp does not light in both C H E C K L F Power W indow Switch
between D K B L U (164) wire and positions. Connector C 2 for poor connections. If
B R N (165) wire at the L F Power O K , R E P L A C E the L F Power W indow
W in d ow Sw itch C onnector C 2 Switch.
C avity A and E. Press the L F
Pow er W indow Sw itch U p and
Down.
2. Connect a test lamp between D K Test lamp lights in both positions. C H E C K the L H W indow Regulator
B L U (164) wire and B R N (165) M otor connector for poor connections.
wire at the L F Pow er W indow If O K , R E P L A C E the L F Side
M o to r. P re s s the L F P o w e r W indow Regulator Motor.
W indow Switch U p and Down. Test lamp does not light in both Repair open between L F Power
positions. W indow Switch Connector C 2 and L F
Power W indow M otor connector in D K
B L U (164) wire or B R N (165) wire.
8A - 12 0 ■ 8 ELECTRICAL DIAGNOSIS_____________________________________________
POWER WINDOWS
RF, LR, OR RR WINDOW IS INOPERATIVE FROM INDIVIDUAL WINDOW SWITCH, BUT

OPERATES NORMALLY FROM THE LF WINDOW SWITCH
TEST RESULT ACTION
1. Place the Ignition Switch in the Test lamp lights. G O to step 2.
R U N p osition . Place the Sid e Test lamp does not light. R E P A IR open in D K B L U (1307) wire
W in d o w L o c k o u t S w itc h in for rear door between S263 and the
N o rm al. C on n ect a test lam p inoperative window switch. For R F
between the inoperative window door, R E P A IR open in Y E L (343) wire
switch connector D K B L U (1307) between IP Fuse B lo ck and R F Power
for L r W indow and R R Pow er W indow switch.
W indow switch, or Y E L (343) for
R F W indow switch, and ground.
2. C o n n e c t a te st la m p at the Test lamp lights in both positions. G O to step 3.
in o p e r a t iv e w in d o w sw itc h
Test lamp does not light in both C H E C K inoperative window switch for
connector between wire D K B L U positions. a poor connection. If O K , R E P L A C E
(666) wire and B R N (667) wire the inoperative window switch.
for R F or D K B L U (668) wire and
B R N (669) wire for L r and R R .
Press the Power W indow Switch
U p and Dow n.
3. Connect a test lamp between D K Test lamp lights in both positions. C H E C K the inoperative window
B L U (666) wire and B R N (667) regulator motor for a poor connection.
wire for R F or D K B L U (668) If O K , R E P L A C E the Power W indow
wire and B R N (669) wire for L r Motor.
and R R at the inoperative window Test lamp does not light in both R E P A IR open in D K B L U (666) wire
motor connector. Press the Power positions. or B R N (667) wire for R F or B R N
W indow Switch U p and Down. (669) wire or D K B L U (668) wire for
L r and R R between the inoperative
window switch and window motor.
ONE WINDOW (OTHER THAN LF) IS INOPERATIVE FROM BOTH THE LF WINDOW
SWITCH AND THE INDIVIDUAL WINDOW SWITCH; ALL OTHER WINDOWS
OPERATE NORMALLY
TEST RESULT ACTION
1. Place Ig n itio n Sw itch in R U N Test lamp lights in both positions. C H E C K the inoperative Power W indow
p osition . C onnect a test lam p M otor for a poor connection. If O K ,
between terminals A and B of the R E P L A C E the Power W indow Motor.
in o p e r a t iv e W in d o w M o t o r Test lamp does not light in both
G O to step 2.
C o n n e c to r. P re ss the P o w e r
positions.
W indow Sw itch U p and Down.
2. C o n n e c t a te st la m p at the Test lamp lights in both positions. G O to step 3.
inoperative Power W indow Switch Test lamp does not light in both
G O to step 4.
Connector between term inals A positions.
and D for L R and R R , or between
terminals J and L for RF. Press the
inoperative Pow er W indow Switch
at the P o w e r W in d o w M a ste r
Sw itch U p and Down.
TEST RESULT ACTION

3. C o n n e c t a te st la m p at the Test lamp lights in both positions. R E P A IR open in D K B L U (666) wire
in o p e ra tiv e W in d o w S w itc h or B R N (667) wire for R F or D K B L U
Connector between term inals G (668) wire or B R N (669) wire for L R
and K for R F or terminals F and and R R between the inoperative
C fo r L R and R R . P re ss the window switch and the inoperative
inoperative W indow Sw itch U p window regulator motor.
and Dow n. Test lamp does not light in both C H E C K the inoperative window switch
positions. for a poor connection. If O K ,
R E P L A C E the inoperative window
switch.
4. Connect a test lam p at the L F Test lamp lights in both positions. R E P A IR loose connectors or opens
Pow er W in d ow M aste r Sw itch between L F Power W indow Switch
connector between terminals B and connector(s) and the inoperative Power
D o n C 2 f o r R F , b e tw e e n W indow Switch C K T 167 or C K T 166
terminals G on C 2 and K on C 2 for RF, C K T 168 or C K T 169 for LR ,
for L R , between terminals H on C K T 170 or C K T 171 for R R .
C 2 and H on C 2 for R R . Press the Test lamp does not light in both Replace the Power W indow Master
inoperative Power W indow Switch positions. Switch.
at the Pow er W in d o w M a ste r
Switch U p and Down.
CIRCUIT OPERATION The regulator motor runs to drive the window up.
A permanent magnet motor operates each of the power W hen the Dow n switch is operated, battery voltage is
side windows. Each motor raises or lowers the glass when supplied to the window regulator motor in the opposite
voltage is supplied to it. The direction the motor turns direction through the B R N (165) wire. The w indow
depends on the polarity of the supply voltage. The side regulator motor is grounded through the D K B L U (164)
window switches control the supply voltage polarity. wire and the window switch U p contact. The motor runs to
The L F D oor Lock and Side W indow Switch controls drive the window down.
all motors. The other window switches controls only the
window regulator motor in that door. INDIVIDUAL WINDOW SWITCH
Each motor is protected by a built-in circuit breaker. If OPERATION
a w indow switch is held too long w ith the w indow W hen the Ignition Switch is in Run, battery voltage is
obstructed or after the window is fully up or down, the supplied to the R F D oor Lock and Side W indow Switch
circuit breaker opens the circuit. The circuit breaker resets through the P W R W D O Circuit Breaker and the Y E L (343)
automatically as it cools. wire to terminal F. W hen the U p switch in the R F W indow
switch is operated, battery voltage is supplied to the R F
MASTER WINDOW SWITCH OPERATION Side W indow Regulator M otor through the D K B L U (666)
W hen the Ignition Switch is in Run, battery voltage is wire. The motor is grounded through the B R N (667) wire,
supplied to the L F D oor Lock and Side W indow Switch the Dow n contact in the window switch, the T A N (167)
through the P W R W D O Circuit Breaker and the Y E L (343) wire and the Dow n contact in the L F D oor Lock and Side
wire. W hen the L F W indow U p Switch is operated, battery W indow Switch. The motor runs to drive the window up.
voltage is supplied to the L F Side W indow Regulator W hen the Dow n switch in the window switch is operated,
M otor through the D K B L U (164) wire. The window motor battery voltage is supplied to the window regulator motor
is grounded through the B R N (165) wire and the window in the opposite direction through the B R N (667) wire. The
switch D ow n contact motor is grounded through the D K B L U (666) wire, the U p
contact in the window switch, the L T B L U (166) wire and
the U p contact in the L F D oor Lock and Side W indow
Switch. The motor runs to drive the window down.
POWER DOOR LOCKS
UTIUTY/SUBURBAN AND CREW CAB
[ HOT AT ALL TIMES

1
HOT AT ALL TIMES

[ ]
1JP DOOR LOCK
FUSE
- T PWR ACCY
CIRCUIT BLOCK
AI BREAKER
20 A
REGULAR/
EXTENDED CAB
30 A EXCEPT
REGULAR/
EXTENDED CAB
c v -/ a v ev* / d v B y r y
2 ORN 540
r ■ ‘ “» CONVENIENCE
.8
I I CENTER .8 LT
WHT 194 BLU 195
*03* I
L. zk -» I BLK ISO
C C210
5-Y1
2 ORNI I 540 SEE GROUNO
DISTRIBUTION
A A
SEE FUSE 2 ORN PAGE 8 A -1 4 -1 4
BLOCK DETAILS
PACE 8 A -1 1 -1 6 S255 540
FROM
PAGE 8 A -1 3 0 -0
FROM
PAGE BA -1 3 0 -0
T
I
2 GRY >
■• S251
2 GRY
2 BLK 150
150
• • S259
5 BLK I 150
G202 _____
IP ~
GROUND 03-10-97
4208W0616
POWER DOOR LOCKS
PICKUP/EXTENDED CAB
.---------- T £
j pWR-ACCY | FUSE
r«
f QRCUIT . b lo c k
, BREAKER 1
L _ r i _ j
2 ORN 540
r — — ““ n CONVENIENCE
1 (>D3
u —Hi___
4200W0617
FROM
PAGE 8 A -130-0
.5 PPL I 328
.5 PPL
r
.5 PPL I 328
T HEADLAMP
| AND PANEL
| OIMMER SWITCH
| INTERIOR
'LIGHTS
| SECTION 8A-114
J
GROUNO
0 3 -2 0 -9 7
4208W0618
POWER DOOR LOCKS
COMPONENT LOCATION 201-P 6 RG. CONN

Convenience Center.............. Under L H of IP, on Bulkh e ad .............................. 3 3 ... .. 44
Power D oor Contact or C a rgo .. Upper R H Rear Body Opening and D oor
D oor Jamb Switch, L F .......... A t L H end of IP ............................................... 4 5 ... .. 59
D oor Jamb Switch, L R .......... Center inside edge of L H B P illa r....................... 6 8 ... .. 88
D oor Jamb Switch, R F .......... A t R H end of I P ............................................... 4 5 ... .. 59
D oor Jamb Switch, R R .......... Center inside edge of R H B P illa r....................... . 6 8 ... .. 88
D oor Lock Control M odule..... Attached to body, forward o f L R W heelhousing....... 7 8 ... .. 104.... 202-68
D oor Lock Motor, L F ............ Inside L F Door, part of D oor H andle.................... 6 1 ... .. 79
D oor Lock Motor, L R ........... Inside L R Door, part of D oor Handle.................... 6 2 ... .. 80
D oor Lock Motor, R F ........... Inside R F Door, part o f D oor H andle..................... 6 1 ..... 79
D oor Lock Motor, R R ........... Inside R R Door, part of D oor Handle.................... 6 2 ... .. 80
D oor L o ck Motor, C argo........ Inside R R Door, at lower R H com er.................... 7 6 ... .. 102
D oor Lock Relay.................. Under center o f IP, near Remote Control D oor Lock
Receiver....................................................... 4 1 ... .. 5 3 .... 202-68
D oor Lock Switch, L F .......... O n L F D oor Trim Panel, below Inside D oor Handle, 6 1 ... .. 7 9 .... 202-41,
68
D oo r L o ck Switch, R F .......... O n R F D oor Trim Panel, below Inside D oor Handle. 6 1 ... .. 7 9 .... 202-31

Sw itch.............................. Low er L H o f I P ............................................... 3 2 ... ,. 43 .... 202-34
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ................... 3 2 ... ,. 43
C O N N EC T O R S:
C 2 0 8 .................................. Inside lower L H A P illa r.................................... 6 1 ... „ 7 9 .... 202-51
C 2 1 0 .................................. A t Convenience Center....................................... 3 3 ... .. 44 .... 202-51
C 2 1 3 .................................. Inside lower R H A P illa r.............................. ..... 6 1 ... .. 7 9 .... 202-52
C 2 9 8 .................................. Behind L H of IP, near Convenience Center............. 3 2 ... .. 43 .... 202-17,

18
C301 A t L F K ic k Panel, 4 7 ... .. 6 2 .... 202-20,

56
C 3 0 2 .................................. A t L F K ic k Panel......................................... 4 7 ... „ 6 2 .... 202-56
C 4 9 7 .................................. R H B Pillar................................................. 6 2 ... .. 80 .... 202-59
C 4 9 9 .................................. L H B Pillar................................................. 6 2 ... , 80.... 202-59
G R O U N D S:
G 200.................................. Behind L H of IP, below Fuse Block, on Tie Bar 3 2 ... ,. 43
G 202.................................. R H of IP, mounted to H V A C Plenum Bracket 50..... . 65
G 400.................................. R H B Pillar, near D oor Striker....................... 5 8 ... „ 76
G R O M M ETS:
P 5 0 0 .................................. A t L F D oor................................................ 6 1 ... . 79
P 6 0 0 .................................. A t R F D o o r................................................ 6 1 ... , 79


P 7 0 0 ................. A t L R D o o r............................................................... 62 80
P 8 0 0 ................. A t R R D o o r................................................................ 62 80
S P L IC E S :
S 2 0 4 ................. IP Harness, approx. 10 cm from Steering Colum n Harness

Breakout
S 2 0 8 ................. IP Harness, approx. 6 cm from IP Compartment B o x Lam p
Breakout
S 2 1 8 .............................. IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S 2 5 1 .............................. Crossbody Harness, approx. 13 cm right of L F D oor

S255 (Crew C a b )............. Crossbody Harness, approx. 20 cm from C 210 Breakout,

S255 (Pickup/Extended Cab) Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness
5255 (Suburban/Utility)..... Crossbody Harness, approx. 18 cm from C 210 Breakout,

5256 (2-Door
Utility/Pickup/
Extended Cab)............... . Crossbody Harness, approx. 12 cm from C 210 Breakout,

Suburban)..................... Crossbody Harness, approx. 19 cm from C210 Breakout,
5256 (Crew C a b ).............. Crossbody Harness, approx. 1 cm from D oor Lock Relay
5257 (Crew C a b ).............. Crossbody Harness, approx. 8 cm left o f D oor Lock Relay
S257 (Pickup/Extended Cab). Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness Breakout
5257 (Suburban/Utility)...... Crossbody Harness, approx. 5 cm from C231 Breakout,

toward D oor lock relay Breakout
5258 (2-Door Utility)......... Crossbody Harness, approx. 12 cm from Seat Belt Switch
Breakout, toward R H D oor Harness Breakout

Suburban)..................... Crossbody Harness, approx. 11 cm from C210 Breakout,
5259 .......................... Crossbody Harness, approx. 7 cm into Seat Belt Switch,

toward C299
5260 .......................... Crossbody Harness, approx. 6 cm from Seat Belt Switch

5261 .......................... Crossbody Harness, approx. 12 cm from Seat Belt Switch

Breakout, toward R H Door Harness Breakout
POWER DOOR LOCKS

S262 (Crew C a b )................. Crossbody Harness, approx. 19 cm from Seat Belt Switch
S262 (Suburban/Utility)......... Crossbody Harness, approx. 25 cm from Seat Belt Switch


S264 (Gas, Suburban/

U tility )............................. IP Harness, approx. 8 cm from Instrument Cluster Breakout,
Breakout


D o o rs).................... ......... Front-to-Rear Body Harness, approx. 7 cm from Rear Dom e
Lam p Harness Breakout, toward Rear W indow Defogger
Breakout

w/Rear Heat)..................... Front-to-Rear Bod y Harness, approx. 7 cm from Rear
W indow Defogger Harness Breakout, toward L R Speaker
Breakout

w/o Rear H eat).................. Front-to-Rear Bod y Harness, approx. 32 cm into Crossbody
Harness Breakout

w/o C 6 9 )......................... Front-to-Rear B od y Harness, approx. 65 cm into Crossbody
Harness Breakout
S432 (2-Door U tility w/Cargo

D o o rs)............................. Front-to-Rear Bod y Harness, approx. 7 cm from L H D oor
Speaker Breakout, toward Rear Dom e Lam p Switch
Breakout

w/o C 6 9 )......................... Front-to-Rear Body Harness, in Crossbody Harness
Breakout, approx. 140 cm from C301 Breakout

w/o Rear H eat).................. Front-to-Rear Body Harness, in Crossbody Harness
Breakout, approx. 13 cm from C 232 Breakout

Suburban)......................... Front-to-Rear Bod y Harness, approx. 7 cm from Rear Dom e
Lam p Harness Breakout, toward L R Speaker
S434 (2-Door U tility )............ Front-to-Rear Bod y Harness, approx. 7 cm from Front
Breakout

Harness Breakout, toward Rear Dom e Lam p Harness
Breakout

w/o C 6 9 )......................... Front-to-Rear Body Harness, approx. 25 cm into Crossbody
Harness Breakout
S500 Inside L F D oor Harness, approx. 8 cm from Tweeter


w /R K E )............................ Inside R F D oor Harness, approx. 8 cm from W indow
Regulator M otor Breakout, toward D oor Lock M otor

w /R K E)............................ Inside R F D oor Harness, approx. 11 cm from W indow
DIAGNOSIS - POWER DOOR LOCKS
TROUBLESHOOTING HINTS: malfunction but prove G O O D in a continuity/voltage

I. C H E C K that P W R A C C Y Circuit Breaker and C IG check with a system disconnected. These circuits may
L T R Fuse 13 are not open. If fuse is open, L O C A T E be intermittent or resistive w hen loaded, and if
and R E P A IR source o f overload, then R E P L A C E fuse. possible, should be checked by m onitoring for a
If circuit breaker is open, L O C A T E and R E P A IR voltage drop with the system operational (under load).
source o f overload, then C H E C K circuit breaker for • C H E C K fo r proper in sta lla tio n o f afterm arket
proper operation. If breaker does not reset, R E P L A C E electronic equipment which m ay affect the integrity of
circuit breaker. other systems. See Troubleshooting Procedures.
• C H E C K for a broken (or partially broken) wire inside 2. See Section 8 A -1 3 2 for ve h icles equipped w ith
o f the in s u la tio n w h ic h c o u ld cau se sy ste m Remote Keyless Entry.
POWER DOOR LOCKS
POWER DOOR LOCKS INOPERATIVE FROM EITHER SWITCH (PICKUP)

TEST RESULT ACTION
1. Connect a test lamp from O R N Test lamp lights. G O to step 2.
(540) wire from L H Power D oor Test lamp does not light. L O C A T E and R E P A IR open in O R N
Lock Switch Connector to ground. (540) wire between Splice S255 and
the Convenience Center or from
Convenience Center to Fuse Block.
2. Connect a test lamp from O R N Test lamp lights. R E P L A C E L H lock switch.
(540) wire to B L K (150) wire at Test lamp does not light. L O C A T E and R E P A IR open in B L K
L H P ow er D o o r L o c k Sw itch (150) wire(s) from Power D oor Lock
Connector. Switch to Splice S500 or from Splice
S500 to Connector C208 or from
Connector C208 to Splice S251 or
from Splice S251 to Convenience
Center Connector C 210 or from
Convenience Center to Ground G200.
BOTH POWER DOOR LOCK SWITCHES OPEN ONLY ONE POWER DOOR LOCK (PICKUP)
TEST RESULT ACTION
1. Disconnect m alfunctioning D oo r Test lamp lights. G O to step 2.
L o ck M otor Connector. Connect a Test lamp does not light. L O C A T E and R E P A IR open in T A N
test lamp from T A N (294) wire at (294) wire from Power D oor Lock
Power Door Lock Motor M otor Connector to Splice S600.
Connector to ground. M ove one
P o w e r D o o r L o c k S w itc h to
U N L O C K position.
2. Connect a test lamp from G R Y Test lamp lights. R E P L A C E Power D oor Lock Motor.
(295) wire to T A N (294) wire at Test lamp does not light. L O C A T E and R E P A IR open in G R Y
in o pe rative P ow er D o o r L o c k (295) wire from inoperative Power
Motor. M o ve one o f the Power D oor Lock M otor to Splice S601.
D oo r Lock Switch to U N L O C K
position.
BOTH POWER LOCK MOTORS INOPERATIVE (SUBURBAN/UTILITY)

TEST RESULT ACTION
1. Disconnect the L F Pow er D o o r Test lamp lights. G O to step 2.
L o ck Switch. Connect a test lamp Test lamp does not light. L O C A T E and R E P A IR open in
from O R N (640) wire at L F Power O R N (640) wire between Convenience
D oo r L o ck Switch to ground. Center and IP Fuse Block.
2. Connect a test lamp from O R N Test lamp lights. L O C A T E and R E P A IR the open in
(540) wire to B L K (150) wire at W H T (194) wire and L T B L U (195)
Pow er D oor Lock Relay. wire between Splices S257 and S261
and Power D oor Lock Relay. If no
open is found, R E P L A C E L H Power
D oor Lock Switch.
(150) wire between Power D oor Lock
Relay and Splice S251 or between
Splice S251 and Convenience Center.
A lso C H E C K B L K (150) wire from
Convenience Center to IP Ground
G 200 and O R N (540) wire between
Power D oor lock Relay and IP Fuse
Block.
BOTH POWER DOOR LOCK SWITCHES ONLY OPEN ONE POWER DOOR LOCK
(SUBURBAN/UTILITY)
TEST RESULT ACTION
1. D isco n n e c t in o pe rative Pow er Test lamp lights. G O to step 2.
D oor Lock Motor. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in T A N
lam p from T A N (294) wire at (294) wire from inoperative Power
P o w e r D o o r L o c k M o t o r to D oor Lock M otor to Splice S258.
ground. M o ve one Pow er D oor
L o c k S w it c h to U N L O C K
position.
2. C onnect test lam p from G R Y Test lamp lights. R E P L A C E D oor Lock Motor.
(295) wire to T A N (294) wire at Test lamp does not light. L O C A T E and R E P A IR open in G R Y
inoperative P ow er D o o r L o c k (295) wire from inoperative Power
M o to r C o n n e c to r. M o v e one D oor Lock M otor Connector to Splice
P o w e r D o o r L o c k S w itc h to S260.
POWER DOOR LOCKS ONLY WORK FROM ONE POWER DOOR LOCK SWITCH
(SUBURBAN/UTILITY)
TEST RESULT ACTION
1. D isco n n e c t inoperative P ow er Test lamp lights. G O to step 2.
D oor Lock Switch. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in O R N
lam p from O R N (640) wire to (640) wire between inoperative Power
P ow er D o o r L o c k Sw itch and D oor Lock Switch and Splice S256.
ground.
2. C onnect a fused jum per from Doors lock and unlock. Replace Switch.
inoperative Pow er D o o r L o c k Doors do not lock and unlock. Check C K T 194 and C K T 195 for
Switch Terminal “D ” to Terminal opens. R E P A IR as necessary.
“E ” , then to Terminal “C ” .
POWER DOOR LOCKS ONLY WORK FROM ONE LOCK SWITCH (2 DOOR PICKUP)
TEST RESULT ACTION
1. Connect a test lamp from O R N Test lamp lights. R E P L A C E inoperative Power D oor
(540) wire at inoperative Power Lock Switch.
D oor Lock Switch to ground. Test lamp does not light. L O C A T E and R E P A IR open in O R N
(540) wire from inoperative Power
D oor Lock Switch to Splice S255.
POWER DOOR LOCKS
CARGO DOOR LOCK MOTOR DOES NOT LOCK /UNLOCK (SUBURBAWUTILITY)

TEST RESULT ACTION
1. Open Rear Cargo Doors. Connect Test lamp lights. G O to step 2.
a test lamp from T A N (294) or Test lamp does not light. L O C A T E and R E P A IR open in T A N
G R Y (295) wire(s) at Cargo Door (294) or G R Y (295) wire(s) from
Contactor to ground. M ove one Contactor to Splice(s) S260 or S258.
power D oor Lock Switch to the
L O C K or U N L O C K position.
2. Close Cargo Doors. Connect a test Test lamp lights. G O to step 3.
lam p from G R Y (295) wire at Test lamp does not light. L O C A T E and R E P A IR open in G R Y
P o w e r D o o r L o c k M o to r (295) wire from Power D oor Lock
Connector to ground. M ove one M otor to Contactor.
P o w e r D o o r L o c k S w itc h to
3. Connect a test lamp from G R Y Test lamp lights in both positions. R E P L A C E Cargo D oor Lock Motor.
(295) wire to T A N (294) wire at Test lamp does not light in one or both L O C A T E and R E P A IR open in T A N
Pow er D o o r L o ck Motor. M ove positions. (294) wire from Power D oor Lock
P o w e r D o o r L o c k S w itc h to M otor to Contactor.
L O C K and then to U N L O C K
positions.
CIRCUIT OPERATION A sim ilar action occurs with either of the Power D oor
(LH/RH DOORS) Lock Switches closes to the U N L O C K position. The T A N
W hen a Power D oor Lock Switch is operated, all of (294) wires to the motors supply battery voltage and the
the doors w ill L O C K or U N L O C K . Each lock can also be G R Y (295) wires are grounded. The polarity of the voltage
operated manually. The locks are operated by reversible to the motors has reversed. The motors run in the opposite
motors that receive voltage from the P W R A C C Y Circuit direction to U N L O C K the Doors.
Breaker. The Power D oor Lock Switches operate to turn The Power D oor Lock Switches are usually closed for
the motors on by supplying battery voltage to one o f the just a moment. If the Power D oor Lock Switches are held
terminals and by grounding the other terminal. closed, a circuit breaker in each motor w ill open to protect
W hen either Power D oor Lock Switch is moved to the against damage. The circuit breakers close automatically
L O C K position, the circuit to the motors is complete. when they cool off.
Voltage is supplied to the G R Y (295) wire and to the D oor
Lock Motors, which are grounded by the T A N (294) wire REAR CARGO DOORS
from the other terminal of the motor ,through the other The Rear Cargo D oors must be fully closed for the
switch contact and through the D oor Lock Relay to the Power D oor Lock M otor to operate. The Power D oor Lock
B L K (150) wire and Ground G200. The motor in each door M otor is located in the R R Cargo Door. Contactors are
runs to operate the Power D oor Locks. W hen the Power located on the Rear Cargo D oor opening on the body and
D oor Lock Switch is released, the circuit is opened, and the also on the R R Cargo Door.
motors turn off.
REMOTE KEYLESS ENTRY
■
I HOT AT ALL TIMES
r — ----------------
t
1
i i p
• CIGLTR I FUSE
I S FUSE 13 I BLOCK TO INTERIOR
LAMPS
I C 20 A I
PAGE 8 A -I1 4 - 9
I C3 I
l _ __
1 ORN 640
DOOR LOCK
PICKUP
SUBURBAN/ EXTENDED CAB CONTROL
utility
CREW CAB ONLY MOOULE
.A .
REAR
.8ORN DOOR DOOR
LOCK UNLOCK JAM SWITCH
BATTERY SIGNAL SIGNAL SWITCH SIGNAL GROUND
FROM
PAGE 8 A - 1 3 2 -0 V
TO 03-10*97
PAGE 8 A - 1 3 2 - 2 4208W 0620
FROM
rO N T A C T O B
FROM
PAGE 8 A - 1 3 2 -1
.5 PPL I 328
c ;I /C 3 0 2
.5 PPL I 328
| a DOOR| | 2 DOOR 1
.5
DOOR JAMB
SWITCH. RR
(CLOSED
WITH DOOR
OPEN)
328
1 HEADLAMP
| ANO PANEL (
| DIMMER SWITCH
I SEE INTERIOR
1 LAMPS
| SECTION 8 A - I 1 4
GROUND
03* 10 *9 7
4200W 0022
FROM
PAGE 8 A - 1 3 2 - 0
SEE LIFTGATE
WMDOW RELEASE
SECTION B A -1 3 4
■ ■
T
.8BLK I 1576
m + S 265
SEE GROUNO
DISTRIBUTION
PAGE 8 A - 1 4 - 4 , 5
S J i? 8 A - 1 4 - 6 , 7
(DIESEL)__________
T T
I I
— J |
S I 62 (GAS) _
0 V Cl
I S 107 (DC SEL) |
150 |
.8 BLK 150
5 SBLK
t 47 | a150 ■ ■ m am m m J
03-10-97
4209W 0623

Cargo D oor Contactor, L H ...... Rear Body Opening and Door, upper L H .................. 76.... .. 101
Cargo D oor Contactor, R H ...... Rear Body Opening and Door, upper R H .................. 76.... .. 102
D oor Lock Switch, L a st......... Top of R H D Pillar............................................... 78.... .. 105
D oor Lock Switch, L F ........... O n L F D oor Trim Panel, below Inside D oor H andle... 61.... .. 7 9 .... 202-41,
68
D oor Lock Switch, R F .......... O n R F D oor Trim Panel, below Inside D oor Handle... 61.... .. 7 9 .... 202-31
Convenience Center.............. Under L H of IP, on Bulkhead................................. 3 3 ..... 44
Data L in k Connector ( D L C ) ... Under L H of IP, L H of Steering Colum n, mounted to

bottom of Knee Bolster....................................... 4 3 ..... 5 5 .... 202-30
D oor Jamb Switch, C a rg o ...... Rear Body Opening, part of R R Cargo D oor Contactor 7 6 ..... 102
D oor Jamb Switch, L F .......... A t L H end of IP ................................................... 4 5 ..... 59
D oor Jamb Switch, L R .......... Center inside edge of L H B P illa r........................... 6 8 ..... 88
D oor Jamb Switch, R F .......... A t R H end of I P .................................................. 4 5 ..... 59
D oor Jamb Switch, R R .......... Center inside edge of R H B P illa r........................... 6 8 ... .. 88
D oor Lock Control M odule..... Attached to body, forward of L R W heelhousirig.......... 7 8 ... .. 104.... 202-68
D oor Lock Motor, C argo........ Inside R R Door, at lower R H com er........................ 7 6 ... .. 102
D oor Lock Motor, L F ............ Inside L F Door, part of D oor H and le....................... 6 1 ... .. 79
D oor Lock Motor, L R ........... Inside L R Door, part of D oor Handle....................... 6 2 ..... 80
D oor Lock Motor, R F ............ Inside R F Door, part of D oor H andle....................... 6 1 ..... 79
D oor Lock Motor, R R ........... Inside R R Door, part o f D oor Handle....................... 6 2 ..... 80
D oor Lock Relay.................. Under center of IP, near Remote Control D oor Lock
Receiver........................................................... 4 1 ... .. 5 3 .... 202-68
D oor Lock Switch, L F ........... 202-41,

O n L F D oor Trim Panel, below Inside D oor H andle... 6 1 ... „ 7 9 .... 68
D oor Lock Switch, R F .......... O n R F D oor Trim Panel, below Inside D oor Handle... 6 1 ... .. 7 9 .... 202-31

Sw itch............................. Low er L H of I P ................................................... 3 2 ... .. 4 3 .... 202-34
Horn Sw itch......................... Top of Steering Colum n under Steering W heel P ad..... 4 7 ... .. 61
IP Fuse B lo ck ...................... L H of IP, near L F Door Jamb Sw itch ...................... 3 2 ... „ 43
Liftgate Release M o to r.......... In R H center of Liftgate......................................... 6 8 ... .. 8 7 .... 202-68

Receiver........................... Under center of IP, R H of Knee B o lste r................... 2 7 ... ,. 4 3 .... 202-45
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender..................... 5 ....... 9
CONNECTORS:
C 2 0 8 .................................. Inside lower L H A Pillar............................ ........... 6 1 ... . 7 9 .... 202-51
C 2 0 9 .................................. Inside lower L H A Pillar........................................ 6 1 ... . 7 9 .... 202-51
C 2 1 0 .................................. A t Convenience Center.......................................... 3 3 ... „ 4 4 .... 202-51
C 2 1 3 .................................. Inside lower R H A P illa r....................................... 6 1 ... , 7 9 .... 202-52

C 2 9 8 ................................ Behind L H of IP, near Convenience Center.............. ....... 3 2 .... 43.... 202-17,
18
C 3 0 1 ............................... A t L F K ic k Panel................................................ ....... 4 7 .... 6 2 .... 202-20,

56
C 3 0 2 ............................... A t L F K ic k Panel................................................ ....... 4 7 .... 6 2 .... 202-56
C 4 9 7 ................................ R H B Pillar........................................................ ....... 6 2 .... 80.... 202-59
C 4 9 9 ............................... L H B P illar........................................................ ....... 6 2 .... 80.... 202-59
GROMMETS:
P 5 0 0 ................................ A t L F D oo r........................................................ ....... 6 1 .... 79
P 6 0 0 ............................... A t R F D o o r........................................................ ....... 6 1 .... 79
P 7 0 0 ................................ A t L R D o o r........................................................ ....... 6 2 .... 80
P 8 0 0 ................................ A t R R D o o r....................................................... ....... 6 2 .... 80
GROUNDS:
G 105 ............................... R F of Engine b lo c k ............................................. ....... 13.... 17
G 200 ............................... Behind L H o f IP, below Fuse Block, on Tie B a r....... ....... 3 2 .... 43
G 202 ............................... R H of IP, mounted to H V A C Plenum Bracket........... ........ 5 0 .... 65
G 400 ............................... R H B Pillar, near D oor Striker............................... ........ 5 8 .... 76
SPLICES:
S 2 0 4 ............................... IP Harness, approx. 10 cm from Steering Colum n Harness
Breakout
S 2 0 8 ............................... IP Harness, approx. 6 cm from IP Compartment B o x Lam p

Breakout
S 2 1 3 ............................... IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
S 2 1 8 ............................... IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S 2 4 6 ............................... Crossbody Harness, approx. 22 cm from L F D oor Harness

Breakout
S 2 5 1 ............................... Crossbody Harness, approx. 13 cm right of L F D oor

S255 (Crew C a b ).............. Crossbody Harness, approx. 20 cm from C 210 Breakout,

S255 (Pickup/Extended Cab). Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness
5255 (Suburban/Utility)...... Crossbody Harness, approx. 18 cm from C 210 Breakout,

S 2 5 6 ( 2 - D o o r U t ilit y /
Pickup/Extended C a b )...... Crossbody Harness, approx. 12 cm from C 210 Breakout,

Suburban)..................... Crossbody Harness, approx. 19 cm from C 210 Breakout,

S256 (Crew C a b ).................. Crossbody Harness, approx. 1 cm from D oor Lock Relay
S257 (Crew C a b ).................. Crossbody Harness, approx. 8 cm left o f D oor Lock Relay
S257 (Pickup/Extended C ab )... Crossbody Harness, approx. 5 cm from C231 Breakout,

S257 (Suburban/Utility).......... Crossbody Harness, approx. 5 cm from C231 Breakout,

toward Door lock relay Breakout
S258 (2-Door U tility)............. Crossbody Harness, approx. 12 cm from Seat Belt Switch

Suburban)......................... Crossbody Harness, approx. 11 c m from C 210 Breakout,
S 2 5 9 .......................... ........ Crossbody Harness, approx. 7 cm into Seat Belt Switch,

toward C299
S 2 6 0 .................................. Crossbody Harness, approx. 6 cm from Seat Belt Switch


S262 (Crew C a b ).................. Crossbody Harness, approx. 19 cm from Seat Belt Switch
S262 (Suburban/Utility).......... Crossbody Harness, approx. 25 cm from Seat Belt Switch


S410 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 37 cm from R R D oor

Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 12 cm from R R Door

D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from Rear Dom e
Breakout

w/Rear Heat)..................... Front-to-Rear Body Harness, approx. 7 cm from Rear
Breakout

w/o Rear H eat).................. Front-to-Rear Body Harness, approx. 32 cm into Crossbody
Harness Breakout

w/o C 6 9 ).......................... Front-to-Rear Body Harness, approx. 65 cm into Crossbody
Harness Breakout
D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from L H Door
Breakout


w/o Rear H eat)................. Front-to-Rear Body Harness, in Crossbody Harness

Suburban)........... . Front-to-Rear Body Harness, approx. 7 cm from Rear Dom e
S434 (2-Door U tility )............ Front-to-Rear Body Harness, approx. 7 cm from Front
Breakout

Breakout

Harness Breakout
DIAGNOSIS - REMOTE KEYLESS ENTRY

TROUBLESHOOTING HINTS: should be checked by monitoring for a fuse voltage
1. C H E C K that Grounds G200, G202, and G 400 are drop with the system operational (under load).
clean and tight. •CHECK fo r proper in sta lla tio n o f afterm arket
2. C H E C K G AUG ES F u se 4 b y o b s e r v in g the electronic equipment which may affect the integrity of
Instrument Cluster Gauges. other systems. See Troubleshooting Procedures.
3. C H E C K C IG L T R Fuse 13 by operating the Cigar 6. If a second Transmitter is available, T R Y it. If it
Lighter. works, C H A N G E the Batteries in the first Transmitter
4. C H E C K P W R A C C Y Circuit Breaker for an open and T R Y again. If it still doesn’t work, it is defective.
R E P L A C E Transmitter.
condition. If breaker is open, L O C A T E and R E P A IR
7. C H E C K that Portable Transmitter Battery Terminals
source of overload. R E P L A C E breaker.
are clean and make good contacts with the Battery.
5. C H E C K term inal contact before re p lacin g any
8. If in doubt as to the condition o f the Transmitter
component.
Batteries, R E P L A C E them with new ones. C H E C K
• C H E C K for a broken (or partially broken) wire inside Battery Voltage with a D M M for proper results.
o f the insulation which could cause system failure but R E F E R to for Remote Control D oor Lock Receiver
prove "good " in a continuity/voltage check with a section access and additional information. C H E C K for
sy ste m d isco n n e cte d . T h e se c irc u its m ay be a broken (or partially broken) wire inside o f the
intermittent or resistive when loaded, and if possible, insulation which could cause system failure but prove
G O O D in continuity/voltage check.
REMOTE KEYLESS ENTRY DOES NOT OPERATE

TEST RESULT ACTION
1. Does the R H Power D oor Lock Yes G O to Step 2.
operate from either o f the vehicle’s N o R E F E R to S E C T IO N 8A-130 for
Power D oor Lock Sw itches? diagnosis of Power D oor Locks.
2. D oes the Rear W indow operate Yes G O to Step 3.
from v e h ic le ’s R e a r W in d o w N o R E F E R to Rear W indow Release in
Release Sw itch? S E C T IO N 8A-134.
3. D o e s L H P o w e r D o o r L o c k Yes G O to Step 4.
operate from either of vehicle’s N o R E F E R to S E C T IO N 8A-130 for
Power D oor Lock Sw itches? diagnosis of Power D oor Locks.
4. Disconnect the connector at the Test lamp lights. G O to Step 5. module.
R e m o te C o n t r o l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in B L K
Receiver. Connect a test lam p (150) wire between Remote Control
b etw een B L K (1 5 0 ) w ire at D oor Lock Receiver and Ground G202.
R e m o te C o n t ro l D o o r L o c k
Receiver Connector Cavity N and
B+.
R e m o te C o n tro l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in P N K
Receiver Connector Cavity J for (39) wire between Remote Control
the P N K (39) wire and ground. D oor Lock Receiver and the IP Fuse
T\im Ignition K ey O N. Block.
R e m o te C o n t ro l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in P N K
Receiver Connector Cavity F for (540) or P N K (640) wire between
the O R N (540-W /Lift Gate) or Remote Control Door Lock Receiver
(640-W /Cargo D o o rs) wire and and the IP Fuse Block.
ground.
R e m o te C o n tro l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in P N K
Receiver Connector Cavity E for (540)or P N K (640) wire between
the O R N (540) wire and ground. Remote Control D oor Lock Receiver
arid the IP Fuse Block.
8. Disconnect the connector at the Test lamp lights. G O to Step 9.
D oor Lock Relay. Connect a test Test lamp does light. L O C A T E and R E P A IR open in B L K
lamp between D oo r L o ck Relay (150) wire between D oor Lock Relay
Connector Cavity D for the B L K and Ground G202.
(150) wire and B+.
9. Connect a test lamp between D oor Test lamp lights. G O to Step 10.
Lock Relay Connector Cavity C Test lamp does light. L O C A T E and R E P A IR open in O R N
fo r the O R N (5 4 0 ) w ire and (540) wire between D oor Lock Relay
ground. and IP Fuse Block.
10. C on n ect the connector at the Test lamp lights. R E P L A C E the D oor Lock Relay.
R e m o te C o n t ro l D o o r L o c k Test lamp does not light. R E P L A C E the Remote Control D oor
Receiver. C onnect a test lam p Lock Receiver.
between the W H T (194) wire at
D o o r L o c k R e la y C o n n e c to r
Cavity A and ground. Push the
L O C K B u tton on the Rem ote
Transmitter.
8A - 132 ■ 10 ELECTRICAL DIAGNOSIS________________________________
ALL POWER DOORS DO NOT LOCK USING TRANSMITTER
TEST RESULT ACTION
1. Disconnect the connector at the Test lamp lights. G O to Step 3. module.
D oor Lock Relay. Connect a test Test lamp does not light. G O to Step 2.
lamp between W H T (194) wire at
D o o r L o c k R e la y C o n n e c to r
C avity A and ground. Push the
L O C K button on the transmitter.
2. Disconnect the connector at the Test lamp lights. R E P L A C E the Remote Control D oor
R e m o te C o n t r o l D o o r L o c k Lock Receiver.
Receiver. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in W H T
test lam p between the Rem ote (194) wire between D oor Lock Relay
C o n tro l D o o r L o c k R e c e iv e r and Remote Control D oor Lock
C onnector C a vity B and D o o r Receiver.
Lock Relay Connector Cavity A
for the W H T (194) wire. Check
for continuity.
3. Disconnect the connector at the L F Test lamp lights. R E P L A C E the D oor Lock Relay.
D o o r L o c k M otor. C on n ect a Test lamp does not light. L O C A T E and R E P A IR open in G R Y
self-powered test lam p between (295) wire between D oor Lock Relay
th e L F D o o r L o c k M o t o r and Splice S260.
C onnector C a vity A and D o o r
Lock Relay Connector Cavity E
for the G R Y (295) wire. Check for
continuity.
LF POWER DOOR DOES NOT UNLOCK USING TRANSMITTER

TEST RESULT ACTION
1. Disconnect the connector at the L F Test lamp lights. G O to Step 3.
D oor Lock Motor. Connect a test Test lamp does not light. G O to Step 2.
lamp between T A N (694) wire at
L F D o o r L o ck M otor Cavity B
and ground. Push the U N L O C K
button on the transmitter.
Receiver. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in T A N
test lam p between the Rem ote (694) wire between D oor Lock Relay
C o n tro l D o o r L o c k R e c e iv e r and L F D oor Lock Motor.
Connector Cavity A and L F D oor
Lock M otor Connector Cavity B
for the T A N (694) wire. Check for
continuity.
3. Connect a test lamp between the Test lamp lights. R E P L A C E the L F D oor Lock Motor.
L F D oor Lock M otor Connector Test lamp does not light. G O to Step 4.
Cavity A for the G R Y (295) and
Bat +.
4. Disconnect the, connector at the Test lamp lights. R E P L A C E the D oor Lock Relay.
D o o r L o c k R e la y. C o n n e ct a Test lamp does not light. L O C A T E and R E P A IR open in G R Y
self-powered test lam p between (295) wire between D oor Lock Relay
the D oor Lock Relay Connector and L F D oor Lock Motor.
C a v ity E and L F D o o r L o c k
M otor Connector Cavity A for the
G R Y (2 9 5 ) w ire . C h e c k fo r
continuity.
RF AND RR POWER DOORS DO NOT UNLOCK USING TRANSMITTER

TEST RESULT ACTION
D oor Lock Relay. Connect a test Test lamp does not light. G O to Step 2.
lamp between L T B L U (195) wire
at D oo r L o ck Relay Connector
Cavity F and ground. Push the
U N L O C K b u t t o n o n th e
transmitter.
Receiver. Connect a self-powered Test lamp does not light. L O C A T E and R E P A IR open in L T
test lam p between the Rem ote B L U (195) wire between D oor Lock
C o n tro l D o o r L o c k R e c e iv e r Relay and Remote Control D oor Lock
Connector C avity R and D o o r Receiver.
Lock Relay Connector Cavity F
for the L T B L U (195) wire. Check
for continuity.
3. Disconnect the connector at the Test lamp lights. R E P L A C E the D oor Lock Relay.
R F D oor Lock Motor. Connect a Test lamp does not light. L O C A T E and R E P A IR open in T A N
self-powered test lam p between (294) wire between D oo r Lock Relay
th e R F D o o r L o c k M o t o r and Splice S258.
C onnector C a vity B and D o o r
Lock Relay Connector Cavity B
for the T A N (294) wire. Check for
continuity.
CARGO POWER DOOR INOPERATIVE USING TRANSMITTER

TEST RESULT ACTION
1. Disconnect the connector C302. Test lamp lights. G O to Step 4.
C on n ect a test lam p between Test lamp does not light. G O to Step 2.
Connector C 302 C avity A and
ground for the T A N (294) wire.
Push the U N L O C K button on the
transmitter.
R e m o te C o n t r o l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in
Receiver. Connect a self-powered B L K / W H T (56) wire between
test lam p between the Rem ote Connector C 302 and Remote Control
C o n tro l D o o r L o c k R e c e iv e r D oor Lock Receiver.
C o n n e c t o r C a v it y G a n d
Connector C 302 Cavity Pin A for
the B L K / W H T (56) wire. Check
for continuity.
Cargo D oor Lock Motor. Connect Lock Receiver.
a self-powered test lamp between Test lamp does not light. Check that D oor Contactors are O K.
the C a rg o D o o r L o c k M o to r L O C A T E and R E P A IR open in T A N
C o n n e c t o r C a v it y B an d
(294) wire between Connector C302
Connector C 302 Cavity A for the and Rear Cargo D oo r Lock Motor.
T A N (294) wire. C L O S E doors.
Check for continuity.
4. C onnect a test lam p betw een Test lamp lights. G O to Step 5.
Connector C302 Cavity B for the
G R Y (295) wire and B+.
8A ■ 132 ■ 12 ELECTRICAL DIAGNOSIS
TEST RESULT ACTION
5. Disconnect the connector at the Test lamp lights. R E P L A C E the Cargo D oor Lock
R e ar C argo D o o r L o c k M otor. Motor.
Connect a self-powered test lamp Test lamp does not light. C H E C K that D oor Contactors are O K .
between the C argo D o o r L o c k L O C A T E and R E P A IR open in G R Y
M o to r Connector C avity A and (295) wire between Connector C 302
Connector C 302 Cavity B for the and Cargo D oor Lock Motor.
G R Y (295) wire. C L O S E doors.
6. Disconnect the connector at the Test lamp lights. R E P L A C E the D oor Lock Relay.
D o o r L o c k R e lay. C o n n e ct a Test lamp does not light. L O C A T E and R E P A IR open in G R Y
self-powered test lam p between (295) wire between Connector C 302
the D oor Lock Relay Connector and Splice S260.
C a vity E and C onnector C 3 0 2
Cavity B for the G R Y (295) wire.
LIFTGATE WINDOW RELEASE INOPERATIVE USING TRANSMITTER

TEST RESULT ACTION
Liftgate Release Motor. Connect a Test lamp does not light. G O to Step 2.
test lam p between the Liftgate
Release M otor Connector Cavity
A and ground. Push the Liftgate
Release button on the transmitter.
Receiver. Connect a self-powered Test lamp does not ligh t L O C A T E and R E P A IR open in B L K
test lam p between the Liftgate (1576) wire between the Remote
Release M otor Connector Cavity Control D oor Lock Receiver and Rear
A and Remote Control D oor Lock Cargo D oor Lock Motor.
Receiver Connector Cavity G for
the B L K (1576) wire. Check for
continuity.
3. C on n ect a test lam p between Test lamp lights. R E P L A C E the Liftgate Release Motor.
Liftgate Release M otor Connector Test lamp does not lig h t G O to Step 4.
Cavity B for the Y E L (1737) wire
and B +.
4. Disconnect the connector at the Test lamp lights. R E P L A C E the Liftgate Release Motor.
P ark/N e u tral P o sitio n Sw itch . Test lamp does not ligh t L O C A T E and R E P A IR open in Y E L
Connect a self-powered test lamp (1737) wire between Park/Neutral
between the Park/Neutral Position Position Switch and Liftgate Release
Sw itch Connector Cavity A and Motor.
Liftgate Release M otor Connector
C avity B for the Y E L (1737) wire.
ONE DOOR LOCK INOPERATIVE. USING TRANSMITTER (EXCLUDING LF DOOR)

TEST RESULT ACTION
D oor Lock Motor. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in T A N
lam p betw een the D o o r L o c k (294) wire between the D oor Lock
M otor Connector Cavity B for the M otor and Splice S258.
T A N (294) wire and ground. Push
the U N L O C K b u tto n on the
transmitter.
2. Connect a test lamp between the Test lamp lights. R E P L A C E the D oor L o ck Motor.
D o o r L o c k M o to r C o n n e c to r Test lamp does not light. L O C A T E and R E P A IR open in G R Y
Cavity A for the G R Y (295) wire (295) wire between the D oo r Lock
and B+. M otor and Splice S260.
HORN CHIRP FUNCTION INOPERATIVE USING TRANSMITTER

TEST RESULT ACTION
1. Disconnect the connector C210. Test lamp lights. R E F E R to S E C T IO N 8A -40 for
C on n ect a test lam p between diagnosis of Horn.
Connector C 210 Cavity F for the Test lamp does not light. G O to Step 2.
B L K (28) wire and B +. Push the
L O C K b u tto n tw ic e o n the
transmitter.
2. Disconnect the connector at the Test lamp lights. R E P L A C E the Remote Control Door
R e m o te C o n t ro l D o o r L o c k Lock Receiver.
Receiver. Connect a Self-powered Test lamp does not light. L O C A T E and R E P A IR open in B L K
test lam p between the Rem ote (28) wire between the Remote Control
C o n tro l D o o r L o c k R e c e iv e r D oor Lock Receiver and Connector
C o n n e c t o r C a v it y C an d C210.
Connector C 210 Cavity F for the
B L K (2 8 ) w ire . C h e c k fo r
continuity.
COURTESY LAMPS INOPERATIVE USING TRANSMITTER

TEST RESULT ACTION
R e m o te C o n t ro l D o o r L o c k Test lamp does not light. L O C A T E and R E P A IR open in W H T
Receiver. Remove the C T S Y Fuse (156) wire between the Remote Control
3 fro m the IP F u se B lo c k . D oor Lock Receiver and Splice S246.
Disconnect the Front Dom e and
Reading Lam p Connector. Connect
the Fro nt D om e and R e a d in g
Lam p Connector C avity A and
R e m o te C o n t r o l D o o r L o c k
Receiver Connector Cavity S for
the W H T (156) wire. Check for
continuity.
2. Disconnect the connector at the Test lamp lights. R E P L A C E the Remote Control Door
H ead lam p and P an e l D im m e r Lock Receiver.
Switch. Connect a self-powered L O C A T E and R E P A IR open in G R Y
test lamp between the Headlamp (157) wire between the Headlamp and
a n d P a n e l D im m e r S w it c h Panel Dim m er Switch and the Remote
Connector and the Remote Control Control D oor Lock Receiver.
D o o r L o ck Receiver Connector
Cavity S for the W H T (156) wire.
8A - 132 ■ 14 ELECTRICAL DIAGNOSIS__________________________
TRANSMITTER FUNCTIONS DO NOT OPERATE
TEST RESULT ACTION
1. Replace Transmitter Batteries with Yes System O K.
fresh ones if condition of Batteries N o G O to Step 2.
is unknown. D oes Transmitter now
operate all Remote Control Door
Lock functions?
2. Connect a fused jumper wire from Yes G O to Step 3.
B L K / W H T (1 4 5 5 ) w ire at the N o G O to Step 4.
D L C to ground. D o all Pow er
D oors lock and unlock?
3. Jumper connected. Obtain known Yes R E P L A C E inoperative Transmitter.
g o o d T ra n s m it t e r. O p e ra te Reprogram Remote Control D oor Lock
Transmitter by pressing a single Receiver to replacement Transmitter.
button once. Disconnect jumper N o R E P L A C E Remote Control D oor Lock
w ire. D o e s k n o w n go o d Receiver. Reprogram replacement
Transmitter now operate all remote Remote Control D oor Lock Receiver to
control functions? Transmitter.
4. Disconnect jumper wire. Connect Test lamp lights. L O C A T E and R E P A IR the B L K / W H T
a test lam p fro m B L K / W H T (1455) wire for a short to ground and
(1455) wire at the D L C , terminal reprogram Remote Control D oor Lock
8 to ground. Receiver.
No G O to Step 5.
CIRCUIT OPERATION supplied through the Remote Control D oor Lock Receiver.
Ground for the other three motors is supplied through the
POWER DOOR LOCKS/REMOTE KEYLESS D oor Lock Relay Assembly.
ENTRY
The Power D oor Locks/Remote Keyless Entry control U N LO C K
system allows the driver to operate the vehicle Door Locks W hen either of the Front D oo r L o ck Switches is
and Rear W indow Release from outside the vehicle using a pressed to the U N L O C K position, voltage is supplied from
hand-held radio Transmitter. The Transmitter operates in P W R A C C unlocking the doors. Ground for the M otors is
supplied through the D oor Lock Relay.
the U H F band and it sends coded signals to the Remote
Control D oor Lock Receiver. The Remote Control D oor
DOOR LOCK OPERATION - REMOTE
Lock Receiver detects and decodes the signal and issues
KEYLESS ENTRY
signals to control the D o o r L o ck s and Rear W indow
Release. These systems can also can be operated manually
LO CK
using the Power D oor Lock Switches. For information on
W hen the L O C K button is pressed on the Transmitter
the operation of the Rear W indow Release System, See
and the Remote Control D oor Lock Receiver receives a
Release Systems.
signal with a valid Vehicle Access Code (VA C), the lock
function sequence is performed. The Remote Control Door
DOOR LOCK OPERATION - SWITCHES Lock Receiver w ill lock all doors.
The Remote Control D oo r L o ck Receiver supplies
LO CK battery voltage to the coil of the Lock Relay (part of the
W hen either the L H or R H Front Power D oor Lock D oor Lock Relay Assem bly) through the C K T 195 wire.
Switches are pressed to the L O C K position, voltage is The L o ck Relay is energized, and battery voltage is
supplied from the P W R A C C Circuit Breaker, through the supplied to the D oor Lock Motors. Ground for the L H
O R N (540) wire, through the D o o r L o ck Sw itch to D oor Lock M otor is provided at the Remote Control Door
Terminal F of the D oor Lock Relay Assembly. This voltage Lock Receiver through internal contacts of the module.
energizes the Lock Relay Coil, allowing voltage to flow G round for the other D o o r L o ck m otors is provided
through the contacts of the U N L O C K Switch, inside the
through the relay to the D oor Lock Motors, locking all
D oor Lock Relay Assembly. A ll D oor Lock M otors run to
doors. Ground for the L H Front D oor Lock M otor is
Lock all Doors.
UN LO C K L H Rear and R H Rear D oor Lock Motors. The motors are

The unlock function is separated into two operations grounded through contacts of the Lock Switch, inside the
depending on how the U N L O C K button is pressed on the D oor Lock Relay Assembly. The motors run to unlock the
Transmitter. If the U N L O C K button is pressed once, only R H Front, L H Rear and R H Rear doors.
the L H D oor is unlocked. If the U N L O C K button is
pressed twice within one to five seconds, the other doors REAR WINDOW RELEASE
w ill be unlocked. W hen the Rear W indow Release button is pressed on
W hen the U N L O C K button is pressed once on the the Transm itter and the Rem ote C ontrol D o o r L o ck
Transmitter and the Remote Control D oor Lock Receiver Receiver receives a valid V A C , the Remote Control Door
receives a va lid V A C , the u n lock function sequence is Lock Receiver supplies battery voltage is applied to the
performed. The Remote C ontrol D o o r L o c k Receiver Liftgate G lass Release Motor.
supplies battery voltage to the L H Front D oor Lock M otor
through the C K T 694 wire. The motor is grounded through W ITH AU TO TR A N SM ISSIO N
the contacts of the Lock Switch inside the D oor Lock G round for the Liftgate G lass Release M otor is
Relay Assembly. The L H D oor Lock M otor runs to unlock supplied through the Park/Neutral Position Switch only in
the L H Front Door. the P A R K or N E U T R A L position. T h is prevents the
If the U N L O C K button on the Transmitter is pressed window from being opened while the vehicle is being
twice to U N L O C K all doors, the Remote Control Door driven.
Lock Receiver activates the door U N L O C K output. The
Remote Control D oor L o ck Receiver supplies battery W ITH M A N U A L TR A N SM ISSIO N
voltage to the coil of the unlock relay in the D oor Lock G round for the Liftgate G lass Release M otor is
Relay Assembly. The unlock relay is energized and closes supplied through the Park Brake Switch. This prevents the
its contacts, battery voltage is supplied to the R H Front, window from being opened while the vehicle is being
driven.
LIFTGATE WINDOW RELEASE
T IP
OG LTR | FUSE
j BLOCK
FUSE 13
20 A
I
J
.8 ORN I 6 4 0
SEE FUSE
: W■
S 264 , BLOCK DETAILS
PAGE 8 A - 1 1 - 1 2
.8ORN |
C,
T T
I6 f
640
1 LfTGATE
I f | RELEASE
| / | SWITCH
ENGINE
GROUND
03-19-97
4206W 0584

Convenience Center............. ,. Under L H of IP, on Bulkhead.............. ......................... . 3 3 .... 44
IP Fuse B lo ck ..................... .. L H of IP, near L F D oor Jamb Sw itch ............................ . 3 2 ... . 43
Liftgate W indow Release

M o to r................................ In R H center o f Liftgate............................................... . 6 8 .... 8 7 .... 202-68
Liftgate W indow Release

Sw itch............................ .. Center of IP, L H o f Radio

Switch, Connector C l ....... ... A t L H center of Transm ission....................................... . 2 3 .... 3 1 .... 202-67

Switch, Connector C 2 ....... ... A t L H center of Transm ission....................................... . 2 3 .... 3 1 .... 202-67

Receiver.......................... .. Under center of IP, R H of Knee B o lste r......................... . 27...... 4 3 .... 202-45
C O N N EC T O R S:
C 100 (D ie sel)........................ Engine Harness to IP Harness, L R of Engine Compartment,

at Bulkhead................................. ........................... . 4 ..... 8 ...... 202-0
C 200 (G a s)........................ .. Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 49...... 202-10
C 2 1 0 ................................. .. A t Convenience Center...... .......................................... . 3 3 .... 4 4 .... 202-51
C 2 9 8 ................................. .. Behind L H of IP, near Convenience Center..................... . 3 2 .... 4 3 .... 202-17,

18
C 3 0 1 ................................. .. A t L F K ic k Panel....................................................... . 4 7 .... 6 2 .... 202-20,

56
C 314 (Suburban/Utility)........ .. A t center and rear of body, near Endgate........................ 202-56
C 450 (Suburban/Utility)........ .. Inside Endgate................................................ ........... . 6 8 .... 8 7 .... 202-58
G R O M M ETS:
P 1 0 1 ................................. .. R R of Engine Compartment, at Bulkhead........................ . 7 ...... 12
G R O U N D S:
G 105 ................................. .. R F of Engine block...................... ..... ......................... . 1 3 .... 17
S P L IC E S :
S107 (4.3L) ......................... Engine Harness, approx. 25 cm from E G R Valve Breakout,

S107 (5.0L, 5.7L) ............... ,. Engine Harness, approx. 35 cm from E G R Valve Breakout,
S107 (6.5L, H D ) ................. .. Engine Harness, approx. 30 cm from E B C M Breakout,

S107 (6.5L, L D ) .................. .. Engine Harness, approx. 24 cm from E B C M Breakout,

S107 (7.4L) ......................... Engine Harness, approx. 18 cm from E B C M Breakout,


LIFTGATE WINDOW RELEASE


Breakout
S I 62 (4.3L, 5.0L, 5.7L - L D ) .. Engine Harness, approx. 17 cm from Starter Solenoid

Breakout, toward L H O xygen Sensor Breakout
S I 62 (5.0L -H D , 5.7L - H D )... Engine Harness, approx. 43 cm from L H Oxygen Sensor

S I 62 (7.4L - A/T)................. Engine Harness, approx. 40 cm from L H O xygen Sensor

S I 62 (7.4L - M / T )................ Engine Harness, approx. 15 cm from R H Bank Oxygen


5264 (Gas, Suburban/

5265 (Suburban/Utility)......... Crossbody Harness, approx. 8 cm from L F D oor Breakout
DIAGNOSIS - LIFTGATE WINDOW RELEASE
TROUBLESHOOTING HINTS: be interm ittent or re sistive w hen loaded and if

1. C H E C K to see that C IG L T R Fuse is not open. If fuse possible, should be checked by m onitoring for a
is open, L O C A T E and R E P A IR source o f overload. voltage drop with the system operational (under load).
R E P L A C E Fuse. 3. C H E C K fo r proper in sta lla tio n o f afterm arket
2. C H E C K for a broken (or partially broken) wire inside electronic equipment which may affect the integrity of
o f the in s u la tio n w h ic h c o u ld cau se sy ste m other systems. See Troubleshooting Procedures.
malfunction but prove G O O D in a continuity/voltage 4. C H E C K for mechanical binding o f linkage.
check with a system disconnected. These circuits may
LIFTGATE WINDOW RELEASE INOPERATIVE

TEST RESULT ACTION
1. S e t P a r k B r a k e . P l a c e Test lamp lights. G O to Step 2.
Transm ission in Park or Neutral. Test lamp does not light. L O C A T E and R E P A IR open in
C o n n e c t a t e st la m p fro m O R N (640) wire between Liftgate
B L K ( 1 5 7 6 ) w ire at L iftg a te W indow Release Switch and IP Fuse
W in d o w R e le a s e S w it c h to Block. If O K , R E P L A C E Liftgate
ground. Press Liftgate W indow W indow Release Switch.
Release Switch.
2. D isc o n n e c t L iftg a te W in d o w Test lamp lights. G O to Step 3.
Release M otor. C onnect a test Test lamp does not light. L O C A T E and R E P A IR open in B L K
lam p from B L K (1 5 7 6 ) w ire at (1576) wire between Liftgate W indow
Liftgate W indow Release M otor to Release Switch and Liftgate W indow
ground. Press and hold switch. Release Motor.
3. Connect a self-powered test lamp Test lamp lights. R E P L A C E Liftgate W indow Release
from G R N (1737) wire at Liftgate Motor.
W indow Release M otor to ground. Test lamp does not light. L O C A T E and R E P A IR open in Y E L
(1737) wire between Liftgate Release
M otor and Park/Neutral Position Switch
or open in B L K (1 5 0 ) wire between
Park/Neutral Position Switch and
ground. If no open is found,
R E P L A C E Park/Neutral Position
Switch.
CIRCUIT OPERATION This switch is closed to ground with the Transm ission
Voltage to the R ear W in d ow Release system is in Park or Neutral. C losing the Liftgate W indow Release
available at all times through the C IG L T R Fuse and O R N switch allows current to flow through the Switch and B L K
(640). Ground for the Rear W indow Release M otor is (1576) to the Liftgate W indow Release Motor.
provided through Y E L (1737) through the Park/Neutral
Position Switch (A/T).
8A - 138 - 0 ELECTRICAL DIAGNOSIS______________________________
BRAKE TRANSAXLE/TRANSMISSION SHIFT INTERLOCK (BTSI)
HOT IN RUN OR START

1
r — ^ — — — tip
! H 4T TURN 8 / U J
^ FUSE 16 | BL0CK
I
20 A |
* J3
L. _
TURN
/HAZARO
FLASHER
SECTION 8 A -1 1 0
◄
■8 PNK
139
/ “ ' “ ‘I 1
139
C7 V / C100
I
.8 PNK 139
r— PARK/NEUTRAL
I 9 | POSITION SWITCH
I \ | (a O S E D W PARK ONLY)
I 1
L' ± ____J
B 'w
V -//CC1I
RN 1
.8 LT GRN I 27 75
5
A pioi
F I (OIESEL)
D I (GAS)
y C200
.8 LT CRN I 2 75
.8LT GRN TRANSFER
■CASE
]/ ~ 275 CONTROLS
C y C227
.8LT CRN I 275
r
I TSTOPLAMP
| T I SWITCH
I / I (SHOWN W/BRAKE
APPLIED)
I l.J t i" " '"
L____
.8DK CRN/WHT
Y1 1135
.8BLK 1 150
A16 / i s C266
.8BLK | 150
SEE GROUND
S 204 • m mm mm m ^ DISTRIBUTION
| ^ PACE 8 A - 1 4 - 3
3 BLK 1 ISO
T
_ J lr C 2 0 0
03-17-97
— IP GROUND 4208W 0672

Brake/Transmission Shift
Interlock (B T S I) Solenoid... ,. L H of IP, R H of Steering Colum n, under Support Bracket.... 4 4 .... 57
IP Fuse B lo ck ..................... ,. L H of IP, near L F D oor Jamb Sw itch ............................. . 3 2 .... 43

Switch, Connector C l ........,. A t L H center of T ransm ission....................................... . 2 3 .... 31 .... 202-67

Switch, Connector C 2 .......... A t L H center of T ransm ission....................................... . 2 3 .... 3 1 .... 202-67
Stoplamp Switch.................. ,. Top of Brake Pedal..................................................... . 4 4 .... 5 7 .... 202-70
C O N N EC T O R S:
C 1 0 0 ................................. ,. Engine Harness to IP Harness, L R of Engine Compartment,

at Bulkhead............................................................ . 4 ...... 8 ..... 202-0
C 200 (D ie se l)..................... ,. Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-11
C 200 (G a s)........................ ,. Behind R H of IP, near Heater Motor, in foam w rap.......... . 3 7 .... 4 9 .... 202-10
C227 (Stoplamp Sw itch)........,. A t Convenience Center................................................ . 4 4 .... 5 7 .... 202-70
G R O M M ETS:
P 1 0 1 ................................. ,. R R of Engine Compartment, at Bulkhead........................ . 7 ...... 12
G R O U N D S:
G 200................................. . Behind L H o f IP, below Fuse Block, on H e B a r.............. . 3 2 .... 43
S P L IC E S :

Breakout
DIAGNOSIS - BRAKE TRANSMISSION SHIFT INTERLOCK

(BTSI)
TROUBLESHOOTING HINTS: be intermittent or resistive when loaded, and if
1. The Sh ift Lever should lock in P A R K w ith the possible, should be checked by m onitoring for a
ignition key in the R U N position and the Brake Pedal voltage drop with the system operational (under load).
released. If the Shift Lever can be moved from the •CH ECK fo r p rop er in sta lla tio n o f afterm arket
P A R K position, with the key in the R U N position and electronic equipment which may affect the integrity of
without depressing the Brake Pedal, C H E C K H im other systems. See Troubleshooting Procedures.
Signal operation. If the Turn Signals do not operate 2. W ith the ignition key in the O F F position, the Shift
correctly, check T U R N / B U Fuse 16 to see if it is open Lever should not move from the P A R K position. If the
(the H im Signal Flasher is on the same circuit as lever moves, the problem may be with the B T S I
B T S I). If the fuse is open, L O C A T E and R E P A IR Solenoid, or the Shift Linkage itself. If the shift
source o f the overload. R E P L A C E the fuse. If the fuse linkage is binding, refer to the Transm ission Section.
is good (H im Signals operate correctly), C O N T IN U E If the shift linkage does not appear to be binding,
with diagnostics. continue with B T S I Diagnostics.
• C H E C K for a broken (or partially broken) wire inside 3. If the Park/Neutral P osition (P N P ) Sw itch needs
o f the in s u la tio n w h ic h c o u ld cau se syste m adjustment or replacement, refer to the Transm ission
malfunction but prove G O O D in a Continuity/Voltage Section.
8A - 1 3 8 - 2 ELECTRICAL DIAGNOSIS______________________________
BRAKE TRANSAXLE/TRANSMISSION SHIFT INTERLOCK (BTSI)
TRANSMISSION MAY BE SHIFTED FROM PARK WITHOUT ACTUATION OF THE BRAKE

PEDAL AND WITH IGNITION SWITCH IN RUN
TEST RESULT ACTION
between Connector C266 Cavity Test lamp does not light. L O C A T E and R E P A IR open in B L K
A 1 6 and ground.
(150) wire between Brake/Transmission
Shift Interlock Solenoid and Ground
G200.
2. Place Transm ission in P A R K and Test lamp lights. A D J U S T or R E P L A C E
Ignition Switch in R U N . Connect Brake/Transmission Shift Interlock
unpow ered test lam p between Solenoid, refer to Standard or Tilt
Connector C 266 Cavity A 17 and Steering Colum n Repair.
3. Disconnect connector at Stoplamp Test lamp lights. G O to Step 4.
Sw itch . D isc o n n e c t C on n ector Test lamp does not light. L O C A T E and R E P A IR open in D K
C 2 6 6 at the Steering Colum n. G R N /W H T (1135) wire between
Connect self-powered test lam p
TCC/Stoplam p Switch and Connector
b e t w e e n S t o p la m p S w i t c h C266.
Connector Cavity F and Connector
C 266 Cavity A 17.
between Stoplamp Switch Pins E Test lamp does not light.
R E P L A C E Stoplamp Switch.
and F.
5. D is c o n n e c t C o n n e c to r C l at Test lamp lights. G O to Step 6.
P ark/N eu tral P o sitio n Sw itch . Test Lam p does not light.
L O C A T E and R E P A IR open in L T
G R N (275) wire between Park/Neutral
betw een Park/N eutral P o sitio n Position Switch and Stoplamp Switch.
Sw itch Connector C l C avity B
and Stoplam p Sw itch connector
C avity E.
6. C o n n e c t te st la m p b e tw e e n Test lamp lights. C H E C K adjustment of Park/Neutral
P a rk / N e u tra l P o s it io n S w itc h Position Switch. Refer to Transm ission
C o n n e c to r C l C a v ity C and Section. If adjustment does not correct
ground. condition, then R E P L A C E Park/Neutral
Position Switch.
Test lamp does not light. L O C A T E and R E P A IR open in P N K
(139) wire between IP Fuse B lo ck and
Park/Neutral Position Switch.
TRANSMISSION WILL NOT SHIFT FROM PARK WITH THE BRAKE PEDAL ACTUATED AND
IGNITION SWITCH IN RUN
TEST RESULT ACTION
1. Ensure that transm ission linkage is Test lamp remains illuminated with R E P L A C E Stoplamp Switch.
p ro p e rly a d ju ste d , R e fe r to brake pedal depressed.
Transm ission Section. Disconnect Test lamp extinguishes with the brake G O to Step 2.
connector at Stoplam p Sw itch. pedal depressed.
between Stoplamp Switch Pins E
and F. Depress the brake pedal.
2. Connect test lam p between the Test lamp does not light. C H E C K for mechanical binding.
S to p la m p S w itc h C o n n e c to r A D J U S T or R E P L A C E
Cavity F and ground. Brake/Transmission Shift Interlock
Solenoid.
Test lamp lights. L O C A T E and R E P A IR short to voltage
in D K G R N /W H T (1135) wire between
Stoplamp Switch and
Brake/Transmission Shift Interlock
Solenoid.
CIRCUIT OPERATION contacts in the Park/Neutral Position Switch are open and
The Brake/Transmission Shift Interlock requires that no current can flow to energize the solenoid when the
the brake pedal be depressed before the autom atic brake pedal is released.
transm ission may be shifted from Park position. Once the
transm ission is placed in Park, and the Ignition Switch is in m Important:
R U N or ST A R T , current flow s from T U R N B/U Fuse 16
through the contacts of the Park/Neutral Position Switch • The Brake/Transmission Shift Interlock Solenoid is
(closed-in-Park), through the TCC/Stoplam p Switch, and energized through the Stoplamp Switch Pins E and
through the Brake/Transmission Shift Interlock Solenoid to F with the Brake Pedal in the released position.
Ground G200. The solenoid is energized preventing the Actuating the Brake Pedal opens the Stoplamp
transm ission from being placed in another gear. W hen the Sw itch, causing the Brake/Transm ission Shift
brake pedal is actuated, the normally-closed contacts in the Interlock Solenoid to de-energize, unlocking the
TCC/Stoplam p Switch open. Current flow is stopped and Transm ission Shift Lever. The lock-out function is
the B ra ke / T ra n sm issio n S h ift In te rlo ck S o le n o id is only active with the Ignition K e y in the R U N or
de-energized. The transm ission may be placed in another S T A R T position.
gear. Once the transm ission is in any other gear, the
POWER SEATS
4206W0742

Convenience Center.............. Under L H of IP, on Bulkhead.......................................... 3 3 ... 44
IP Fuse B lo ck ...................... L H o f IP, near L F D oor Jamb Sw itch .............................. 3 2 ... 43
Power Seat Adjuster Sw itch.... In L F Seat, on bottom, mounted to frame.......................... 6 3 ... 8 1 .... 202-68
Power Seat Front Tilt M otor... In lower L H of L F Seat................................................. 6 3 ... 81
Power Seat Forward/Rearward

M o to r.............................. Under D rive r’s Seat

U p and Dow n Sw itch.......... O n lower L H of L F Seat................................................ 6 3 ... 81
Pow er Seat Front Tilt Switch.... O n lower L H o f L F Seat................................................ 6 3 ... 81
Power Seat Rear Tilt M o to r.... In lower L H of L F Seat................................................. 6 3 ... 81
Power Seat Rear Tilt Sw itch... O n lower L H of L F Seat
C O N N EC T O R S:
C 2 1 0 .................................. A t Convenience Center.................................................. 3 3 ... 4 4 .... 202-51
C 2 1 2 .................................. Under L F Seat............................................................. 6 5 ... 8 3 .... 202-52
C 2 2 9 .................................. Crossbody Harness to R F Power Seat, under R F Seat......... 6 5 .... 8 3 .... 202-54
C 3 0 4 .................................. Under L F Seat
G R O U N D S:
G 202 .................................. R H o f IP, mounted to H V A C Plenum Bracket.................... 5 0 ... 65
S P L IC E S :
S 2 2 8 .................................. R F Seat Harness, approx. 5 cm from Power Seat Lum bar

Switch Breakout

Switch Breakout
S255 (Crew C a b ).................. Crossbody Harness, approx. 20 cm from C 210 Breakout,

S255 (Pickup/Extended C ab)... Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness
S255 (Suburban/Utility).......... Crossbody Harness, approx. 18 cm from C 210 Breakout,


toward C299
S 3 0 3 .................................. Pow er Lum bar Seat Jumper, approx. 20 cm from R H Power

Seat Breakout, toward C299.
8A - 14 0 • 2 ELECTRICAL DIAGNOSIS
POWER SEATS
DIAGNOSIS - POWER SEATS

1. C H E C K that the P W R A C C Y Circuit Breaker resets. o f the in s u la tio n w h ic h c o u ld cau se sy ste m
Replace if necessary. malfunction but prove G O O D in a continuity/voltage
2. C H E C K that Ground G 202 is clean and tight. check with a system disconnected. These circuits may
3. C H E C K that there are no obstructions under the seat be intermittent or resistive when loaded, and if
or in the carriages which may affect Pow er Seat possible, should be checked by m onitoring for a
operation. voltage drop with the system operational (under load).
4. R E F E R to Seats section for diagnosis and repair of all 6. C H E C K fo r proper in sta lla tio n o f afterm arket
non-electrical system components. electronic equipment which may affect the integrity of
POWER SEAT INOPERATIVE

TEST RESULT ACTION
1. Disconnect Power Seat Adjuster Test lamp lights. G O to Step 2.
Switch. Connect a test lamp from Test lamp does not light. L O C A T E and R E P A IR open in O R N
O R N (540) wire at Pow er Seat (540) wire between Power Seat
A d ju ste r S w itc h C a v ity F to Adjuster Switch and IP Fuse Block.
ground.
2. Connect a test lamp between B L K Test lamp lights. R E P L A C E Power Seat Adjuster
(150) wire and O R N (540) wire at Switch.
P o w e r Se a t A d ju ste r S w itc h Test lamp does not light. L O C A T E and R E P A IR open in B L K
Cavity F .
(150) wire between Power Seat
Adjuster Switch and Ground G202.
POWER SEAT FRONT TILT MOTOR INOPERATIVE

TEST RESULT ACTION
1. Connect a fused jumper wire from M otor moves. R E P L A C E Power Seat Adjuster
Y E L (2 8 2 )(L H ) / D K B L U Switch.
(298)(RH ) wire to B L K (150) wire M otor does not move. G O to Step 2.
at Pow er Seat Adjuster Switch.
Connect a fused jumper from L T
B L U (283)(LH ) / Y E L (288)(RH )
wire to O R N (540) wire at Power
Seat Adjuster Switch.
L T B L U (2 8 3 )(L H ) / Y E L Switch.
(2 8 8 )(R H ) w ire at Pow er Seat M otor does not move. G O to Step 3.
Sw itch to B L K (1 50) w ire at
P o w e r Seat A d ju ste r S w itch .
Connect a fused jumper wire from
Y E L (2 8 2 )(L H ) / D K B L U
(2 9 8 )(R H ) w ire to O R N (540)
w ire at P o w e r Seat A d ju ste r
Switch.
3. U s i n g a D M M , c h e c k f o r Continuity. R E P L A C E Front Tilt Motor.
continuity in the Y E L (282)(LH ) / N o Continuity. L O C A T E and R E P A IR open Y E L
D K B L U (298)(RH ) wire and the (282)(LH ) / D K B L U (298)(RH ) wire
L H B L U (2 8 3 )(L H ) / Y E L and/or L T B L U (283)(LH ) / Y E L
(2 8 8 )(R H ) wire between Pow er (288)(RH ) wire between Front H it
Seat Adjuster Switch and Front M otor and Power Seat Adjuster Switch.
Tilt Motor.
POWER SEAT REAR TILT MOTOR INOPERATIVE

TEST RESULT ACTION
D K G R N (286)(LH ) / D K B L U Switch.
D K B L U (287)(LH ) / D K G R N
(2 9 7 )(R H ) w ire to O R N (540)
Switch.
D K B L U (287)(LH ) / D K G R N Switch.
(297) (R H ) wire to B L K (150) wire M otor does not move. G O to Step 3.
D K G R N (286)(LH ) / D K B L U
(298)R H wire to O R N (540) wire
at Power Seat Adjuster Switch.
3. U s in g a D M M , C H E C K fo r Continuity. R E P L A C E Rear Tilt Motor.
C o n t i n u i t y in the D K B L U N o Continuity. L O C A T E and R E P A IR open in D K
(287)(LH ) / D K G R N (297)(RH ) G R N (286)(LH ) / D K B L U (298)(RH)
wire and the D K G R N (286)(LH ) / wire or D K B L U (287)(LH ) / D K
D K B L U (298)(RH ) wire between G R N (297)(R H ) wire from Rear Tilt
Power Seat Adjuster Switch and M otor to Power Seat Adjuster Switch.
Rear Tilt Motor.
POWER SEAT FORWARD/REARWARD MOTOR INOPERATIVE

TEST RESULT ACTION
D K B L U (284)(LH ) / L T G R N Switch.
T A N (2 8 5 )(L H ) / D K G R N
(2 9 7 )(R H ) w ire to O R N (540)
Switch.
T A N (285)(LH) / D K G R N Switch.
L T G R N (284)(LH ) / D K G R N
(2 8 4 )(R H ) w ire to O R N (540)
Switch.
3. U s in g a D M M , C H E C K fo r Continuity. R E P L A C E Forward/Rearward Motor.
continuity in the T A N (285)(LH ) / N o continuity. L O C A T E and R E P A IR open in T A N
D K G R N (297)(RH ) wire and the (285)(LH ) / T A N (296)(RH ) wire
L T G R N (2 8 4 )(L H ) / L T G R N and/or L T G R N (284)(LH ) / L T G R N
(284)R H wire between Power Seat (284)(RH ) wire from Forward/Rearward
Adjuster Switch and Forward/Rear M otor to Power Seat Adjuster Switch.
Motor.
8A • 1 4 0 - 4 ELECTRICAL DIAGNOSIS
POWER SEATS
CIRCUIT OPERATION The Rear Tilt M otor is operated in the same manner
Three reversible motors operate the Power Seats. One through the Rear Tilt Switch.
motor raises or lowers the front of the seat. One motor M oving the Forward/Rearward U p and Dow n Switch
raises or lowers the rear of the seat. The third motor moves up or down operates the Front Rear Tilt M otors at the same
the seat forward or backward. time.
M o vin g the Front Tilt Switch U P supplies voltage to M o vin g the Forward/Rearward U p and Dow n Switch
the Front Tilt M otor through the Y E L (282)(LH ) / L T B L U forward or backwards operates the Foreward/Rearward
(289)(RH ) wire. The motor is grounded through the Front Motor, and the seat moves forward or backward.
Tilt Switch to Ground G 202 and the front o f the seat is
raised. M o v in g the Front T ilt Sw itch to the D O W N
position reverses the polarity, and the front o f the seat is
lowered.
LUMBAR SUPPORTS
BUCKET AND SPLIT BENCH SEAT W/O HEATED SEATS
CROSSBODY
GROUND
03-20-87
4206W 0743
BUCKET AND SPLIT BENCH W/HEATED SEATS
CR0SS80DY
GROUND
03-20-97
4206W 0745
LUMBAR SUPPORTS
BENCH SEATS
CROSSBODY
GROUND
03-20-97
4208W 0746

Convenience Center............. . Under L H of IP, on Bulkhead.......................................... 3 3 .... 44
IP Fuse B lo c k ..................... . L H o f IP, near L F D oor Jamb Sw itch ............................ ... 3 2 .... 43

L F ................................. . Under L F Seat, mounted to Seat fram e.......................... ... 6 3 .... 81

R F ................................. . Under R F Seat, mounted to Seat fram e..........................., 6 3 .... 81

L F ................................. . O n lower L F of L F Seat............................................. ... 6 3 .... 81

R F ................................. . O n lower R F of R F Seat............................................. ... 6 3 .... 81
C O N N EC T O R S:
C 2 1 0 ................................. . A t Convenience Center................................... ............. .. 3 3 .... 4 4 .... 202-51
C 2 1 2 ................................. . Under L F Seat.............................................................. 6 5 .... 8 3 .... 202-52
C 2 4 0 ................................. . Crossbody Harness, approx. 100 cm from Seat Belt Switch

Breakout................................................................... 6 5 .... 8 3 .... 202-55
G R O U N D S:
G 202 ................................. . R H of IP, mounted to H V A C Plenum Bracket..................... 5 0 .... 65
S P L IC E S :
S 2 2 7 ................................. . L F Seat Harness, approx. 5 cm from Power Seat Lum bar

Switch Breakout
S 2 3 7 ................................. . R F Seat Harness, approx. 4 cm from Power Seat Lum bar

Switch Breakout
S 2 4 1 ................................. . L F Seat Harness, approx. 4 cm from Power Seat Lum bar

Switch Breakout
S255 (Crew C a b )................. . Crossbody Harness, approx. 20 cm from C 210 Breakout,

S255 (Pickup/Extended Cab)..... Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness
S255 (Suburban/Utility)......... . Crossbody Harness, approx. 18 cm from C 210 Breakout,

S256 (2-Door
Utility/Pickup/
Extended Cab).................. . Crossbody Harness, approx. 12 cm from C 210 Breakout,

Suburban)........................ . Crossbody Harness, approx. 19 cm from C 210 Breakout,
S256 (Crew C a b )................. . Crossbody Harness, approx. 1 cm from D oor Lock Relay

toward C299
LUMBAR SUPPORTS


S 3 0 0 .................................. Power Lum bar Seat Jumper Harness, approx. 13.5 cm from
R H Power Seat Breakout, toward Crossbody Harness
S310 (Suburban)................... Front to rear Body Harness, approx. 6 cm from C301

Breakout, toward front Dom e Lam p Harness
DIAGNOSIS - LUMBAR SUPPORTS
TROUBLESHOOTING HINTS: 4. R E F E R to Seats section for diagnosis and repair of all

1. C H E C K condition of C IG L T R Fuse. If fuse is open, non-electrical system components.
L O C A T E and R E P A IR source o f overload. R E P L A C E • C H E C K for a broken (or partially broken) wire inside
fuse. o f the in su la tio n w h ich c o u ld cau se sy ste m
2. If lumbar supports are inoperative, C H E C K O R N malfunction G O O D in a continuity/voltage check with
(540) or O R N (640) between Splice S256, S255, or a system disconnected. These c irc u its m ay be
S300 and IP Fuse Block or B L K (150) between Splice intermittent or resistive when loaded, and if possible,
S259 and Ground G202. should be checked by monitoring for a voltage drop
3. If one Seat Lum bar Support is inoperative, C H E C K with the system operational (under load).
for: •CH ECK fo r proper in sta lla tio n o f afterm arket
— pinched or punctured bladder tubing electronic equipment which may affect the integrity of
— punctured bladder other systems. See Troubleshooting Procedures.
— evidence o f motor overheating, pinched or broken
wires
— R E P L A C E or R E P A IR as necessary
LUMBAR SUPPORTS - POWER LUMBAR INOPERATIVE

TEST RESULT ACTION
1. D is c o n n e c t P o w e r L u m b a r Test lamp lights. G O to Step 2.
C o n n e c to r C 2 1 2 . C o n n e c t a Test lamp does not light.
R E P A IR open in B L K (150) between
se lf-p o w e re d test lam p fro m Connector C212 and Ground G202.
Connector C 212 Term inal B to
ground.
2. C o n n e c t a te st la m p fro m Test lamp lights. G o to Step 3.
Connector C 2 I2 Terminal A or D Test lamp does not light. R E P A IR open in O R N (640) between
to ground. Connector C212 and IP Fuse Block.
3. Connect a test lamp from switch Test lamp lights. G O to Step 4.
connector Term inal A or D to Test lamp does not light. R E P A IR open in O R N (640) between
ground. switch connector and Connector C212
Terminal A or D.
TEST RESULT ACTION

4. Connect a self-powered test lamp Test lamp lights. R E P L A C E Lum bar Support Switch.
from switch connector Terminal B Test lamp does not light. R E P A IR open in B L K (150) between
to ground. Switch Connector and Connector C 212
Terminal B. If no open is found, G O
to Step 5.
5. Disconnect Power Lum bar Support M otor runs. G O to Step 4.
Switch. Connect a fused jumper M otor does not run. R E P L A C E Power Lum bar Motor.
wire from Terminals A to B.
CIRCUIT OPERATION applied, and current flow s in the corresponding direction

W ith bucket and split bench seat combinations, each through the Power Lum bar Motor.
seat incorporates a power inflate/deflate pneumatic system W ith a bench seat, one pump and pneumatic system is
for changing the contour of the seat. Ground is supplied at used to supply the seat lumbar supports. Individual control
all times to both Power Lum bar Support Switches. W hen switches are incorporated into each side of the seat to
the Power Lum bar Support Switch is closed, voltage is change the seat contour.
$
U)
B
m
m
D
X
Cross Body
Ground
Seat Belt
Switch
N .C .
(Open whan
belt Is
bucMtl)
V
V
ELECTRICAL DIAGNOSIS 8A - 143 -

Cross Body
Ground
HEATED SEATS

Heated Seat Module, L H ........ Under L F Power Seat.................................................. . 6 3 .... 81.... 202-64
Heated Seat Module, R H ....... Under R F Power Seat.................................................. . 6 3 .... 81.... 202-64
Heated Seat Switch, L H ......... A t L F of L F Power Seat.............................................. . 6 3 .... 81
Heated Seat Switch, R H ......... A t R F of R F Power Seat............................................. . 6 3 .... 81
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................. . 3 2 .... 43

Seat Belt Switch, R H ............ A t R F Stationary Belt Connector.................................... . 5 6 .... 72
CONNECTORS:
at Bulkhead............................................................ . 4 ...... 8...... 202-0
C 2 0 8 .................................. Inside lower L H A P illa r............................................. . 6 1 .... 7 9 .... 202-51
C 2 1 2 .................................. Under L F Seat........................................................... . 6 5 .... 83.... 202-52
C 2 2 9 .................................. Crossbody Harness to R F Power Seat, under R F Seat........ . 6 5 .... 83.... 202-54
C 2 3 6 .................................. L F Seat Harness, approx. 4 cm from Power Seat Lum bar

Switch Breakout....................................................... . 6 5 .... 83.... 202-55
C 2 3 7 .................................. R F Seat Harness, approx. 4 cm from Power Seat Lum bar

Switch Breakout....................................................... . 6 5 .... 83.... 202-55
C 2 9 8 .................................. Behind L H of IP, near Convenience Center..................... . 3 2 .... 4 3 .... 202-17,

18
GROUNDS:
G 202.................................. R H of IP, mounted to H V A C Plenum Bracket.................. . 5 0 .... 65
SPLICES:
Switch Breakout

Breakout
S 2 3 3 .................................. Crossbody Harness, approx. 25 cm from S D M Breakout
S 2 3 8 .................................. Crossbody Harness, approx. 20 cm from S D M Breakout

toward C299
5 2 7 3 ................................ L H Heated Seat Harness, approx. 10 cm from Heated Seat

Control M odule Breakout
5274 ................................ R H Heated Seat Harness, approx. 10 cm from Heated Seat

S 2 7 7 .................................. L H Heated Seat Harness, approx. 5 cm from Heated Seat


Suburban)......................... Crossbody Harness, approx. 32 cm from C210 Breakout,
S 3 0 3 .................................. Power Lum bar Seat Jumper, approx. 20 cm from R H Power

Seat Breakout, toward C299.
DIAGNOSIS - HEATED SEATS

1. C H E C K that the Heated Seats Circuit Breaker. If the o f the in s u la tio n w h ic h c o u ld cau se syste m
Circuit Breaker is open, L O C A T E and R E P A IR cause malfunction G O O D in a continuity/voltage check with
of overload and R E S E T Circuit Breaker. a system disconnected. These circu its m ay be
2. C H E C K that G 202 is clean and tight. intermittent or resistive when loaded, and if possible,
3. If neither Heated Seat operates and the Power Seat should be checked by monitoring for a voltage drop
Heater Sw itch is inoperative, the L O C A T E and with the system operational (under load).
R E P A IR the open in the O R N (1840) wire between 6. C H E C K fo r proper in sta lla tio n o f afterm arket
the IP Fuse Block and the Power Seat Heater Switch. electronic equipment which may affect the integrity of
4. R E F E R to Seats section for diagnosis and repair of all other systems. See Troubleshooting Procedures.
non-electrical system components.
HEATED SEATS INOPERATIVE

TEST RESULT ACTION
1. Connect a test lamp to ground, Test lamp lights. G O to Step 2.
B a c k p ro b e P o w e r S e a t H e at Test lamp does not light. L O C A T E and R E P A IR open in B L K
Control M odule C avity F B L K (150) wire between Power Seat Heat
(150). Control M odule and Ground G202.
2. Place Ign ition Sw itch to R U N . Test lamp lights. R E P L A C E Heated Seat LH/RH.
Place Power Seat Heater Switch to Test lamp does not light. L O C A T E and R E P A IR open in B R N
H IG H . B a ckp rob e B R N (3 41) (341) wire between IP Fuse Block and
Cavity D of Power Seat Heater Power Seat Heater Switch.
Switch with test lamp to ground.
HEATED SEATS
POWER SEAT HEATER SWITCH OPERATIVE

TEST RESULT ACTION
1. D isco n n e ct Pow er Seat Heater Resistance correct? G o to Step 2.
Switch. Connect D M M measure Resistance incorrect. R E P L A C E Power Seat Heater Switch.
resistance between Cavity C and D
o f the Pow er Seat Heater with
switch in H IG H . Resistance should
be 0 ohms. Place switch in LO W ,
resistance should be 5900 ohms.
2. Disconnect Cavity A and E of the Resistance correct? G o to Step 3.
Power Seat Heat Control Module. Resistance incorrect. R E P L A C E NTC.
Place a D M M between Cavity C
and D of the Norm al Temperature
C o n t r o lle r ( N T C ) m easure
re s is ta n c e . Is re sista n c e
a p p ro x im a te ly 3 0 0 0 to 5 0 0 0
ohm s?
3. Disconnect Cavities A and E to Resistance correct? G o to Step 4..
the P o w e r Seat H eat C o n tro l Resistance incorrect.
R E P L A C E Heated Seat Back Cushion
Module. Place a D M M to Cavities
Element.
A an d B o f the S e a t B a c k
E le m e n t. Is r e s is ta n c e
approximately 1 ohm ?
4. Disconnect Cavities A and E of Resistance Correct? R E P L A C E Power Seat Heat Control
the P o w e r Seat H eat C o n tro l Module.
Module. Place D M M to Cavities Resistance incorrect. R E P L A C E the Heated Seat Cushion
A and B o f the Seat C u shion
Element.
E le m e n t. Is re sista n c e
approximately 1 ohm ?
HEATED SEAT INOPERATIVE WHEN SEAT BELT IS CONNECTED (RF Only)

TEST RESULT ACTION
1. Connect a D M M at Cavity E Y E L Continuity? R E P L A C E Seat Belt Switch.
(182) wire of the Power Seat Heat
N o continuity. L O C A T E and R E P A IR open in Y E L
Control M odule and ground.
(182) or B L K (150) between Power
Seat Heat Control M odule and Ground
C202.
CIRCUIT OPERATION
W hen L O is pressed on the Heated Seat Switch and
Ignition Sw itch is in R U N , the Heated Seat Control
M odule L O input terminal is momentarily grounded. This
causes the Seat Control M odule to turn on the Heater in the
seat. The Heated Seat Control M odule monitors the seat
surface temperature through a therm istor located in the
center seat bottom. The Heated Seat Control M odule w ill
maintain the seat surface temperature at approximately
37.5 C (98.5F) when L O has been selected. The H I mode
is sim ilar to L O operation except the temperature increases
approximately 5 degrees. W hen the O F F Switch is pressed,
the Heated Control M od u le ’s O F F input is grounded
momentarily. The module w ill react by turning off the
voltage applied to the seat heaters. The module w ill also
turn off the Heated Seats whenever the Ignition Switch has
been turned OFF. The passenger Heated Switch w ill not
operate unless the Seat Belt is connected. This is a safety
mechanism that insure that the seat w ill never be left on.
POWER MIRRORS
S248
HOT AT ALL TIMES | a ogN .8 ORN I 40

40
Ir — t— — i ip
I T
i SEE FUSE
I J>F^3|g ^ BLOCK DETAILS
PAGE 8 A -1 1 -8 ,9
AO C298 .8 ORN
I 1 2° A I
L j .8 ORN I 40 M
I .8 ORN PSOO
40
S242
.8 ORN 40
POWER OUTSIDE
LEFT DOWN RIGHT UP ' V

------------------, ------------------ , ------------------ 1
1 1
-O , <>--------------------------------------------------- 1 > ..................
1
y ~ ' \ ' . V ' , j
'
\
*
------------------ ................................. •
1
..
S ... ........ i ------------------ )
.8 BLK
150
L fL _
\ OFF f R
\
V 1 k ,
« S o d LAMPS
L t - _ > 0FF ? * 1 ^ o
____________^ ^ ------------------------ *
/ \1 / SS sU
G202
IP
GROUND
03-12-97
4206W0583

Convenience Center.............. Under L H of IP, on Bulkhead.......... 33 44
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Switch 32 43

Switch, M aste r.................. O n L F Door, near center of A Pillar

Motor, L H ........................ O n L F Door, near center o f A P illa r.. 6 1 .... 79 202-66,
67

M irror, R H ....................... O n L F Door, near center of A P illa r............................... 6 1 .... 79 202- 66,
67
CONNECTORS:
C 2 0 7 .................................. Inside lower L H A Pillar........................ 6 1 .... 79 202-13
C 2 1 0 .................................. A t Convenience Center.......................... 3 3 .... 44 202-51
C 2 1 4 .................................. Inside lower R H A P illa r....................... 6 1 .... 79 202-52
C 2 9 8 .................................. Behind L H of IP, near Convenience Center 3 2 .... 43 202-17,

18
GROMMETS:
P 5 0 0 .................................. A t L F D oo r................................................................ 6 1 ..... 79
P 6 0 0 .................................. A t R F D o o r............................................................... 6 1 ..... 79
GROUNDS:
G 202 .................................. R H of IP, mounted to H V A C Plenum Bracket................... 5 0 ..... 65
SPLICES:
Breakout
S 2 4 8 .................................. Crossbody Harness, approx. 10 cm from L F D oor Harness

Breakout


toward C299
S 5 0 3 .................................. Inside L F D oor Harness, approx. 25 cm into Outside

Rearview M irror Breakout
S 6 0 2 .................................. Inside R F D oor Harness, approx. 10 cm from Power

Outside Rearview M irror M otor
POWER MIRRORS
DIAGNOSIS - POWER MIRRORS
TROUBLESHOOTING HINTS: be intermittent or resistive when loaded, and if

1. C H E C K that the C T S Y Fuse 3 is not open. possible, should be checked by m onitoring for a
2. C H E C K that G 202 is clean and tight. voltage drop with the system operational (under load).
3. C H E C K for a broken (or partially broken) wire inside 4. C H E C K fo r proper in sta lla tio n o f afterm arket
o f the in s u la tio n w h ic h c o u ld cau se s y ste m electronic equipment which may affect the integrity of
malfunction but prove G O O D in a continuity/voltage other systems. See Troubleshooting Procedures.
LH MIRROR WILL NOT ADJUST UP AND DOWN

TEST RESULT ACTIO N
1. D isco n n e ct L H Pow er O utside Test lamp lights. G O to Step 2.
Rearview M irror. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in Y E L
lam p from Y E L (1496) wire to (1496) wire between L H Power Outside
g ro u n d . P r e s s s w it c h in U P Rearview M irror Switch and Mirror. If
position. O K , R E P L A C E Power Outside
Rearview M irror Switch.
2. Connect a test lamp from L T G R N Test lamp lights. R E P L A C E L H Power Outside
(89) wire to ground. Press switch Rearview Mirror.
in D O W N position. Test lamp does not light. L O C A T E and R E P A IR open in L T
G R N (89) wire between M irror and
Switch. If O K , R E P L A C E Power
Outside Rearview M irror Switch.
RH MIRROR WILL NOT ADJUST UP AND DOWN

1. D iscon n e ct R H Pow er O utside Test lamp lights. G O to Step 2.
Rearview M irror. Connect a test
Test lamp does not light. L O C A T E and R E P A IR open in Y E L
lamp from Y E L (1496) wire to (1496) wire between M irror and Power
g ro u n d . P r e s s s w it c h in U P Outside Rearview M irror Switch. If
position.
O K , R E P L A C E Power Outside
2. C o n n e c t a te s t l a m p f r o m Test lamp lights. R E P L A C E R H Power Outside
P P L/W H T (889) wire to ground. Rearview Mirror.
Press switch in D O W N position. Test lamp does not light. L O C A T E and R E P A IR open in
PPL/W H T (889) wire between M irror
and Power Outside Rearview M irror
Switch.. If O K , R E P L A C E Power
LH MIRROR WILL NOT ADJUST LEFT AND RIGHT

TEST RESULT ACTION
1. D iscon n ect L H Pow er O utside Test lamp lights. G O to Step 2.
Rearview Mirror. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in Y E L
lam p from Y E L (1 4 9 6 ) w ire, (1496) wire between M irror and Power
(cavity B ) to ground. Press switch Outside Rearview M irror Switch. If
in the L E F T position. O K , R E P L A C E Power Outside
2. Connect a test lamp from L T B L U Test lamp lights. R E P L A C E L H Power Outside
in the R IG H T position. Test lamp does not light. L O C A T E and R E P A IR open in L T
B L U (82) wire between M irror and
Switch. If O K , R E P L A C E Power
RH MIRROR WILL NOT ADJUST LEFT AND RIGHT

TEST RESULT ACTIO N
1. D isconnect R H Pow er O utside Test lamp lights. G O to Step 2.
Rearview M irror. Connect a test Test lamp does not light. L O C A T E and R E P A IR open in Y E L
lam p from Y E L (1 4 9 6 ) w ire, (1496) wire between M irror and Power
(cavity. B ) to ground. Press switch Outside Rearview M irror Switch. If
in the R IG H T position. O K , R E P L A C E Power Outside
2. Connect a test lamp from G R Y Test lamp lights. R E P L A C E R H Power Outside
in the L E F T position. Test lamp does not light. L O C A T E and R E P A IR open in G R Y
(90) wire between M irror and Power
Outside Rearview M irror Switch. If
O K , R E P L A C E Power Outside
NEITHER MIRROR IS OPERATIONAL

TEST RESULT ACTIO N
1. D i s c o n n e c t P o w e r O u t s i d e Test lamp lights. G O to Step 2.
Rearview M irror Switch. Connect Test lamp does not light. L O C A T E and R E P A IR open in O R N
a test lamp from O R N (40) wire to (40) between IP Fuse Block and Power
ground. Outside Rearview M irror Switch.
2. Connect a test lamp from O R N Test lamp lights. L O C A T E and R E P A IR open in Y E L
(40) wire to B L K (150) wire at (1496) wire between switch and Splice
switch. S503. If O K , R E P L A C E Power
(150) wire between switch and ground.
CIRCUIT OPERATION The M irror assemblies contain two Motors. One M otor
positions the M irro r up and down, the other M otor
POWER MIRRORS positions the M irror to the left or right. B y reversing the
Voltage is supplied at all times to the Power Outside polarity of the Motors, the M otors w ill move the M irrors
M irror Switch through the C T S Y Fuse. either up/down or left/right.
AUTOMATIC DAY-NIGHT MIRRORS
1
COM PONENT LOCATION 201 -PG FIG. CONN

Automatic Day/Night M irror,
L H Outside....................... Mounted on outside of L F Door, near A P illa r................. . 6 1 .... 79
Automatic Day/Night M irror,

R H O utside...................... Mounted on outside of R F Door, near A P illa r................. . 6 1 .... 79
Backup Lam p Switch (M G 5) .... L H of Transmission, below Shift Tower.......................... . 2 7 .... 38
Backup Lam p Switch (M W 3 )... L H top of Transm ission................................................ . 2 6 .... 36
M irror with C om p ass......... O n top inside o f W indshield center, part of Inside Rearview
M irror.................................................................... . 5 4 .... 69
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch ............................ . 3 2 .... 43

Switch, Connector C l ......... A t L H center of Transm ission....................................... . 2 3 .... 3 1 .... 202-67

Switch, Connector C 2 ......... A t L H center of Transm ission....................................... . 2 3 .... 3 1 .... 202-67
Temperature Sensor, Outside

A ir .................................. In Engine Compartment, near lower Radiator Support........ . 8 ..... 13
CONNECTORS:
C 1 0 0 .................................. Engine Harness to BP Harness, L R of Engine Compartment,
at Bulkhead............................................................ . 4 ..... 8 ...... 202-0
C 1 0 2 .................................. Forward Lam ps Harness to BP Harness, L R of Engine

mounted on Fender................................................... . 4 ..... 8 ...... 202-2
C207 (Upfitter O ption).......... Inside lower L H A Pillar.............................................. . 6 1 .... 7 9 .... 202-13
C 2 7 1 .................................. In-line to Spotlamps (Z56, Police Package)...................... 202-16
C 2 9 8 .................................. 202-17,
Behind L H of IP, near Convenience Center..................... . 3 2 .... 4 3 .... 18
C 5 0 1 .................................. In-line to L H Power Outside Rearview M irro r................. . 6 1 .... 7 9 .... 202-21
C 6 0 1 .................................. In-line to R H Power Outside Rearview M irro r................. . 6 1 .... 7 9 .... 202-59
GROMMETS:
P 5 0 0 .................................. A t L F D o o r............................................................... . 6 1 .... 79
P 6 0 0 .................................. A t R F D o o r............................................................... . 6 1 .... 79
GROUNDS:
G 200.................................. Behind L H of IP, below Fuse Block, on Tie B a r.............. . 3 2 .... 43
SPLICES:




Breakout

Breakout


S316 (Suburban/Crew
DIAGNOSIS - ELECTROCHROMATIC AND

DAY-NIGHT MIRRORS
TROUBLESHOOTING HINTS: malfunction but prove G O O D in continuity/voltage

1. C H E C K G A U G E S Fuse 4. If fuse is open, L O C A T E C H E C K with a system disconnected. These circuits
and R E P A IR source of overload, and R E P L A C E Fuse. may be intermittent or resistive when loaded, and if
2. C H E C K that ground G 200 is clean and tight. possible, should be checked by m onitoring for a
3. C H E C K that photocells for dirt or obstruction. voltage drop with the system operational (under load).
4. C H E C K for poor connections at related components • C H E C K fo r proper in sta lla tio n o f afterm arket
and in -lin e h arn e ss connector term inals before electronic equipment which may affect the integrity of
component replacement. other system. See Troubleshooting Procedures.
• C H E C K for a broken or partially broken wire inside
o f the in s u la tio n w h ic h c o u ld cause sy ste m
SYSTEM CHECK
ACTION NORMAL RESULTS
[1]
• Turn Ignition Switch to ON. Mirror gradually darkens.
• Gear Selector in PARK.
• Cover Ambient Light Sensor (windshield side) with
dark cloth.
• Shine light on Headlamp Sensor (mirror side).
[2] Gear Selector in REVERSE.
[3] Gear Selector in PARK.
Mirror gradually darkens.
[4] Remove cloth and light.
ELECTROCHROMATIC AND AUTOMATIC DAY-NIGHT MIRRORS INOPERATIVE

TEST RESULT ACTION
Connect a test lamp between the Test lamp does not light. L O C A T E and R E P A IR open in P N K
Electrochromatic M irror cavity 1 (39) between IP Fuse Block and
and ground. Electrochromatic M irror cavity 1.
2. Connect a test lamp between B + Test lamp lights. R E P L A C E Electrochromatic Mirror.
and Electrochromatic Rear View Test lamp does not light. L O C A T E and R E P A IR open in B L K
M irror cavity 2. (150) between Electrochromatic Rear
View M irror and ground G200.
LH/RH OUTSIDE AUTOMATIC DAY-NIGHT MIRROR DOES NOT OPERATE PROPERLY

TEST RESULT ACTION
1. D isco n n e ct O utside Autom atic Test lamp lights. G O to Step 2.
D ay-N ight M irror Connector C501 Test lamp does not light. L O C A T E and R E P A IR open in G R Y
(L F), or Connector C601 (RF). (1690) between C501/C601 and
Connect a self-powered test lamp Electrochromatic Rear View Mirror.
between C501/C601 cavity G and
In s id e A u t o m a t ic D a y - N i g h t
M irror cavity 4.
2. Connect a self-powered test lamp Test lamp lights. G o to Step 3.
between C501 (L F) cavity H or Test lamp does not light. L O C A T E and R E P A IR open in P N K
C 6 0 1 ( R F ) c a v it y B and (1691) between C501/C601 and
E l e c t r o c h r o m a t ic R e a r V i e w Electrochromatic Rear View Mirror.
M irror cavity 5.
3. Connect a self-powered test lamp Test lamp lights. R E P L A C E LF/R F Outside Automatic
between Electrochrom atic Rear Day-N ight Mirror.
View M irror cavities 4 and 5.
AUTOMATIC DAY-NIGHT MIRRORS INOPERATIVE

TEST RESULT ACTION
W ith a test lam p, b ackp rob e Test lamp does not light. R E P L A C E Electrochromatic Rear View
Electrochromatic M irror connector Mirror.
cavity 5 ground.
2. C onnect a test lam p between Test lamp lights. G o to Step 3.
cavity 4 o f the Electrochrom atic Test lamp does not light. R E P L A C E Electrochromatic Rear View
Rear View M irror and B+. Mirror.
3. Connect a test lamp between S279 Test lamp lights. G O to Step 4.
and ground. Test lamp does not light. R E P A IR open in P N K (1691) from
connector cavity 5 to S279.
4. Connect a test lamp between S278 Test lamp lights. R E P L A C E Automatic Day-Night
and B+. M irrors.
Test lamp does not light. R E P A IR open in G R Y (1690) from
connector cavity 4 to S278.
8A - 148 - 4 ELECTRICAL DIAGNOSIS__________________________________
AUTOMATIC DAY-NIGHT MIRRORS INOPERATIVE IN REVERSE

TEST RESULT ACTIO N
1. D i s c o n n e c t c o n n e c t o r at Test lamp lights. R E P L A C E Electrochromatic Rear View
E le c t r o c h r o m a t ic R e a r V i e w Mirror.
Mirror. W ith the Ignition in R U N , Test lamp does not light. G O to Step 2.
place the Transm ission in reverse.
C o n n e c t a te st l a m p f r o m
E le c t r o c h r o m a t ic R e a r V i e w
M irror cavity 3 to ground.
2. C on n ect a test lam p between Test lamp lights. C H E C K for an open in 24 (LT G R N )
cavity C of C l (A/T) or cavity B between Backup Lam p Switch and
(M /T) at the Backup Lam p Switch cavity 3 o f Electrochromatic Rear View
to ground. M irror. If O K , R E P L A C E Backup
Lam p Switch.
Test lamp does not ligh t R E P A IR open in 24 (LT G R N )
between Backup Lam p Switch and IP
Fuse Block.
CIRCUIT OPERATION Sw itch in R U N , battery voltage is ap p lie d to the

The Electrochromatic Rear View M irror and Automatic Electrochromatic Rear View M irror connector cavity 1.
D ay-N ight M irrors uses two photocell sensors to determine W ith the gear selector in reverse, battery voltage is applied
light conditions in front and back o f the vehicle. A t night to cavity 3 o f the Electrochromatic Rear View M irror, and
as the glare of headlamps from behind increases, the m irror the m irror w ill gradually change to a clear state. The
gradually becomes darker to absorb the glare. In the Electrochromatic Rear View M irror has four positions:
daytime, the mirror is in a clear state. W ith the Ignition
RADIO AND POWER AMPLIFIER
WITH POWER AMPLIFIER
HOT IN ACCT OR RUN
i ] [ HOT AT ALL TIMES ] [

WITHOUT POWER AMPLIFIER
HOT AT ALL TIMES

1 HOT AT ALL TMES
1
I ■ — I— — — — T IP r — — — — HEADLAMP
l™ * I 1 I AND PANEL
J ------------ I b lo c k I J I DIMMER
C1 | | head -• O ff *25 121

, I ^ PARK I
---------------- I V I
ANTENNA L _________— _ J TO DATA LINK
CONNECTOR
PACE 8 A -S 0 -0
SEE INSTRUMENT ^ .8
8 PPL/W
P PL/W H
HTt Y| ’1382
382 14 W
PANEL DIMMING B mMB
b B• S 216
2 I6 I
II CRN■I
PAGE 8 A -1 1 7 -0 | ------ .35 DK I 835
.5 YEL
INTERIOR LAMPS DIMMING
COAXIAL
.8 P PL/W H T I 1382 I PM* ■ *^ >
, 7 "1
......X...... JU.?~Xc.
CABLE
9 /" \C 1 io /*\.
.................. .... TK ...., = /A - gAOjO
1 IGNITION ANTENNA BATTERY POWER OtSMAy

DISPLAY | PANEL JA A
l_ * r -
OFF ON
POWER
INPUT
INPUT INPUT DIM SIGNAL
“ (D
V
il8
L R (+ ) L R (-) R R (+ ) R R (-) L F (-) L F (+ ) R F (-) R F (+ )G R 0un0

vss
SIGNAL 1 1 1 1 1 ‘ 1 " 1 1 "
$Y2
MOOULE (VCM ) SENSOR SPEAKER. LF SPEAKER. RF

ENGINE BUFFER
CONTROLS
TRANSMISSION
CONTROLS
S k A
W -tl-tT
WITH REMOTE PLAYBACK UNIT
1 RAOK)
^82
Sp g l
fin
25S
35
lY ' y - 12 13 15
.3 5 O R N /B LK 1406
.3 5 PNK 314 .5 BARE 5 14 .3 5 BLK 150 .3 5 ORN
.3 5 LT CRN 1407
.3 5 TAN 1405
.3 5 GRY .3 5 OK GRN 835
0 3 -1 1 -9 7
4208W 0613

Convenience Center.............. Under L H of IP, on B ulkhead ....................................... . 3 3 .... 44

Sw itch............................. Low er L H of I P ......................................................... . 3 2 .... 43 .... 202-34
IP Fuse B lo ck...................... L H of IP, near L F D oor Jamb Sw itch ............................ . 3 2 .... 43
Power Am plifier................... Under L H of IP, R H of Brake Pedal Bracket................... . 3 4 .... 5 7 .... 202-40
Power Am plifier R e lay.......... Under L H o f IP, R H of Brake Pedal Bracket................... . 3 4 .... 5 7 .... 202-67
Radio, Connector C l ............. Center of IP ............................................................... . 3 5 .... 4 6 .... 202-43
Radio, Connector C 2 ............. Center o f IP ............................................................... . 3 5 .... 4 6 .... 202-44
Remote Playback U n it........... Center of IP, under Heater C ontrols................................ . 4 8 .... 63
Speaker, L F .......................... A t lower R H of L F D o o r............................................. . 6 1 .... 79
Speaker, L R ......................... Behind L R Seat in P illar.............................................. . 5 6 .... 73
Speaker, L R D o o r................. A t lower R H of L R D o o r............................................ . 6 2 .... 80
Speaker, L R R o o f................. In Headliner, near L R D oor opening............................... . 5 7 .... 74
Speaker, R F ......................... A t lower R F D oor P an e l.............................................. . 6 1 .... 79
Speaker, R R ......................... Behind R R Seat, in B P illa r......................................... . 5 6 .... 73
Speaker, R R D o o r................. A t lower L H o f R R D o o r............................................ . 6 2 .... 80
Speaker, R R R o o f................. In Headliner, near R R D oor opening.............................. . 5 7 .... 74

( V C M ) .................. .......... Engine Compartment, near E B C M ................................. . 3 7 .... 48

(D ie sel)............................ Under R H of I P ......................................................... . 3 7 .... 49.... 202-70
C O N N EC T O R S:

at Bulkhead............................................................ . 4 ...... 8 ...... 202-0
C 2 0 6 .................................. Inside lower L H A P illa r............................................. . 6 1 .... 7 9 .... 202-50,

51
C 2 1 0 .................................. A t Convenience Center................................................ . 3 3 .... 44.... 202-51
C 2 9 9 .................................. Behind R H of IP, above H V A C Evaporator H o u sin g......... . 4 3 .... 5 6 .... 202-19
C 3 0 1 .................................. A t L F K ic k Panel....................................................... . 4 7 .... 6 2 .... 202-20,

56
C 4 1 0 .................................. Top center rear of vehicle............................................ . 7 0 .... 91.... 202-58
C 4 9 6 .................................. In R H B Pillar........................................................... . 6 2 .... 80.... 202-58
C 4 9 8 .................................. L H B P illar............................................................... . 6 2 .... 80.... 202-59
G R O U N D S:
G 200 .................................. Behind L H of IP, below Fuse Block, on Tie B a r.............. . 3 2 .... 43

S P L IC E S :
S216 (Diesel and U p le ve l).... .. IP Harness, approx. 12 cm from Instrument Cluster

S216 (Gas, A ll Except
U plevel)......................... .. IP Harness, approx. 16 cm from Instrument Cluster
S 2 2 1 ................................. .. IP Harness, approx. 40 cm from Instrument Cluster
Breakout
S221 (G as)......................... .. IP Harness, approx. 20 cm from IP Cluster Breakout,

toward Radio Harness Breakout
S249 (Suburban/Utility)........ ,. Crossbody Harness, approx. 4 cm from L H D oor Harness

Breakout, toward Body Harness Breakout
S250 (Suburban/Utility).........,. Crossbody Harness, approx. 8 cm from L H D oor Harness

S 2 5 1 ................................. ,. Crossbody Harness, approx. 13 cm right of L F D oor

S252 (Suburban/Utility)......... . Crossbody Harness, approx. 4 cm from C210 Breakout,

toward L H D oor Harness Breakout
S254 (Suburban/Utility)......... . Crossbody Harness, approx. 12 cm from C 210 Breakout,

toward Power Am plifier Breakout
S256 (2-Door
Utility/Pickup/
Extended Cab).................. . Crossbody Harness, approx. 12 cm from C210 Breakout,

Suburban)........................ . Crossbody Harness, approx. 19 cm from C 210 Breakout,
S256 (Crew C a b )................. . Crossbody Harness, approx. 1 cm from D oor Lock Relay

toward C299

U tility )............................ . IP Harness, approx. 4 cm from Instrument Cluster Breakout,

S 2 9 8 ................................. . IP Harness, approx. 24 cm from Instrument Cluster

S 5 0 4 .................................. Inside L F D oor Harness, approx. 11 cm into W indow

Regulator Breakout
5505 .................................. Inside L F D oor Harness, approx. 11 cm from Tweeter

Speaker Breakout, toward L F W indow Regulator

5603 (Suburban/Utility w /RKE,
Pickup/Extended Cab w/o
R K E )............................... Inside R F D oor Harness, approx. 4 cm from W indow
Regulator M otor Breakout, toward Door Lock M otor
5604 (Pickup/Extended Cab

Regulator M otor Breakout, toward Door Lock M otor
S604 (Suburban/Utility w /RKE,

DIAGNOSIS - RADIO AND POWER AMPLIFIER
TROUBLESHOOTING HINTS: resistive when loaded, and if possible, should be

1. C H E C K condition of R A D IO Fuse 17, R A D IO B A T T checked by monitoring for a voltage drop with the
Fuse 19, and C IG L T R Fuse 13. If fuse(s) is open, system operational (under load).
L O C A T E and R E P A IR source o f overload. R E P L A C E • C H E C K for proper installation o f aftermarket
fuse(s). electronic equipm ent w hich m ay affect the
• C H E C K for a broken (or partially broken) wire integrity of other systems. See Troubleshooting
inside o f the insulation which could cause system Procedures.
m a l f u n c t i o n b u t p r o v e “ G O O D ” in a 2. C H E C K Instrum ent Panel Lam ps. If inoperative,
C o n t i n u i t y / V o l t a g e C h e c k w ith a s y st e m R E P A IR before p ro ce e d in g with R a d io L am p
disconnected. These circuits may be intermittent or diagnosis.
AUDIO SYSTEM DIAGNOSTIC OVERVIEW

1. Verify customer complaint. • To test for audio reception/noise, P O S IT IO N the
2. Refer to the Delco Sound Service Guide (D E S S G ) vehicle outside o f the building with the hood down.
and the Dealer Service Manuals. F ill out the Service • D U P L IC A T E the customer’s complaint before trying
Writer Form provided in the (D E SSG ). to d ia g n o s e the s y ste m . H a v e the c u s to m e r
3. Follow radio service procedures. D E M O N S T R A T E the condition. T E S T D R IV E the
vehicle with the customer and then test drive another
IDENTIFYING CONCERNS sim ilar model vehicle (with a sim ilar audio system) to
• C H E C K for technical service bulletins. C H E C K the do a comparison o f the two vehicles to determine if
Dealer Com m unication System for any applicable the condition is abnormal.
Prelim inary Information (P/I) for customer concerns. • Before diagnosing, ID E N T IF Y com ponents, their
• C H E C K for stored diagnostic trouble codes. R E F E R features and the customer’s complaint.
to Engine Controls • D E T E R M IN E if any afterm arket equipm ent is
• For reception concerns, D E T E R M IN E if the station is in stalle d on the v e h ic le. D I S C O N N E C T the
obtainable in the customer’s listening area. aftermarket equipment and determine if the customer’s
• For an F M reception concern, R E F E R to the F M complaint still exists. F O L L O W G M guidelines for
reception section in the D E SSG . installation of aftermarket components. R E F E R to the
• For an A M reception concern, R E F E R to the A M D E SSG .
reception section in the D E SSG .
• P E R F O R M the follow ing steps to identify a noisy • Cassette tapes could be damaged if not stored in the
component: case. The vibration in the vehicle can cause the tape to
1. ID E N T IF Y ignition key switch position in which unwind inside the cartridge.
the noise appears, such as acc, or K E Y O N engine • Use trouble trees/noise charts in the D E SSG .
running/not running. • Before rem oving speaker(s), check all connectors and
2. R E M O V E fuses one at a time until the complaint w iring to the speaker(s). Exam ine the connectors for
condition has been eliminated. bent or loose pins. See Troubleshooting Procedures.
3. M A R K the complaint fuse(s) and IN S T A L L all • If a test antenna is used in diagnostics, ground the
fuses and circuit breakers. antenna base to the vehicle body, and do not hold the
4. R E F E R to S E C T IO N 8A - 10 and S E C T IO N 8A - 11 mast.
to identify all systems and components powered by
the complaint fuse(s). Important:
5. D IS C O N N E C T the components powered by the
complaint fuse(s) one at a time until the complaint • C H E C K the antenna coax connectors for corrosion
condition has been elim inated and the n o isy or bad connections/crimps. Route coax separately
component is identified. from the other wires. S h ie ld antenna coax
6. C H E C K the ground integrity o f the complaint interconnections with aluminum or nickel tape as
causing component. described in the D E SSG .
• A n interference condition is not necessarily an audible • C H E C K all vehicle grounds, not just radio and
noise. antenna grounds. Refer to the antenna diagnostic
• M ost noises can be found on weak stations near the section.
low end of the band and are considered to be a normal
condition. — Coated screws or bolts can act as poor grounds.
• Ig n itio n noise on F M could indicate a p ossible — U se a braided gro u nd strap w hen a p p lyin g
defective ignition system. grounds. Keep the ground strap as short as
• Malfunctioning and marginal components, relays, and possible, the shorter the ground strap the better.
solenoids may induce noise and/or poor reception. • W hen shielding the dash, wires, hoses (most hoses are
conductive unless they have a white stripe), etc., use
CORRECTIVE ACTION aluminum foil tape or nickel tape to shield against
• Use proper tools for diagnostics and repairs. m agnetically induced interference. F o r optim um
• Follow E S D guidelines. results, try varying the follow ing ground techniques:
• Use available noise suppression devices: — Add a ground at both ends of the tape.
— 220 m F (50V ) capacitor G M P/N 1227895 — Add a ground to just one end of the tape.
— 0.47 m F capacitor G M P/N 1227894 — D o not add ground to the tape.
— Fuse block capacitor G M P/N 469328 • W hen shielding a harness with tape, attach a ground
— Feed through capacitor G M P/N 477371 strap to the end o f the tape and then wrap the strap
— Filter package G M P/N 1224205 360 degrees around the tape securing the other end of
— T\im signal suppression G M P/N 3861565 the strap to a known good chassis ground.
— Fuel pump suppresser G M P/N 25027405 • A n y interference is best corrected by suppression at
— 21 inch braided ground strap G M P/N 8910791 the source o f the interference, if possible.
— 19 inch braided ground strap G M P/N 6286800 • Care should be used when applying suppression.
— 10.5 inch braided ground strap G M P/N 6287160 Signal w ires (such as sensor outputs, clock, and
— 8.5 inch braided ground strap G M P/N 12091511 communication circuits) cannot be suppressed. Battery
• Utilize J 39916-A test tape/CD Diagnostic K it G M and ignition wires can be suppressed. After adding any
P/N to optimize proper audio diagnostics. suppression, all vehicle system s (even those not
• If the condition requires the radio to be sent to the related to the audio system) should be checked for
service center, describe the symptoms on the warranty proper operation and function.
form accurately. A lo n g with the warranty form, send a • In t e r f e r e n c e can u s u a lly be e l i m i n a t e d b y
copy of the Service W riter Check List with the unit. shielding/grounding or suppressing.
• D o not leave a C D disc or tape in the car. Extreme • C ap acitors w ork best on switch pops and low
heat could cause permanent damage. frequency noise. Filters work best on high frequency
whines and static.
• W henever possible, make a test harness that includes • C H E C K for a faulty mounting of the generator to the
filters and capacitors. A lw ays check the effectiveness engine.
and operation before permanently installing a F IX . • M ake sure all ground straps between the engine and
• Recommended capacitor application for an audible pop the frame are clean and tight.
induced from a switching operation is: • Try the follow ing fixes:
— Add a capacitor across the contacts of the switch. 1. If noise is still present, C H E C K the charging
— Add a capacitor from the hot side of the switch to system. Refer to the Charging System section.
ground. 2. If the charging system is functioning normally,
— Add a capacitor to each side of the switch to C H E C K fo r technical service bulletins on
ground. generator whine.
• If a com plaint condition is only present with the 3. IN S T A L L a filter G M P/N 1224205 in the battery
ignition switch key in the R U N position and the feed to the radio.
engine running, perform the follow ing checks: 4. IN S T A L L the filter with the follow ing variations if
— C H E C K the integrity o f the ign itio n system noise is not eliminated.
(proper spark plug wire routing, no m isfiring, etc.), — IN S T A L L the filter with the single wire side
refer to the Ignition System section. toward the radio and the ground wire attached
— C H E C K the integrity of the engine compartment to a good ground.
grounds. — R E M O V E the ground to the filter.
— C H E C K for malfunctioning relays, solenoids, or — R E V E R S E the filter so the two wire side is
other components which may be inducing “noise” toward the radio with the ground wire attached
or poor reception. to a good ground.
— C H E C K the ground integrity o f the complaint — R E M O V E the ground from the filter.
causing component. 5. If noise is still present, IN S T A L L another filter
• For noise and/or poor reception, perform the Antenna G M P/N 1224205 in the ignition feed to the radio.
System Test, and make the necessary repairs. IN S T A L L using the same variations as the first
filter. If the installation of this filter causes turn
GENERATOR WHINE CONCERNS O N or turn O F F delays or other noticeable
performance concerns, R E M O V E the filter and
Inspect: IN S T A L L a 0.47 m F capacitor to ground in its
place.
• C H E C K the ground terminal on the battery. 6. R E M O V E any unneeded filters after repair and
• C H E C K for coated mounting bolts on the generator before reassembling the vehicle.
bracket.
RADIO DOES NOT RETAIN STATIONS IN MEMORY OR CLOCK IS INOPERATIVE

TEST RESULT ACTION
1. Disconnect Radio. Connect a test Test lamp lights. R E M O V E Radio. S E N D in for
lamp from O R N (1140) wire at R E P A IR .
R a d io C onnector cavity 10 to Test lamp does not light. L O C A T E and R E P A IR open in O R N
ground. (1140) wire between Radio Connector
Cavity 10 and IP Fuse Block.
RADIO ILLUMINATION LAMPS DO NOT COME ON

TEST RESULT ACTION
1. Disconnect Radio. Place Headlamp Test lamp lights. R E M O V E Radio. S E N D in for
S w i t c h to P A R K an d P a n e l R E P A IR .
Dim m er Switch to H I. Connect a Test lamp does not light. L O C A T E and R E P A IR open in G R Y
test lamp from G R Y (8) wire at (8) wire between Radio Connector
Radio Cavity 7 to ground. Cavity 7 and Fuse Block.
DISPLAY DIMMING FUNCTION IS INOPERATIVE

TEST RESULT ACTION
1. Disconnect Radio. Place Headlamp Test lamp lights. R E M O V E Radio. S E N D in for
Switch in P A R K . Connect a test R E P A IR .
lamp from P P IV W H T (1382) wire Test lamp does not light. L O C A T E and R E P A IR open in
at Radio Connector Cavity 6 to PPL/W H T (1382) wire between Radio
ground.
Connector Cavity 6 and Fuse Block.
DISPLAY IS INOPERATIVE, NO SOUND FROM ANY SPEAKER

TEST RESULT ACTION
1. Disconnect Radio. Place Ignition Voltage is approximately equal to G O to Step 2.
Sw itch in R U N . W ith a D M M , battery voltage.
measure voltage at O R N (1140) Voltage is not approximately equal to L O C A T E and R E P A IR poor connection
wire at Radio between Cavity 10 battery voltage. or open in O R N (1140) wire between
and ground. Radio Connector Cavity 10 and IP
Fuse Block.
2. W ith a D M M , measure voltage at Voltage is e approximately equal to G O to Step 3.
O R N (1 1 4 0 ) w ire at R a d io battery voltage.
between Cavities 10 and 5. Voltage is not approximately equal to R E P A IR poor connection or open in
battery voltage. B L K (150) wire between Radio
Connector Cavity 5 and G200.
3. W ith a D M M , measure voltage at Voltage is approximately equal to C H E C K Radio for Cavitys shorted
Radio between Cavitys 9 and 5. battery voltage. together or poor connections. If O K ,
service Radio.
Voltage is not approximately equal to R E P A IR poor connection or open in
Battery voltage. Y E L (4 3 ) between Radio Connector
Cavity 9 and IP Fuse Block.
NO SOUND FROM ONE SPEAKER

TEST RESULT ACTION
1. T urn Ig n itio n sw itch to O F F . Resistance is 4-15 ohms. G O to Step 2.
D iscon n ect Speaker Connector.
Resistance is not 4-15 ohms. R E P L A C E Speaker.
W ith a D M M , measure resistance
of Speaker.
2. D isc o n n e c t R a d io C on n ectors. Resistance is infinite. G O to Step 3.
W ith a D M M , m e a su re the R E P A IR short to ground in Speaker
Resistance is not infinite.
resistance at the Speaker from
Feed Circuit.
3. W ith a D M M , measure resistance Resistance is infinite. G O to Step 4.
at Speaker from C avity B and
Resistance is not infinite. R E P A IR short to ground in Speaker
ground. Feed Circuit.
4. Reconnect Speaker. W ith a D M M , Resistance is 4-15 ohms. C H E C K for poor connections at Radio
m easure resistance o f Speaker or Speaker. If O K , service Radio.
Feed Circuits at Radio. Resistance is not 4-15 ohms. C H E C K for poor connections at
Speaker or in-line Connectors or for
open in Speaker Feed Circuits.
8A - 150 - 10 ELECTRICAL DIAGNOSIS___________________
TAPE PLAYER IS INOPERATIVE

TEST RESULT ACTIO N
1. C H E C K T a p e P l a y e r f o r Obstruction observed. G O to Step 2.
obstruction through Tape Door. N o obstruction observed. Service Radio.
2. R e m o v e o b s t r u c t i o n . Test Tape operates. Fault was corrected.
N O T IC E : Im p ro p e r re m oval Test Tape inoperative. Service Radio.
may damage Tape Player. Inspect
and clean m oving parts and Tape
H ead or use cleaning cassette.
Insert diagnostic test Tape from
J 39916 as described in A u d io
Systems.
TAPE PLAYS WEAK, SLOW OR GARBLED

1. Inspect and clean m oving parts Does not play back. G O to Step 2.
and Tape Head or use cleaning Plays O K . Advise periodic cleaning.
cassette.
2. Perform M otor Speed test with M otor Speed not O K. Service Radio.
diagnostic test Tape from J 39916 M otor Speed O K . Fault was with Tape.
as described in A ud io Systems.
COMPACT DISC PLAYER DOES NOT OPERATE PROPERLY

TEST RESULT ACTIO N
1. Observe operation o f C D Player. C D Player skipping or muting. C H E C K for proper insertion, scratches,
dirt or finger prints and clean if
necessary. Is usual route over rough (or
dirt) road? If so, condition may be
normal. D U P L IC A T E on good road
surface. T E S T with known good disc
(preferably new disc). Some discs may
contain marks not readily visible that
may make one track or the entire disc
unplayable. If previous steps fail,
S E R V IC E Radio.
Displaying E R R or disc ejected. E R R appears if disc is inserted upside
down, dirty, badly scratched or wet.
E R R appears if moisture has condensed
on the disc (if a cold disc is inserted
into a hot player or visa versa). A llow
up to an hour to evaporate
condensation. C H E C K with known
good disc - V E R IF Y with customer.
Very H igh Internal IP temperatures may
cause the D isc to eject. If previous
tests fail, S E R V IC E Radio.
NOISE/POOR RECEPTION
TEST RESULT ACTIO N
1. Attem pt to duplicate com plaint Complaint condition verified. G O to Step 2.
condition in each Ignition Switch
Complaint condition N O T verified. C O N T A C T customer for explanation of
key position.
complaint condition.
2. C h e c k fo r te c h n ic a l se rv ic e Complaint condition duplicated again. G O to Step 3.
b u lle tin s. P e rfo rm “ A n te n n a
Complaint condition N O T duplicated. Com plaint condition corrected, no
System Test,” make any necessary
further action required.
repairs and then return to this
chart. Attempt to duplicate the
complaint condition again.
3. T\im Ignition Switch to R U N , start Is the complaint condition duplicated G O to Step 4.
engine. only in this position.
Is the complaint condition N O T G O to Step 4.
duplicated only in this position.
4. Is the V e h icle e quipped w ith Aftermarket equipment is present. G O to Step 5.
aftermarket electronic equipment.
Aftermarket equipment is N O T present. C H E C K for stored diagnostic trouble
codes (D T C s) (Refer to Engine
Controls). C H E C K the integrity o f the
Ignition System (proper Spark Plug
wire routing, no m isfiring, etc.).
R E F E R to Ignition System section.
C H E C K the integrity o f the Engine
Compartment grounds. C H E C K for
malfunctioning relays, solenoids or
other components for noise or poor
reception. If O K , R E F E R to Sound
Service Guide.
5. Check for proper installation of Were the G M guidelines followed. G O to Step 6.
aftermarket electronic equipment. Were the G M guidelines N O T C O R R E C T the installation and
See Troubleshooting Procedures. R E T E S T for complaint condition.
followed.
6. Remove fuses and circuit breakers Com plain condition is eliminated. G O to Step 7.
(one at a time) until the complaint Complaint condition is N O T eliminated. R E F E R to Sound Service Guide.
condition has been eliminated.
7. M ark the complaint fuse(s) and Complaint causing component is C H E C K the ground integrity of the
re in sta ll all fu ses and circu it identified. complaint causing component. If O K,
bre akers. R e fe r to S E C T IO N R E F E R to Sound Service Guide.
8A - 10 and 8A -11. Id e n tify all Complaint causing component is not R E F E R to Sound Service Guide.
systems and components powered identified.
by the com plaint fuse(s)/circuit
breakers(s).
8A - 150 - 12 ELECTRICAL DIAGNOSIS_____________________
POWER AMPLIFIER IS INOPERATIVE

TEST RESULT ACTION
1. Place Ignition Switch in A C C or Test lamp lights. G O to Step 2.
R U N position. Connect a test lamp Test lamp does not light. L O C A T E and R E P A IR open in P N K
from P N K (314) wire at Power (314) wire between Power Am plifier
Am plifier Relay to ground. Turn Relay and Radio Receiver. If wire is
R a d io C o n t r o l H e a d to O N good, R E M O V E Receiver and S E N D
position. in for repair.
2. Connect a test lamp from P N K Test lamp lights. G O to Step 3.
314 wire to B L K (150) wire at Test lamp does not light. L O C A T E and R E P A IR open in B L K
Power Am plifier Relay. (150) wire between Power Am plifier
Relay and IP Ground G200.
(640) wire at Pow er A m p lifie r Test lamp does not light. L O C A T E and R E P A IR open in O R N
Relay to ground. (640) wire between Power Am plifier
Relay and IP Fuse Block.
(360) w ire at Pow er A m p lifie r Test lamp does not light. R E P L A C E Power Am plifier Relay.
Relay to ground.
5. Connect a test lamp from O R N Test lamp lights. R E M O V E Power Am plifier and S E N D
(360) wire to B L K (150) wire at in for repair.
Pow er Amplifier. Test lamp does not light. L O C A T E and R E P A IR open in B L K
(150) wire between Power Am plifier
and IP Ground G200.
NO SOUND OR DISTORTED SOUND FROM REAR SPEAKERS

TEST RESULT ACTION
1. D is c o n n e c t su sp e c t S p e a k e r Speaker pops. G O to Step 2.
Connector. Set ohmmeter on R x l N o noise. R E P L A C E Speaker.
scale. Connect ohmmeter across
C avitys of suspect Speaker.
2. Place Ignition Switch in A C C or Varying around 1 Volt A C . L O C A T E and R E P A IR open or short in
R U N position and turn Radio O N. Y E L (116), B R N (199), D K B L U (46)
Tune R adio to a strong signal. or L T B L U (115) between Radio
Connect voltmeter across suspect Connector and Power Am plifier
Speaker. Connector W H T (1859), W H T (1959),
T A N (1855) or R E D (1955).
N o voltage or voltage greater than 1 R E M O V E Power Am plifier and S E N D
Volt A C . in for repair.
ANTENNA SYSTEM TEST

TEST RESULT ACTIO N
1. Disconnect negative Battery Cable. The resistance is less than 0.15 ohms. G O to Step 2.
D isc o n n e c t A n te n n a L e a d in
The resistance is greater than 0.15 C H E C K the base o f the Antenna for a
connector at the Radio Receiver.
ohms. good connection to body ground.
W ith a D M M , measure resistance
C H E C K the Coaxial Cable
b e t w e e n the c o a x ( o u t e r
interconnects for a poor connection or
conductor) R adio Connector and corrosion. C H E C K the ground
the N e g a tiv e B a tte ry C a b le .
connection from the Battery Negative
N O T I C E : To avoid
Cable to the body. R E P A IR the
m isdiagnosis, “ zero” the D M M
Antenna ground circuit as necessary.
meter before taking measurements.
2. G R A S P the Antenna mast. W hile The D M M indicates no intermittent G O to Step 3.
observing the D M M , w iggle the continuity.
Antenna.
The D M M indicates intermittent C H E C K the base o f the Antenna for a
continuity. good connection to body ground.
C H E C K the Coaxial Cable
interconnects for a poor connection or
corrosion. C H E C K the ground
connection from the Battery Negative
Cable to the body. R E P A IR the
Antenna ground circuit as necessary.
3. W ith a D M M , measure resistance The measured resistance is less than2 G O to Step 4.
b e tw e e n the R a d io C o a x ia l ohms (RG -58 or R G -59) 3.5 ohms or
L e a d - In C o n n e c t o r (c e n te r (RG -62 or R G -62M ).
conductor) and the Antenna mast. The measured resistance is not less C H E C K the Coaxial Cable
N O T I C E : To avoid than 2 ohms (RG -58 or RG -59) 3.5 interconnects for a poor connection or
m isdiagnosis, “ zero” the D M M
ohms or (R G -62 or R G -62M ). corrosion. R E P A IR / R E P L A C E the
before taking measurements.
Antenna Coaxial Circuit as necessary
and R E T U R N to the N O ISE /P O O R
R E C E P T IO N chart.
4. W hile observing the D M M , wiggle The D M M indicates intermittent C H E C K the Coaxial Cable
the Antenna Coax. continuity. interconnects for a poor connection or
corrosion. R E P A IR / R E P L A C E the
Antenna Coaxial Circuit as necessary
and the R E T U R N to the N O ISE /P O O R
R E C E P T IO N chart.
The D M M indicates N O intermittent R E T U R N to the N O ISE /P O O R
continuity. R E C E P T IO N chart.
USE AND CONSTRUCTION OF A NOISE CUSTOMER’S TIPS

“SNIFFER”
The Noise Sniffer can be used along with the vehicle’s HOW TO ENJOY FM STEREO
Radio to locate “hot spots” which are generating Radio 1. Select Stations W ithin Range - The best F M fidelity
noise interference. These “hot spots” can be found in the w ill be obtained from stations within the 10-40 mile
harnesses, in the upper part o f the dash or even between range. Beyond that, “noise” or “flutter” may begin to
the hood and the windshield. The Sniffer can be made from appear due to the “line o f sight” range limitations of
F M signals. S O L U T IO N : Reduce treble response by
an old piece o f Antenna Lead-In from a mast or Power
m oving the treble control down (or to the left) in
Antenna. The longer the Lead-In the better. M ake the Noise
fringe areas. O n E Q Radios, slow ly slide the 10K
Sniffer as shown in Figure 1. The 2 inch section with the
control down.
black coating and braided shield stripped back becomes the
2. Realize Tall Structures Can Interfere - Tall buildings
Antenna when the Sniffer is plugged into the R ad io’s
or hills may cause “ shadows” or cancellation of F M
Antenna socket. The Sniffer can then be used to probe and
signals (this is sim ilar to the “ghost” or “flutter”
search out “hot spots.”
effect seen on television sometimes when airplanes are
1. W hile listening to the complaint noise, disconnect the flying in the vicinity). It w ill sound like a “pop” or
Antenna and plug the Sniffer into the Antenna socket. momentary “hiss.” S O L U T IO N : Reduce the treble or
2. Turn the Radio Volume up. 10K setting to a lower volume.
3. Search for the noise source, keeping fingers off the 2 3. Interference From Another Station - Although the
inch probe. W hen checking for noise on wire, the best circuits in Delco receivers are the most advanced
results w ill be achieved when the sniffer is placed available, there are rare instances where a station w ill
parallel to the wire, refer to Figure 2. be interfered w ith by another station. T h is only
happens when the stations are on almost the same
frequency and certain geographical criteria are present.
WHITE PUSTC INSULATOR S O L U T IO N : Select another station or switch to a Tape
CENTER CONDUCTOR WRE or C D .
ANTENNA LEAOHN
WITH ANTENNA BASE
b 2" or COAX SHCLD
CUT AWAY
HOW TO ENJOY AM
R eception C h aracteristics
CONNECTOR REMOVED A M does not have the flutter characters o f F M (caused
by tall buildings, hills, etc.). However, it is subject to
01-08-96 interference from powerlines, neon signs, atmospheric
AffflOBB/MBO
conditions and unwanted stations.
Figure 1—Noise Sniffer
WAYS TO REDUCE NOISE
1. M ove Treble Control down.
2. T\me to a stronger station.
CIRCUIT OPERATION
RADIO
Voltage to the Radio is available at all times through
the O R N (1140) wire. T his Circuit provides voltage for
Radio Station M em ory Storage. It also provides voltage for
the C lock Memory. W ith the Ignition Switch in A C C or
R U N , voltage is supplied to the Radio through the R A D IO
"use and the Y E L (43) wire. Each Speaker has its own pair REMOTE CASSETTE TAPE PLAYER
of leads. The Radio/Clock Display brightness is at full (OPTIONAL)
intensity with the Ignition Switch in A C C or R U N ; voltage W ith the Ign ition Sw itch in R U N and the R adio
is supplied by the Y E L (43) wire. W hen the Parklam ps or Control Head O N , voltage is supplied to the Cassette Tape
Headlamps are turned on, voltage is supplied to the Radio Player through the Radio.
through the P P L/W H T (1382)wire. W hen the Radio senses W ith the Remote Cassette Tape Player in P LA Y , the
this signal, the Radio switches voltage for the display from Tape Player returns a Tape O N signal and the Stereo A udio
the Y E L (4 3 ) w ire to the G R Y (8 ) w ire. The d isp la y signals to the Radio. The Tape O N signal causes the
brightness is then controlled by the Panel and Interior Receiver circuitry to ignore the signals from the Timer and
Lam ps C ontrol Sw itch. The R ad io Illum ination B u lb to send the audio signals from the Tape Player to the
voltage is supplied by the G R Y (8) wire. Speakers. W ith a Cassette Tape in F W D , R EV , or S E E K ,
the Tape Player applies a mute signal to the Radio to
POWER AMPLIFIER (SUBURBAN ONLY) prohibit the audio sound of these functions from being
The optional amplifier boosts the sound of the Four heard. W hen the E J E C T Button is pushed on the Tape
Rear Speakers in the Suburban when equipped with the Player, the Tape O N signal is terminated and the Radio
premium sound system. returns to normal operation.
W ith the Ignition Switch in A C C or R U N position and
the Radio Control Head O N , Battery voltage is supplied to AUXILIARY SPEAKER - Z56
the Power Am plifier Relay through the P N K / B L K (143) If the vehicle is equipped with the option W X 7 as part
and O R N (40) wires. The Relay is grounded through the o f the police package Z56, the Front D oor Speakers are not
B L K (150) wire at the IP Ground G200. W hen the relay connected to the radio. They are, instead, connected to a
contacts close, Battery voltage is supplied to the Power jumper harness blunt cut and coiled under the center of the
Am plifier through the O R N (140) wire, and ground is IP. This is done in order to allow the Front D oor Speakers
ompleted through the B L K (150) wire at the IP Ground to be con n e cte d d ire c tly up to a n y afterm arket
1200. radio/communication equipment.
MASTER COMPONENT TABLE
A/C Com pressor................... L F of En gin e ........................................................... ... 1 4 .... 18
A/C Com pressor Clutch.......... Front of A/C Compressor, L F of Engine....................... .... 1 4 .... 18

Relay............................... In Underhood Fuse-Relay Center, L R of Engine
Compartment, on Fender.......................................... ... 6 ...... 10

Compartment, on Bulkhead...................................... .... 17.... 21

Cutout Sw itch ................... O n rear of A/C Compressor, L F of Engine.................... .... 1 0 .... 14

L in e .................................................................... .... 1 0 .... 14
A/C Control M odule, Front..... Part of H V A C Control Module, Front........................... .... 5 3 .... 68
A/C Control M odule, Rear...... Part o f H V A C Control Module, Rear................................. 5 3 .... 68
Accelerator Pedal Position

M odule (D iesel)................. Part of Accelerator Pedal........................................... .... 4 1 .... 53.... 202-22

Pump (5 .7L)..................... L F of Engine Com partm ent........................................ .... 9 ...... 14A

Pump (7.4L)...................... Low er R F of En gin e ................................................. ..... 16...... 20

Pum p C lu tch ..................... O n front of A.I.R. Pum p........................................... .... 1 6 .... 20

Compartment, on Fender......................................... .... 5 ...... 9 ...... 202-60
Antenna.............................. R H Fender.............................................................. .... 4 ....... 7
A sh Tray L a m p .................... In A sh Tray H o u sin g................................................ .... 4 9 .... 64
Audio Alarm M odule............. Under L H of IP, at R H of Convenience Center.............. .... 3 3 .... 44

Automatic Day/Night Mirror,
L H O utsid e ...................... Mounted on outside of L F Door, near A P illa r.............. .... 6 1 .... 79
Automatic Day/Night Mirror,

R H O utside...................... Mounted on outside of R F Door, near A P illar.............. .... 6 1 .... 79

Control M odule, Connector
C l .................................. Under L H of IP, near Convenience Center..................... .... 3 4 .... 45.... 202-23

Control M odule, Connector
C 2 .................................. Under L H of IP, near Convenience Center.......................... 3 4 .... 45.... 202-60

Switch, Connector 1 ........... A t center rear o f IP, near Remote Control D oor Lock
Receiver.................................................................... 4 8 .... 63.... 202-59

Receiver................................................................... 4 8 .... 63.... 202-60
ELECTRICAL DIAGNOSIS 8A - 20 0 -1

Automatic Transm ission Input
Shaft Speed Sensor............. L F of Transm ission...................................................... 25...... 34
Auxiliary A/C Control Module,

Front............................... In Overhead Console.................................................... 53.... .. 68 202-26
Auxiliary A/C Control Module,

R e a r................................ In rear Headliner......................................................... 5 3 ..... 68, 202-26
Auxiliary Battery.................. L F of Engine Compartment........................................... 1 .... .. 4
Auxiliary Battery R e lay......... L R of Engine Compartment, on Fender, near Underhood

Fuse-Relay Center..................................................... 5 .... .. 9
Auxiliary Blow er M o to r......... Behind R R W heelhousing.............................................. 6 6 ..... 85

H ig h ................................ O n top of Auxiliary H V A C Plenum, near R R W heelhousing. 6 6 ...,. 85. 202-60

L o w ................................ O n top of Auxiliary H V A C Plenum, near R R W heelhousing. 6 6 ... ,. 85. 202-60

M e d iu m ........................... O n top of Auxiliary H V A C Plenum, near R R W Tieelhousing. 6 6 ... . 85. 202-60
Auxiliary Blow er R esistor...... O n top of Auxiliary H V A C Plenum, near R R W^heelhousing. 6 6 ...„ 85
Auxiliary Blow er Sw itch ........ O n IP, R H of R ad io..................................................... 6 6 ...,. 85
Auxiliary C ooling Fan Motor.... R H of Engine Compartment, front of Radiator.................. 0 .... ,. 2
A uxiliary C ooling Fan Relay .... L R of Engine Compartment........................................... 4 .... ,. 7... 202-60
Auxiliary G rille Lam p (Police

Package, Z 5 6 )................... Behind Grille, in front of Radiator........... ....................... 4 8 ...,. 63. 202-65
Auxiliary Heater Control

Module, Fro n t................... L H of IP, R H of Steering C olu m n .................................. 5 3 ...,. 68. 202-26
Auxiliary Heater Control

Module, R e a r.................... L H of IP, R H of Steering C olu m n .................. ................ 5 3 ...,. 68. 202-26
Auxiliary H V A C Control Lamp,

Fro nt............................... Front of Overhead Console, part of H V A C Controls........... 5 3 ...,. 68
Auxiliary H V A C Control Lam p,

R e a r................................ Rear of Overhead Console M olding, in Headliner, part of
H V A C Controls........................................................ 5 3 ..... 68

M odule............................ In Overhead Console..................................................... 5 3 ...,. 68. 202-25
Module, Fro n t................... Front of Overhead Console, near W indshield..................... 5 3 ..... 68. 202-26
Module, R e a r.................... Rear of Overhead Console M olding, in Headliner.............. 5 3 ..... 68. 202-26
Auxiliary H V A C Fan Switch .... Rear of Overhead Console, in Headliner.......................... 4 8 ..... 63. 202-60
Auxiliary Lights Relay (Z56,

Police Package)................. 5 .... .. 9
Auxiliary M ode D oor M o to r... In Auxiliary H V A C Plenum, forward of L R Wheelhousing.... 6 6 ..... 85
Auxiliary Power Center (6 J1)... Center of IP, below Heater C on trols............................... 4 2 ..... 54
Auxiliary Power Connectors.... Center lower R H of IP, L H of A sh Tray.......................... 4 8 ..... 63

A uxiliary Power Stud (Z56,
Police Package)................. Mounted on Fan Shroud, between Battery and Fan 1 ..... . 3
Auxiliary Speakers (Police

Package, Z 5 6 )................... 4 8 ... . 63 .... 202-65

M o to r.............................. In Auxiliary H V A C Plenum, near L R W heelhousing.......... 6 6 ... . 85
Backup Lam p, L H Cab

C hassis............................. Rear of vehicle........................................................... 7 3 ... . 97
Backup Lam p, L H
Pickup/Utility.................... Rear of vehicle........................................................... 7 4 ... . 99
Backup Lamp, R H Cab

C hassis............................. Rear of vehicle........................................................... 7 3 ... . 97
Backup Lam p, R H
Pickup/Utility.................... Rear of vehicle........................................................... 7 4 ... . 99
Backup Lam p Switch (MG5).... L H of Transmission, below Shift Tower........................... 2 7 ... . 38
Backup Lam p Sw itch (M W 3)... L H top of Transm ission................................................ 2 6 ... . 36
Battery................................ R F of Engine Compartment........................................... 1 ....., 4
Blow er M o to r...................... R H of IP, behind IP Compartment B o x ............................ 5 0 ... „ 65
Blow er M otor Relay, H ig h ..... Behind IP Compartment Box, on H V A C Plenum ............... 5 0 ... „ 65 .... 202-60
Blow er R esistor.................... O n top of H V A C Plenum .............................................. 5 0 ...,. 65 ...., 202-61
Blow er Switch, Connector C 2 .. O n top of H V A C Plenum .............................................. 5 0 ...,. 65.... 202-28
Brake Lam p R e la y ................ In Underhood Fuse-Relay Center, L R o f Engine

Compartment, on Fender............................................ 6 ....... 10
Brake Pressure W arning

Sw itch................... O n rear of E B C M casting, near Brake Master Cylinder, at
L F W heelhousing...................................................... 6 ....... 9
Brake/Transmission Shift
Interlock (B T S I) Solenoid.... L H of IP, R H of Steering Column, under Support Bracket.... 4 4 ..... 57
Camshaft Position Sensor....... In Distributor.............................................................. 1 2 ..... 16
Cargo D oor Contactor, L H ...... Rear Body Opening and Door, upper L H ......................... 7 6 ..... 101
Cargo D oor Contactor, R H ..... Rear Body Opening and Door, upper R H ......................... 7 6 ..... 102

L R ........................... ....... O n L R Cargo D oor G la ss............................................. 7 6 ..... 101

R R .................................. O n R R Cargo D oor G la ss............................................. 76.... .. 102
Cargo Lam p (P icku p )............ Rear center of cab, above Rear Window, part o f C H M S L ... 69.... .. 90
Cargo Lam p Switch (Pickup).... Center of IP, center L H o f R ad io ................................... 48.... .. 63
Catalytic Converter (Police

Package, Z 5 6 )................... 29.... .. 40
Catalytic Converter Ground

Strap (Police Package,
Z 5 6 )................................ 29...... 40

Cargo Lam p Sw itch .............. 202-61

(C H M S L , Pickup).............. A t top rear center of cab............................................ .... 6 9 .... 9 0 .... 202-64

(C H M S L , Suburban/Utility)... A t top rear center of vehicle, part o f R o o f..................... ... 7 0 .... 9 2 .... 202-64
Cigar L igh te r....................... Low er R H center o f EP, L H of A sh T ra y....................... ... 4 9 .... 64
Clearance Lamp, L F ............. Front of L R Fender................................................... .... 6 9 .... 89
Clearance Lamp, L R ............. Rear of L R Fender.................................................... .... 6 9 .... 89
Clearance Lamp, R F ............. Front of R R Fender.................................................. .... 6 9 .... 89
Clearance Lamp, R o o f........... O n L H and R H top front of roof, at each end of R oof
M arker Lam ps....................................................... ... 6 9 .... 89.... 202-69
Clearance Lamp, R R ............. Rear o f R R Fender.................................................... .... 6 9 .... 89
Clutch Pedal Position Switch.... A t top o f Clutch Pedal.............................................. ... 4 1 .... 5 3 .... 202-61
Convenience Center.............. Under L H o f IP, on Bulkhead...................................... ... 3 3 .... 44
Courtesy Lamp, L H I P .......... Under L H o f IP ........................................................ ... 4 2 .... 54
Courtesy Lamp, R H IP .......... Under R H of IP ........................................................ ... 4 2 .... 54
Courtesy Lamp, L F D o o r....... L H of L F Door, midway u p ....................................... ... 6 1 .... 79
Courtesy Lamp, L R D o o r....... L H of L R D oor Trim, midway u p ................................ ... 6 2 .... 80
Courtesy Lamp, R F D o o r....... R H of R F Door, midway u p ....................................... ... 6 1 .... 79
Courtesy Lamp, R R D o o r...... R H of R R D oor Trim, midway u p ................................ ... 6 2 .... 80
Crankshaft Position (C K P )
Sensor............................. Low er R F of Engine Block, near Crankshaft.................. ... 1 1 .... 15
Cruise Control M odule

( C C M ) ............................ L R of Engine Compartment, on Bulkhead...................... ... 3 1 .... 42.... 202-29
Cruise Control Sw itch............ In 1[\im Signal L e v e r................................................. ... 4 7 .... 61
Data L in k Connector ( D L C ) ... Under L H o f IP, L H of Steering Column, mounted to

bottom of Knee Bolster........................................... ... 4 3 .... 5 5 .... 202-30

(D R L ) M o d u le .................. , Under L H of IP, taped on IP Harness............................ ... 3 4 .... 4 5 .... 202-61

(DRL)/Radio Override
Sw itch............................. . Center of IP, L H of R a d io .......................................... ... 4 9 .... 6 4 .... 202-61

(D R L ) R e la y .................... , Under L H of IP, at lower center of Convenience Center... ... 3 3 .... 44

Package, Z 5 6 )................... , Approx. 22 cm from W indshield centerline, in Headliner....... 6 0 .... 78
Dom e Lamp, Rear (Police

Package, Z 5 6 )................... . Approx. 22 cm from W indshield centerline, in Headliner....... 5 9 .... 77
Dom e Lam p Defeat Sw itch...... L H of IP, L H of Steering Colum n, part of Headlamp and
Panel Dim m er Sw itch.............................................. ... 3 2 .... 43
D oor Jamb Switch, C a rgo ...... , Rear Body Opening, part of R R Cargo D oor Contactor.... ... 7 6 .... 102
COMPONENT LOCATION 201-PQ FIG. CONN
D oor Jamb Switch, L F .......... A t L H end of IP ......................................................... 4 5 ... . 59
D oor Jamb Switch, L R .......... Center inside edge of L H B P illa r.................................. 6 8 ... . 88
D oor Jamb Switch, R F .......... A t R H end of I P ......................................................... 4 5 ... . 59
D oor Jamb Switch, R R ......... Center inside edge o f R H B P illa r................................. . 6 8 ... . 88
D oor Lock Control M odule..... Attached to body, forward of L R W heelhousing................ 7 8 ... . 104.... 202-68
D oor Lock Motor, Cargo........ Inside R R Door, at lower R H com er.............................. 7 6 ... . 102
D oor Lock Motor, L F ............ Inside L F Door, part of D oor H andle............................. 6 1 ... . 79
D oor Lock Motor, L R ........... Inside L R Door, part o f D oor Handle............................. 6 2 ... . 80
D oor Lock Motor, R F ........... Inside R F Door, part of D oor Handle............................. 6 1 ..., 79
D oor L o ck Motor, R R ........... Inside R R Door, part of D oor Handle............................. 6 2 ... „ 80
D oor L o ck Relay.................. Under center of IP, near Remote Control D oor Lock
Receiver................................................................. 4 1 ... „ 53 .... 202-68
D oor L o ck Switch, L a st......... Top of R H D Pillar..................................................... 7 8 ...,. 105
D oor L o ck Switch, L F .......... O n L F D oor Trim Panel, below Inside D oor Handle......... 6 1 ... , 7 9 .... 202-41,
68
D oor Lock Switch, R F .......... O n R F D oor Trim Panel, below Inside D oor Handle......... 6 1 ..., 7 9 .... 202-31
M irror with C om p ass......... O n top inside of W indshield center, part of Inside Rearview
M irro r................................................................... 5 4 ...„ 69
Electronic 4-speed Automatic

Overdrive Transm ission....... Attached to rear of En gin e........................................... 2 3 ...„ 31

M odule (E B C M )................ Near Brake Master Cylinder, at L F W heelhousing............. 6 ....... 10

(EVO )/Passlock M od ule...... Under center of I P ...................................................... 4 0 ..... 52.... 202-31
Emergency R o o f Lam p Switch

(Police Package, Z 5 6 )......... 5 1 ..... 66
Emergency Vehicle Front Lam p

Relay (Z56, Police
Package).......................... Behind R H of IP, mounted to Bracket between R F Door
Jamb Switch and IP Compartment B o x .................... 4 5 ... , 59... . 202-62
Endgate M arker Lam ps.......... O n center and bottom of Endgate.............................. 7 1 ... .. 94
Endgate W indow Release

Sw itch............................. Center of IP, L H of R a d io ....................................... 4 8 ... „ 63

Sender (G a s)..................... L H Cylinder Head, near #1 Spark P lu g....................... 14... „ 18
Sensor (D iesel).................. Low er L F of Engine B lo c k ...................................... 2 1 ... „ 26

Sensor (G as)..................... Top R F of Engine, near Thermostat Housing................ 10... , 14

Sw itch............................. Top R F of Engine, near Thermostat H ousing............... 1 0 ... „ 14
E L E C T R IC A L D IA G N O S IS 8A - 2 0 0 - 5

Purge Solenoid.................. A t top R H of En gin e ..................................................... 1 1 .... 15
Purge Solenoid V alve ......... A t top R H of En gin e ..................................................... 1 1 .... 15
Vent................................ L F of E B C M , near Brake Master Cylinder, at L F
W heelhousing.......................................................... . l i .... 15.... 202-49
Evaporative Em issions Purge
Solenoid Vacuum Sw itch ..... R H top of Engine, toward the rear.................................. l i .... 15
Exhaust Gas Recirculation
(E G R ) Boost Solenoid......... Front of Engine, near Thermostat H ousing........................ 2 0 .... 2 4 .... 202-47
(EG R ) P W M Valve
Solenoid........................... Top of Engine................................................. ........... 2 0 .... 24
(E G R ) Sole n oid ................. Top L H center of Engine, above Valve C ove r................... 2 0 .... 24 .... 202-62

(E G R ) Valve (4.3L)............ Top L H center of Engine, above Valve C o ve r................... 2 0 .... 2 4 .... 202-66

(E G R ) Vent (Diesel) O n top of Intake Plenum .............................................. 2 0 .... 24
Fog Lamp, L H ..................... A t L H lower edge of Front Bum per and A ir Deflector....... 0 ..... 1
Fog Lamp, R H ..................... A t R H lower edge of Front Bum per and A ir Deflector....... 0 ..... 1
Fog Lam p Relay................... Under L H end of IP, on lower L H of Convenience Center.... 3 3 .... 44
Fog Lam p Sw itch.................. Center of IP, R H of Steering Colum n Shift L e v e r............. 4 8 .... 6 3 .... 202-62
Front Axle Actuator.............. R F of Front Drive A xle ................................................ 1 9 .... 2 8 .... 202-62
Fuel Gauge Sender................ In Fuel T ank.............................................................. 6 9 .... 9 0 .... 202-63
Fuel Gauge Sender,

Secondary......................... In Auxiliary Fuel T an k................................................. 6 9 .... 9 0 .... 202-63
Fuel Heater......................... Top rear of E n gin e ...................................................... 6 9 .... 90
Fuel Injection Pump (D ie se l).... O n Intake M an ifold ...................................................... 2 1 .... 2 6 ....
Fuel Injectors (4.3L) ............. In Intake M a n ifo ld ....................................................... 1 9 .... 2 3 .... 202-32
Fuel Injectors (5.0L, 5.7L) .... In Intake M a n ifo ld ...................................................... 13...... 17.... 202-33
Fuel Pump (D iesel)............... Inside L H Frame Rail, below L F D o o r............................ 2 1 .... 26
Fuel Pump, Secondary
(D ie sel)............................ In Auxiliary Fuel T an k................................................. 2 1 .... 26
Fuel Pump and Sender.......... In Fuel T ank.............................................................. 7 3 .... 97
Fuel Pump Balance M od ule .... Inside L H Frame Rail, near Transm ission Crossmem ber...... 6 9 .... 9 0 .... 202-63
Fuel Pump Balance R e la y ...... O n Fuel Pump Balance Module, inside L H Frame Rail, near
Transm ission Crossm em ber......................................... 6 9 .... 9 0 .... 202-63
and Sender (D ie sel)............ Under Intake Manifold, center of Engine.......................... 2 0 .... 2 5 .... 202-63
and Sender (G as)............... Rear top center of Engine, behind D istributor................. .. 12 .... 16.... 202-63
Fuel Pump R e la y ................. In Underhood Fuse-Relay Center, L R of Engine

Compartment, on Fender........................................... .. 6 ...... 10
Fuel Tank Pressure Sen sor..... In Fuel Tank............................................................. .. 7 3 .... 97.... 202-64
Fuse Block A ...................... R F of Engine Compartment, on upper Radiator Support.... .. 3 ...... 6
Fuse Block B ...................... R F of Engine Compartment, on upper Radiator Support.... .. 3 ..... 6
Generator............................. L H Front of Engine
G low Plug Control M odule..... L R of Engine, near Bulkhead....................................... .. 2 2 .... 29 .... 202-64
G low Plug R elay.................. L R of Engine, near Bulkhead....................................... .. 2 2 .... 29
G low P lu g s......................... O n side o f Engine, near Exhaust M a n ifo ld ..................... .. 1 9 .... 23

Sw itch............................. Low er L H o f I P ........................................................ .. 3 2 .... 43 .... 202-34
Headlamp Dim m er S w itch ...... Part of Multifunction Lever.......................................... .. 3 2 .... 43.... 202-34
Headlamp S w itch ................. Part of Multifunction Switch, L H of Steering C olu m n ...... .. 32...... 43.... 202-34

(Com posite)...................... L F of vehicle............................................................ .. 4 ...... 8

(Com posite)...................... R F of vehicle............................................................ .. 4 ........ 7

L H .................................. L F of vehicle............................................................ .. 4 ...... 8

R H ................................. R F of vehicle............................................................ .. 4 ...... 7
(Com posite)...................... L F of vehicle............................................................ .. 4 ........ 8
(Com posite)...................... R F of vehicle............................................................ .. 4 ........ 7
Heated M irror R e la y .............. O n Convenience Center............................................... .. 5 3 .... 68
(H 0 2 S )............................. In Exhaust Pipe, in front and back of Catalytic Converters... 1 5 .... 19.... 202-64
Heated Seat M odule, L H ........ Under L F Power Seat................................................. .. 6 3 .... 81.... 202-64
Heated Seat Module, R H ....... Under R F Power Seat................................................. .. 6 3 .... 81.... 202-64
Heated Seat Switch, L H ......... A t L F o f L F Power Seat............................................. .. 6 3 .... 81
Heated Seat Switch, R H ......... A t R F o f R F Power Seat............................................ .. 6 3 .... 81
Heater Control M odyle, Front... Part o f H V A C C on trols............................................... .. 5 3 .... 68.... 202-35
Heater Control M odule, Rear.... Part o f H V A C C on trols............................................... .. 5 3 .... 68.... 202-35
Horn, L H ............................ A t front of vehicle..................................................... .. 4 ..... . 8
Horn, R H ............................ A t front of vehicle..................................................... .. 4 ....... 7
H orn R e la y ......................... O n Convenience Center, under L H o f I P ........................ .. 6 ...... 10
H orn Sw itch......................... Top of Steering Colum n under Steering W heel Pad.......... .. 47..... 61

H V A C Control Lam p ............. Part o f Heater Controls, center of IP, under R ad io .......... 5 3 ..... 68
H V A C Control M od ule.......... Part o f Heater Controls, center of IP, under R ad io.......... 5 3 ..... 6 8 ..... 202-35
Idle A ir Control (LAC) Valve

M otor.............................. Attached to R R of Throttle B o d y ................................ 1 0 ..... 14..... 202-65
Ignition C o il....................... . R R of Engine........................................................... 1 8 ...,. 22
Ignition Control M o d u le ......... R R of Engine.......................................................... 1 1 ... .. 15..... 202-64
Ignition Sw itch ..................... O n Steering Colum n, under Lock C ylin d er.................... 4 2 ... .. 57
Illuminated Vanity M irror, LH .. Part of L H Sunvisor.................................................. 5 5 ... . 70
Illuminated Vanity M irror, RH .. Part of R H S u n viso r... :............................................ 5 5 ... . 70
Inflatable Restraint Front End

Discrim inating Sensor.......... Under front outside center of Radiator.......................... 0 ..... . 2 ..... 202-65
Inflatable Restraint IP
M odule............................. R H of IP, above IP Compartment B o x ......................... 4 3 ... . 56

Switch (Pickup).................. Center o f IP ............................................................ 4 8 ... „ 6 3 ...., 202-65
Inflatable Restraint Sensing and

Diagnostic M odule (S D M )... Under Carpet Beneath Drivers Seat.............................. 3 9 ... . 5 1 ...., 202-37
Inflatable Restraint Steering

W heel M odule................... Center of Steering W heel........................................... 4 7 ... . 61
Instrument Cluster................. Upper L H end of IP, above Steering C olum n................. 3 2 ... „ 43 ...., 202-38
Intake A ir Temperature (IA T )

Sensor (G as)..................... In A ir Intake Duct.................................................... 1 7 ..... 21
Intake A ir Temperature (IA T )

Sensor (D iesel).................. A t L F of Engine, near Intake M anifold opening............. 2 1 ..... 27

M odule............................ Under center of I P ................................................... 3 8 ..... 5 0 ..... 202-66
IP Compartment B o x L a m p .... In IP Compartment B o x ............................................ 4 2 ..... 54
IP Fuse B lo ck ...................... L H of IP, near L F D oor Jamb Sw itch .......................... 3 2 ..... 43
K e y-In W arning Buzzer

Sw itch............................. In Steering C olum n................................................... 4 7 ..... 61
K nock Sensor (4.3L) ............ Rear o f Engine, on Engine B lo ck................................ 1 2 ..... 16
K nock Sensor (5.0L, 5.7L)...... R F of Engine Block, below Exhaust Manifold, forward of
Starter.................................................................. 15.... .. 19
Knock Sensor (7.4L) ............ L R o f Engine Mount, on Engine.................................. 18.... .. 22
License Lam ps, L H / R H .......... Rear o f vehicle, at License H older............................... 7 4 ..... 98

Liftgate Defogger G rid .......... O n Liftgate G la ss..................................................... 7 7 ..... 103
Liftgate Release M o to r.......... In R H center of Liftgate............................................ 6 8 ..... 87 ..... 202-68
Liftgate Release Sw itch .......... Center o f IP, L H of Radio

M odule (D ie sel)................. Under center of I P ................................................... 37.... .. 4 9 ..... 202-66
(D ie sel)............................ In Coolant Reservoir, R H o f Engine Compartment......... ... 3 7 .... 49
M anifold Absolute Pressure

(M A P ) Sensor (D iesel)........ O n Bulkhead, R H o f Steering C olu m n ........................ .... 0 ...... 2
M anifold Absolute Pressure

(M A P ) Sensor (G as)........... Top R H center o f Intake M anifold, near Fuel Injectors... .... 11.... 15
M arker Lam ps, Front............. Across top front of vehicle....................................... .... 4 ...... 7
M arker Lam ps, R o o f.............. Across top front of ro o f........................................... .... 3 ...... 6
M ass A ir Flow (M A F )
Sen sor............................. A t A ir Intake Duct, near A ir Filter, R H of En gin e ........ .... 1 3 .... 19
M ega Fuse B lo c k ................. R F of vehicle......................................................... .... 3 ...... 6
M ode D oor M otor................. Under IP, on L H o f H V A C Plenum ................................. 5 0 .... 65.... 202-66
M ultifunction L e v e r.............. L H of Steering C olum n............................................ .... 4 7 .... 61
Overhead C on sole ................. A t top center o f W indshield Centerline....................... ..... 5 3 .... 68
Overspeed W arning Alarm

(Export O n ly).................... .... 3 6 .... 47
Park and 1X1111 Lam p, L F ....... A t L F comer o f vehicle........................................... .... 4 ...... 8
Park and Turn Lam p, R F ....... A t R F comer o f vehicle........................................... .... 4 ...... 8
Park Brake W arning Sw itch.... Mounted on Park Brake, under L H end o f I P .............. .... 3 3 .... 44

Switch, Connector C l ......... A t L H center o f Transm ission................................... .... 2 3 .... 31.... 202-67

Switch, Connector C 2 ......... A t L H center of Transm ission................................... .... 23...... 31.... 202-67
Power A m p lifier................... Under L H o f IP, R H of Brake Pedal Bracket............... .... 3 4 .... 57 .... 202-40
Power Am plifier R e la y .......... Under L H o f IP, R H of Brake Pedal Bracket............... .... 3 4 .... 57.... 202-67

Motor, L H ........................ O n L F Door, near center of A P illa r.......................... .... 6 1 .... 79.... 202-66,
67

M irror, R H ....................... O n L F Door, near center of A P illa r.......................... .... 6 1 .... 7 9 .... 202-66,
67

Switch, M aster.................. O n L F Door, near center of A Pillar
Power Seat Adjuster Sw itch.... In L F Seat, on bottom, mounted to frame.................... .... 6 3 .... 81.... 202-68

U p and D ow n Sw itc h ......... O n lower L H of L F Seat......................................... .... 6 3 .... 81

Power Seat Front Tilt M otor... In lower L H of L F Seat........................... ................ .... 6 3 .... 81
Power Seat Front Tilt Sw itch ... O n lower L H o f L F Seat......................................... .... 6 3 .... 81
Power Seat Rear lilt Sw itch... O n lower L H o f L F Seat


L F .................................. Under L F Seat, mounted to Seat fram e....................... .... 6 3 .... 81

R F .................................. Under R F Seat, mounted to Seat frame....................... .... 6 3 .... 81

L F .................................. O n lower L F of L F Seat.......................................... .... 6 3 .... 81

R F .................................. O n lower R F of R F Seat.......................................... .... 6 3 .... 81
Power Seat Rear Tilt M otor.... In lower L H o f L F Seat........................................... .... 6 3 .... 81

Compartment B o x ................................................ .... 3 7 .... 49

Sw itch............................. O n L F Door, below Inside D oor H andle..................... .... 6 1 .... 7 9 .... 202-37,
68
Power W indow Motor, L F ...... In L F Door, near Speaker......................................... .... 6 1 .... 79
Power W indow Motor, L R ...... In L R Door, near Speaker........................................ .... 6 2 .... 80
Power W indow Motor, R F ...... In R F Door, near Speaker.......... .............................. .... 6 1 .... 79
Power W indow Motor, R R ...... In R R Door, near Speaker........................................ .... 6 2 .... 80
Power W indow Switch, L F ..... O n L F D oor Trim Panel, below Inside D oor H andle..... .... 6 1 .... 7 9 .... 202-30
Power W indow Switch, L R ..... L R Door, below Inside D oor H andle.......................... .... 6 2 .... 80.... 202-69
Power W indow Switch, R F ..... O n R F D oor Trim Panel, below Inside D oor handle...... .... 6 1 .... 7 9 .... 202-31
Power W indow Switch, RR.... RR Door, below Inside D oor Handle.......................... .... 6 2 .... 8 0 .... 202-69
Radio, Connector C l ............. Center of IP .......................................................... .... 3 5 .... 4 6 .... 202-43
Radio, Connector C 2 ............. Center o f IP .......................................................... .... 3 5 .... 4 6 .... 202-44
Reading Lam ps, Overhead

C onsole............................ Near W indshield Centerline........................................... 5 3 .... 68
Recirculation D oor M otor....... Under IP, on H V A C Plenum ..................................... .... 5 0 .... 6 5 .... 202-69
Remote Battery Stud............. Part o f Undeihood Fuse-Relay Center, L R of Engine

Compartment, on Fender....................................... ..... 5 ...... 9
Remote C D Player................ Center o f IP, under Heater C ontrols........................... ..... 4 8 .... 63

Receiver........................... Under center o f IP, R H o f Knee B o lste r..................... .... 2 7 .... 43.... 202-45

M irror Sw itch.................... O n L F Door, below Inside D oor Handle
Remote Playback U n it........... Center of IP, under Heater C ontrols........................... ..... 4 8 .... 63
Seat Belt Switch, L H ............. A t L F Stationary Belt Connector............................... ..... 5 6 .... 72
Seat Belt Switch, R H ............ A t R F Stationary Belt Connector..................................... 5 6 .... 72
Secondary Fuel Gauge Sender.. Behind R H side o f IP, near P C M
Selectable 4 W D Indicator
Lam p............................... Part of Transfer Case Selector L e v e r......................... ..... 5 2 .... 67
Spare Power Source
(Convenience Center)......... Under L H of IP, on Bulkhead....................................... 3 3 .... 44
Speaker, L F ......................... A t lower R H of L F D o o r.............................................. 6 1 .... 79
Speaker, L F Tweeter............. In L F D oor Panel........................................................ 6 1 .... 79
Speaker, L R ......................... Behind L R Seat in P illar............................................... 5 6 .... 73
Speaker, L R D o o r................. A t lower R H of L R D o o r............................................. 6 2 .... 80
Speaker, L R R o o f................. In Headliner, near L R D oor opening................................ 5 7 .... 74
Speaker, R F ......................... A t lower R F D oor Panel............................................... 6 1 .... 79
Speaker, R F Tweeter............. In R F D oor Panel........................................................ 6 1 .... 79
Speaker, R R ......................... Behind R R Seat, in B P illa r.......................................... 5 6 .... 73
Speaker, R R D o o r................. A t lower L H of R R D o o r............................................. 6 2 .... 80
Speaker, R R R o o f................. In Headliner, near R R D oor opening............................... 5 7 .... 74
Spotlamp, L H (Z56).............. Mounted in L H A Pillar, near W indshield........................ 4 6 .... 60
Spotlamp, R H (Z 5 6 )............. Mounted in R H A Pillar, near W indshield........................ 4 6 .... 60
Spotlamp R e la y .................... Behind IP, near Convenience Center...............................
Starter M o to r....................... Low er R R of E n g in e ................................................... 1 6 .... 20
Starter M otor Sole n oid .......... O n Starter M o to r......................................................... 1 6 .... 20
Starter R e la y........................ In Underhood Fuse-Relay Center, L R of Engine

Steering A ssist Control

Solenoid........................... Part o f Power Steering Pump, mounted to lower fluid fitting 1 7 .... 21
Steering Handwheel Speed

Sensor (H W S S )................. O n Steering Column, near Bulkhead............................... 4 7 .... 61
Stepper M otor (D ie se l).......... Top of Intake M o to r.................................................... 2 1 .... 26
Stoplamp R e la y .................... In Underhood Fuse-Relay Center, L R of Engine

Compartment, on Fender............................................ 5 ..... 9
Stoplamp Sw itch .................. Top of Brake Pedal...................................................... 4 4 .... 57 .... 202-70
Cab/Chassis...................... L R comer of vehicle.................................................... 7 3 .... 97 .... 202-66
Tail/Stop-T\im Lam p, L R
Pickup/Utility.................... L R comer of vehicle.................................................... 7 4 .... 99 .... 202-66
Cab/Chassis...................... R R comer of vehicle................................................... 7 3 .... 97 .... 202-66
Pickup/Utility.................... L R comer of vehicle................................................... . 7 4 .... 99 .... 202-66
Temperature D oor M o to r........ Under IP, on center of H V A C Plenum ............................. 5 0 .... 65 .... 202-69
Temperature Sensor, Outside
A ir .................................. In Engine Compartment, near lower Radiator Support......... 8 ...... 13
Temperature Sensor, Timed

(D ie sel)............................ Top of Intake M a n ifo ld ................................................ 2 1 .... 26
Throttle Position (TP) Sensor... O n side of Throttle B o d y .............................................. 1 0 .... 14


(T C C M )........................... Under IP, on Steering Colum n Support Bracket.................. 3 8 ... 5 0 .... 202-46
Transfer Case Encoder M otor ... R H center of Transfer Case............................................ 2 6 ... 35

Illum ination L a m p .............. In Transfer Case Select Sw itch........................................ 4 8 ... 63
Transfer Case R e lay.............. R R o f Engine Compartment, near center of Bulkhead........ 2 3 .... 3 0 .... 202-70
Transfer Case Select Sw itch.... Center o f IP, R H of Steering Colum n ShiftL e v e r................ 48 ........... 202-48
63 .....
Transfer Case Shift

Illum ination L a m p ............. Part of Transfer Case Selector L e v e r................................ 5 2 ... 67
Transfer Case Sw itch ............. Top L H of Transfer C a se ..............................................
(M 3 0 )..................................................................... 2 4 ... 32
(M G 5 )..................................................................... 2 8 ... 39
(M T 1 )..................................................................... 2 5 ... 34
(M W 3 ).................................................................... 2 7 ... 37
Transfer Case Synchronizer..... Top o f Transfer C a se .................................................... 2 5 ... 34
Transm ission........................ Under center of vehicle, attached to rear of Engine
(M 3 0 ).......................................................................................... 202-6
(M T 1 ).......................................................................................... 202-7

Connectors C l and C 2 ........ L H of Transm ission...................................................... 202-70
Turbo Pressure Sensor

(D iesel)............................ Top of Intake M anifold................................................. 2 1 .... 27
Tbm/Hazard Flasher.............. Mounted to Convenience Center, under L H of IP, L H of

Steering Column, on Bulkhead.................................... 3 3 .... 44, 202-56
'Him/Hazard Sw itch............... Part of M ultifunction Switch, upper L H of Steering Colum n. 4 7 .... 61
Turn Signal Sw itch ............... Part of Multifunction Switch, upper L H of Steering Colum n. 4 7 .... 61
Underhood Fuse-Relay Center... L R of Engine Compartment, on Fender............................ 5 ..... 9
Underhood Lam p.................. Under R H o f H o o d ...................................................... 7 ...... 12
Universal Transmitter Switch.... In Overhead Console................................................... 5 3 ..... 68

( V C M ) ............................ Engine Compartment, near E B C M ................................. 3 7 ..... 48
Vehicle Speed Sensor

(w /R W D )......................... L R of Transm ission..................................................... 2 3 ..... 31

(w/Selectable 4 W D )............ L R o f Transfer C a se ................................................... 2 4 ..... 32

(D ie sel)............................ Under R H of IP .......................................................... 37 49, 202-70
Wastegate Solenoid (D ie sel).... Top L R of Engine, above Valve C over........................... 2 0 ..... 24
Water-in-Fuel Sensor (D ie se l)... Top rear o f En gin e ...................................................... 1 9..... 23

Water Valve (4-Door

W heel Speed Sensor, L H ....... A t L F Wheel
W heel Speed Sensor, R H ....... A t R F W heel
W indow Defogger Grid,

R e a r................................ O n Rear W in d o w ........................................................ 5 8 .... 76
W indow Defogger Switch,

R e a r................................ Center of IP, part of Heater Controls............................... 5 8 .... 76

R e a r................................ L F Door, below Inside Door Handle, part of Power W indow
Master Sw itch .......................................................... 6 1 .... 7 9 .... 202-69
W indow Washer Pum p Motor,

R e a r................................ In Washer Reservoir, R F of vehicle, behind support........... 5 ...... 10

R e a r................................ O n lower Liftgate g la ss................................................ 7 1 .... 93

M o to r.............................. A t Washer R eservoir.................................................... 7 ...... 11

M o d u le ............................ A t center and rear of Engine Compartment, at Bulkhead..... 4 ...... 8 ..... 202-70
Sw itch............................. A t Steering Colum n, part of Multifunction Lever............... 4 7 .... 61

R e a r................................ Center of IP, R H of R a d io ............................................ 4 9 .... 64.... 202-69
C O N N E C T O R S :.

at Bulkhead............................................................. 4 ...... 8 ...... 202-0
C 1 0 1 .................................. Engine Harness to Forward Lam ps Harness, L R o f Engine

Compartment, near Underhood Fuse-Relay Center........... 4 ...... 8 ...... 202-49

mounted on Fender................................................... 4 ..... 8 ..... 202-2

C 1 0 4 .................................. IP Harness to Front-to-Rear Harness, L R of Engine

C105 (7.4L) ....................... Engine Harness to Fuel Injectors, rear of Intake M an ifold ... 1 8 .... 22.... 202-3

Transm ission............................................................ 2 5 .... 34.... 202-49
C 1 1 0 .................................. IP Harness to S IR Arm ing Sensor, L R of Engine

Compartment, near C l 0 2 ........................................... 3 1 .... 4 2 .... 202-49
C l 12 (D ie se l)...................... Engine Harness to Engine Sensors.................................. 2 0 .... 25.... 202-4
C l 13 (D ie se l)...................... Engine Harness to Engine Sensors.................................. 2 0 .... 25.... 202-5
C 1 1 6 .................................. L F of vehicle, near Core Support................................... 7 ...... 11.... 202-49

ELECTRICAL DIAGNOSIS 8A - 20 0 -1 3

C 1 2 0 ............................. Engine Harness to Front A xle Actuator, rear of Engine, near
Transm ission.................................................. ......... 2 7 ... . 37.... 202-50
C121 (Z56, Police Package) A uxiliary Power Center Harness to Fused Battery Harness,
L H Engine Compartment, near C l 00............................ 3 4 ... . 45.... 202-50
C122 (M 3 0 ).................... O n L H of Transm ission................................................ 2 3 ... . 3 1 .... 202-6
C122 (M T 1 ).................... O n L H of Transm ission................................................ 2 3 ... . 3 1 .... 202-7
C 1 3 0 ............................. Engine Harness, approx. 17.5 cm from V C M Breakout....... 6 ..... . 10.... 202-50
C 1 3 1 ............................. IP Harness, approx. 8 cm from W iper M otor Breakout....... 3 1 ... . 4 2 .... 202-8
C 1 3 2 ............................. IP Harness, approx. 8 cm from W iper M otor Breakout....... 3 1 ... . 4 2 .... 202-9
C 200 (D ie se l)................. Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 ... . 4 9 .... 202-11
C 200 (G a s)..................... Behind R H of IP, near Heater Motor, in foam w rap........... 3 7 ... . 4 9 .... 202-10
C 2 0 3 ............................. Behind R H of IP, near Heater Motor, in foam w rap........... 5 0 ... . 6 5 .... 202-50
C 204 (D ie se l)................. Behind R H of IP ......................................................... 3 7 ... . 49.... 202-12
C 2 0 5 ............................. A t Convenience Center................................................. 3 3 ... ,. 4 4 .... 202-50
C 2 0 6 ............................. Inside lower L H A Pillar............................................... 6 1 ... , 7 9 .... 202-50,

51
C 2 0 7 ............................. Inside lower L H A Pillar.............................................. 6 1 ... . 7 9 .... 202-51
C 2 0 7 ... .......................... Inside lower L H A Pillar............................................... 6 1 ... . 7 9 .... 202-13
C 2 0 8 ............................. Inside lower L H A Pillar............................................... 6 1 ... .. 7 9 .... 202-51
C 2 0 9 ............................. Inside lower L H A Pillar............................................... 6 1 ..., 7 9 .... 202-51
C 2 1 0 ............................. A t Convenience Center................................................. 3 3 ... .. 4 4 .... 202-51
C 2 1 1 ............................. Under L F Seat............................................................ 6 5 ... .. 83.... 202-52
C 2 1 2 ............................. Under L F Seat............................................................ 6 5 ... .. 83.... 202-52
C 2 1 3 ............................. Inside lower R H A P illa r.............................................. 6 1 ..... 7 9 .... 202-52
C 2 1 6 ............................. Inside lower R H A P illa r.............................................. 55.... .. 7 0 .... 202-52
C 2 1 7 ............................. Inside lower L H A Pillar............................................... 55.... .. 7 0 .... 202-52
C 2 1 8 ............................. A t Convenience Center................................................. 33.... .. 44
C 2 2 0 ............................. A t Convenience Center................................................. 33.... .. 44
C 2 2 1 ............................. A t Convenience Center................................................. 4 7 ..... 6 2 .... 202-53
C 2 2 2 ............................. A t Convenience Center................................................. 47.... .. 6 2 .... 202-53
G 223............................. A t Convenience Center................................................. 36.... .. 47 .... 202-53
C 2 2 4 ............................. L R of Engine Compartment, under Brake Master Cylinder.... 31.... .. 4 2 .... 202-53
C 2 2 5 ............................. L R of Engine Compartment, under Brake Master Cylinder.... 31.... .. 4 2 .... 202-53
C 226 ............................ Inside lower R H A P illa r.............................................. 55.... .. 70...... 202-54
C227 (Stoplamp Sw itch).... A t Convenience Center..... ........................................... 44.... .. 57.... 202-70
C 2 2 8 ............................. Crossbody Harness to R F Seat Belt Switch, under R F Seat... 65...... 83.... 202-54
C 2 2 9 .............................. ... Crossbody Harness to R F Power Seat, under R F Seat......... 6 5 .... 83.... 202-54
C 2 3 0 .............................. ... Behind R H of IP, above H V A C Evaporator H o u sin g.......... 2 7 .... 42 .... 202-54
C 2 3 1 .............................. ... IP Harness to S IR Harness............................................ 5 5 .... 7 0 .... 202-54
C 2 3 2 .............................. ... IP Harness to S IR Harness, behind R H of IP .................... 5 5 .... 7 0 .... 202-54
C 2 3 3 .............................. ... IP Harness, approx. 30 cm from Inflatable Restraint Steering

W heel Breakout....................................................... 4 3 .... 56.... 202-55
C 2 3 4 .............................. ... Inline to Steering W heel M odule C o il............................. 5 5 .... 70
C 2 3 5 .............................. ... Auxiliary Power Center Harness to Fused Battery Harness,

L H IP, near P I00
C 2 3 6 .............................. ... L F Seat Harness, approx. 4 cm from Power Seat Lum bar
Switch Breakout....................................................... 6 5 .... 83.... 202-55
C 2 3 7 .............................. ... R F Seat Harness, approx. 4 cm from Power Seat Lum bar
Switch Breakout....................................................... 6 5 .... 83.... 202-55
C 2 3 8 .............................. ... Inline to R oof Harness.................................................. 5 4 .... 69.... 202-71
C 2 4 0 .............................. ... Crossbody Harness, approx. 100 cm from Seat Belt Switch
Breakout................................................................. 6 5 .... 83.... 202-55
C 2 4 2 .............................. ... IP Harness, L H of Steering Column, near Bulkhead (Z56,

Police Package)
C 2 4 3 .............................. ... Crossbody H arness....................................................... 6 0 .... 79.... 202-55
C 2 4 4 .............................. ... IP Harness, L H of Steering Column, near Bulkhead (Z56,

Police Package)

Column, near Bulkhead.............................................. 3 2 .... 43.... 202-14
C 2 9 8 .............................. ... Behind L H of IP, near Convenience Center...................... 3 2 .... 43.... 202-17,
18
C 2 9 9 .............................. ... Behind R H o f IP, above H V A C Evaporator H o u sin g.......... 4 3 .... 56 .... 202-19
C 3 0 0 .............................. ... In Overhead Console.................................................... 3 6 .... 61 .... 202-55
C 3 0 1 .............................. ... A t L F K ic k Panel........................................................ 4 7 .... 62.... 202-20,

56
C 3 0 2 .............................. ... A t L F K ic k Panel........................................................ 4 7 .... 6 2 .... 202-56
C 314 (Suburban/Utility)...... ... A t center and rear of body, near Endgate......................... 202-56
C 4 0 0 .............................. ... R R o f vehicle, above Auxiliary Blow er M o to r.................. 66 .... 85.... 202-56
C 4 0 1 .............................. ... R R of vehicle, above Auxiliary Blow er M o to r.......... - ...... 66 .... 85.... 202-56
C 4 0 2 .............................. ... Top center rear o f vehicle............................................. 4 1 .... 67 .... 202-57
C 4 0 4 .............................. ... Top of L H D P illa r...................................................... 4 5 .... 7 4 .... 202-57
C 4 0 5 .............................. ... Top of R H D Pillar...................................................... 4 5 .... 7 4 .... 202-57
C 4 0 6 .............................. ... Top o f R H D Pillar...................................................... 68 .... 87.... 202-57
C 4 0 7 .............................. ... Beneath L R edge o f b e d ............................................... 7 4 .... 99.... 202-57
C 408 (Pickup/Cab)............ ... Beneath center rear edge of bed..................................... 7 4 .... 99.... 202-57
ELECTRICAL DIAGNOSIS 8A - 2 0 0 -1 5

C408 (Suburban/Utility)...... ... Low er center outside of Endgate.................................... . 7 4 .... 9 9 .... 202-57
C 4 0 9 .............................. ... Beneath rear center of bed, near Bum per......................... , 7 4 .... 9 9 .... 202-58
C 4 1 0 .............................. ... Top center rear of vehicle............................................. , 7 0 .... 9 1 .... 202-58
C 4 1 1 .............................. ... A t L R of cab............................................................. , 7 0 .... 9 1 .... 202-58
C 450 (Suburban/Utility)...... ... Inside Endgate............................................................ , 6 8 .... 87.... 202-58

C 4 9 6 .............................. ... In R H B Pillar...................... ..................................... , 6 2 .... 8 0 .... 202-58
C 4 9 7 .............................. ... R H B Pillar................................................................ 6 2 .... 80 .... 202-59
C 4 9 8 .............................. ... L H B P illar................................................................ 6 2 .... 8 0 .... 202-59
C 4 9 9 .............................. ... L H B P illar................................................................ 6 2 .... 8 0 .... 202-59
C 5 0 1 .............................. ... In-line to L H Power Outside Rearview M irro r.................. 6 1 .... 7 9 .... 202-21
C 6 0 1 .............................. ... In-line to R H Power Outside Rearview M irro r.................. 6 1 .... 7 9 .... 202-59
DIODES:.
D IO D E 1......................... ... In Underhood Fuse-Relay Center, L R of Engine
Compartment, on Fender
D 10 4 (4 .3L)..................... ... Engine Harness, approx. 16 cm from A/C Com pressor
Clutch Connector............................................. ........ 1 0 .... 14
D 10 4 (5.0L, 5 .7 L )............. ... Engine Harness, approx. 10 cm from A/C Com pressor
Clutch Connector..................................... ................ 1 4 .... 18
D 10 4 (6 .5L)..................... ... Engine Harness, approx. 28 cm from A/C Com pressor

Clutch Connector..................................................... 2 0 .... 24
D 104 (7.4L)..................... ... Engine Harness, approx. 8 cm from A/C Com pressor Clutch
Connector................................................................, 1 6 .... 20
D 2 0 2 .............................. ... IP Harness, approx. 11 cm from Crossbody Harness
Breakout, toward Park Brake Switch
D 2 0 3 .............................. ... IP Harness, at R H of Steering Colum n Support................ . 4 1 .... 53
GROMMETS:.
P 1 0 0 .............................. ... L R of Engine Compartment, at Bulkhead above C 1 0 0 ......... 4 ...... 8
P 1 0 1 .............................. ... R R of Engine Compartment, at Bulkhead........................ .. 7 ...... 12
P102 (6J3).......................
P 4 0 0 .............. ................ ... Top rear of body, at R H Liftgate H in ge .......................... .. 7 1 .... 93

P 5 0 0 .............................. ... A t L F D oo r................................................................ . 6 1 .... 79
P 6 0 0 .............................. ... A t R F D o o r............................................................... . 6 1 .... 79
P 7 0 0 .............................. ... A t L R D o o r.............................................................. .. 6 2 .... 80
P 8 0 0 .............................. ... A t R R D o o r............................................................... . 6 2 .... 80
GROUNDS:.
G 101.............................. ... Sheet metal at R F W heelhousing...................................... 2 ...... 5
G 102 (G a s)...................... ... R F of Engine Block, near Damper Pulley........................ . 2 ...... 5
G 102 (D ie sel).................. ..... L F o f Intake M an ifold ................................................. . 1 ...... 4
G 103 (G a s)..................... ... R F o f Engine, near Thermostat H ousing.......................... . 1 4 .... 18
G 104 (Gas, D ie se l).............. R H top center of Cylinder H e ad ............................ 16.... 20
G 105................................. R F of Engine b lo c k ............................................. 13 17
.
G 107................................. L H front Fender (Auxiliary Battery Ground)
G 110................................. R R of Engine Compartment, below Heater Lin e s....... 16.... 20
G i l l ................................. R R of E n g in e ...................................................... 1 6 .... 20
G 112................................. R F of Engine Compartment, at W heelhousing............ 2 ...... 5
G 113................................. O n Radiator Support, near L H Headlamp................. . 4 ..... 8
G 115................................. A.I.R. Pump Ground, mounted on Frame R a il........... . 9 ...... 14
G 150................................. R F of Engine, near Thermostat H o u sin g .................. . 14 18
.
G 200................................. Behind L H of IP, below Fuse Block, on Tie B a r........ 3 2 .... 43
G 201................................. Behind L H of IP, below Fuse Block, on Tie B a r....... . 3 2 .... 43
G 202................................. R H of IP, mounted to H V A C Plenum Bracket........... . 5 0 .... 65
G 400................................. R H B Pillar, near D oor Striker................................ 5 8 .... 76
G 401................................. Rear of L H Frame Rail, behind Bum per................... 7 3 .... 96
G 403................................. Rear of L H Frame Rail, behind Bum per.................. . 7 3 .... 96
G 404................................. Inside L H Frame Rail, near rear Crossmem ber........... 73 96
.
G 451.................................. A t Platform Hitch................................................. 74 ........... 99
S P L IC E S :
S100 (4.3L, 7.4L) ............... Engine Harness, approx. 23 cm from E B C M Breakout,

S100 (5.0L, 5.7L) ............... Engine Harness, approx. 17 cm from E B C M Breakout,

S100 (6.5L - A/T)................ Engine Harness, approx. 31 cm from Taillamp Harness

Breakout
5100 (6.5L - M /T )............... Engine Harness, approx. 37 cm from E B C M Breakout,

5101 (4.3L, 5.0L - L D , 5.7L -

L D , 7.4L - M / T ).............. Engine Harness, approx. 12 cm from E B C M Breakout
S101 (5.0L - H D , 5.7L - H D ,

7.4L - A / T )...................... Engine Harness, approx. 15 cm from E B C M Breakout
S101 (6.5L) ....................... Engine Harness, approx. 5 cm from Starter Solenoid

Breakout

Breakout
S103 (7.4L - M/T)........................ Engine Harness, approx. 12 cm from EGR Breakout


S104 (4.3L, 5.0L - A/T, 5.7L -
M /T)................................ Engine Harness, approx. 12 cm from Fuel Injector Breakout
S104 (5.0L - M/T, 5.7L -
M /T)................................ Engine Harness, approx. 10 cm from Fuel Injector Breakout
S104 (7.4L) ........................ Engine Harness, approx. 30 cm from E B C M Breakout
S I 06 (4.3L) ...................... Engine Harness, approx. 4 cm from Breakout to E G R Valve

Breakout, toward Fuel Injector Breakout


S107 (6.5L, H D ) ................ Engine Harness, approx. 30 cm from E B C M Breakout,


5107 (7.4L) ........................ Engine Harness, approx. 18 cm from E B C M Breakout,

5108 (4.3L) ........................ Engine Harness, approx. 11 cm from Ignition C oil Breakout,
S108 (5.0L - A/T, H D , 5.7L -

A/T, H D ) ......................... Engine Harness, approx. 12 cm from Ignition C oil Breakout,
S108 (5.0L - A/T, L D , 5.7L -

A/T, L D ).......................... Engine Harness, approx. 39 cm from Ignition C oil Breakout,
S108 (5.0L - M/T, 5.7L -

M /T)............................... Engine Harness, approx. 28 cm from Ignition C o il Breakout,
S I 08 (6.5L, A/T).................. Engine Harness, approx. 12 cm from Glow Plugs Breakout
S I 08 (6.5L, M /T )................. Engine Harness, approx. 5 cm from Backup Lam p Switch

Harness Breakout
S I 08 (7.4L) ........................ Engine Harness, approx. 13 cm from Ignition C o il Breakout,

S I 10 (5.0L, 5.7L) ................ Engine Harness, approx. 23 cm from E B C M Breakout,

S I 10 (7.4L) ........................ Engine Harness, approx. 26 cm from E B C M Breakout, near

S i l l (4.3L, 7.4L) ................ Engine Harness, approx. 7 cm from E B C M Breakout
S i l l (5.0L, 5.7L) ................ Engine Harness, approx. 10 cm from E B C M Breakout,

8A - 2 0 0 - 18 ELECTRICAL DIAGNOSIS_____________________________________________
S i l l (6.5L) ........................ Engine Harness, approx. 11 cm from E B C M Breakout,
toward G low Plugs
S I 17 (6.5 - A / T )................. Engine Harness, approx. 23 cm from E B C M Breakout
S I 17 (6.5 - M/T, H D ) .......... Engine Harness, approx. 15cm from Remote Battery Stud,
toward G low Plugs Control M odule
S I 17 (6.5 - M/T, L D ) ............ Engine Harness, approx. 29 cm from E B C M Breakout
S I 1 9 .................................. Forward Lam ps Harness, approx. 16 cm from W indshield

512 0 .................................. Forward Lam ps Harness, approx. 22 cm from W indshield


512 2 .................................. Forward Lam ps Harness, approx. 7 cm from L H Headlamp

512 3 .................................. Forward Lam ps Harness, approx. 20 cm from L H Park

512 4 .................................. Forward Lam ps Harness, approx. 26 cm from L H Headlamp

5125 (D iesel)....................... IP Harness, approx. 20 cm from Instrument Cluster

Breakout
5125 (G as).......................... IP Harness, approx. 13 cm from P I00, toward Forward

Lam ps Harness
5126 (Pickup O n ly ).............. Forward Lam ps Harness, approx. 5 cm from L H Headlamp

Breakout, toward L H Horn
512 7 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp

Breakout, toward R H Horn
512 8 .................................. Forward Lam ps Harness, approx. 5 cm from R H Headlamp

51 4 1 .................................. Auxiliary Battery Harness, approx. 18 cm from Underhood

Fuse-Relay Center
51 4 2 .................................. Auxiliary Battery Harness, approx. 18 cm from Underhood

Fuse-Relay Center
5145 (7.4L) ........................ Engine Harness, approx. 11 cm into E G R Valve Breakout


Breakout
S I47 (7.4L) ................................... Engine Harness, approx. 5 cm from EGR Valve Breakout

S I 48 (w/Leaded Fuel)............ O xygen Sensor Harness, approx. 7 cm from R H Bank
Oxygen Sensor Breakout, toward Engine Harness
5148 (w/o Leaded Fu e l)......... Approx. 19 cm into Oxygen Sensor Harness
5149 (w/Leaded Fuel)............ O xygen Sensor Harness, approx. 7 cm from R H Bank

Oxygen Sensor Breakout, toward L H Bank O xygen
Sensor
5149 (w/o Leaded Fu e l)......... Approx. 25 cm into Oxygen Sensor Harness
5150 .............................. Engine Harness, approx. 13 cm from E B C M Breakout
5151 .............................. Engine Harness, approx. 7 cm from E B C M Breakout
5152 (4.3L, 5.0L - L D , 5.7L -

L D , 7.4L) ........................ Engine Harness, approx. 7 cm from E B C M Breakout
S152 (5.0L - H D , 5.7L - H D ).. Engine Harness, approx. 13 cm from E B C M Breakout
5152 (6.5L) .............. ......... Engine Harness, approx. 4 cm from IP Harness Breakout,
toward P101
5153 .............................. IP Harness, approx. 13 cm from P100, toward C C M
S156 (4.3L, 5.0L - M/T, 5.7L -

M/T, 7.4L - M / T ).............. Engine Harness, approx. 16 cm from V S S Connector
S156 (5.0L, 5.7L - A/T, H D ) ... Engine Harness, approx. 12 cm from V S S Connector
S156 (5.0L, 5.7L - A/T, LD).... Engine Harness, approx. 20 cm from V S S Connector
5156 (7.4L - A/T)................. Engine Harness, approx. 23 cm from V S S Connector
5157 .............................. Engine Harness, approx. 20 cm into E B C M Breakout
5158 .............................. In Washer Pump Jumper Harness
5159 (6.5L - A /T ) ................. Engine Harness, approx. 7 cm from E G R Valve Breakout
S159 (6.5L - M/T, H D ).......... Engine Harness, approx. 31 cm from Glow Plugs Breakout
5159 (6.5L - M/T, L D ) .......... Engine Harness, approx. 6 cm from V S S Breakout




S161 (5.0L - A/T, H D , M/T,

5.7L - A/T, H D , M / T )........ Engine Harness, approx. 8 cm from E G R Valve Breakout,
S161 (5.0L - A/T, L D , 5.7L -

A/T, L D ).......................... Engine Harness, approx. 27 cm from E G R Valve Breakout,
S162 (4.3L, 5.0L, 5.7L - L D ) .. Engine Harness, approx. 17 cm from Starter Solenoid
S162 (5.0L -H D , 5.7L - H D ) ... Engine Harness, approx. 43 cm from L H Oxygen Sensor
S162 (7.4L - A/T)................. Engine Harness, approx. 40 cm from L H Oxygen Sensor
S162 (7.4L - M /T )................ Engine Harness, approx. 15 cm from R H Bank O xygen
5165 .............................. Engine Compartment, IP Harness, approx. 9 cm from P I00,
toward Forward Lam ps Harness Connector
5166 (6.5L - A/T)................. Engine Harness, approx. 8 cm from Fuel Heater Breakout
S I 66 (6.5L - M/T, H D )......... Engine Harness, approx. 5 cm from G low Plugs Breakout
S I 66 (6.5L - M/T, L D ) ......... Engine Harness, approx. 1 cm from Fuel Heater Breakout
S I 66 (G as).......................... Engine Harness, approx. 18 cm from E B C M Breakout
5166 (Z56, Police Package
O nly)............................... Battery Harness, approx. 20 cm from Battery Negative
Terminal
5167 (A ll Except Z56, Police

Package).......................... Engine Harness, approx. 18 cm from G115
O nly)............................... Battery Harness, approx. 35 cm from C l 21
O nly)............................... Battery Harness, approx. 25 cm from C l 21
S181 (6.5L - A/T)................. Engine Harness, approx. 4 cm from Taillamp Harness
Breakout

Diode D 104

5185 (7.4L) ........................ Engine Harness, approx. 17 cm from A/C Com pressor
51 86 (4.3L, 5.0L, 5.7L) ........ Engine Harness, approx. 41 cm from E G R Breakout, at

Diode D 104
5199 (6.5L) ........................ Engine Harness, approx. 31 cm from Taillamp Harness
Breakout
5200 (D iesel)....................... IP Harness, approx. 14 cm from Steering Colum n Harness

Breakout
S200 (G as).......................... IP Harness, approx. 12 cm from Steering Column Harness
Breakout

5 2 0 3 .................................. IP Harness, approx. 12 cm from S IR Harness Breakout
5 2 0 4 .................................. IP Harness, approx. 10 cm from Steering Colum n Harness

Breakout

Breakout

Breakout
5 2 0 6 ................................ IP Harness, approx. 6 cm from Steering Colum n Harness

5 2 0 7 ................................ IP Harness, approx. 12 cm from Steering Colum n Harness

5208 ................................ IP Harness, approx. 6 cm from IP Compartment B ox Lam p

Breakout
5209 ................................ IP Harness, approx. 13 cm from IP Compartment B ox

Lam p Breakout

Breakout
5210 (G as).......................... IP Harness, approx. 4 cm from Auxiliary Power Outlet

Breakout
5211 (D iesel)....................... IP Harness, approx. 16 cm into Instrument Cluster Breakout
5211 (G as).......................... IP Harness, approx. 4 cm from Engine Harness Breakout

(C200)
5212 ................................ BP Harness, approx. 8 cm from Inflatable Restraint Switch

Breakout
5213 ................................ BP Harness, approx. 4 cm from Steering Colum n Harness

Breakout
5214 ................................ IP Harness, approx. 9 cm from Instrument Cluster Breakout
5215 (D iesel)....................... IP Harness, approx. 8 cm from Instrument Cluster Breakout,

5215 (G as).......................... IP Harness, approx. 12 cm from Instrument Cluster

5216 (Diesel and U p level)...... IP Harness, approx. 12 cm from Instrument Cluster

5216 (Gas, A ll Except
U plevel)........................... IP Harness, approx. 16 cm from Instrument Cluster
5 2 1 7 ................................ IP Harness, approx. 16 cm from Instrument Cluster Harness

5 2 1 8 ................................ IP Harness, approx. 16 cm from Inflatable Restraint Switch

Breakout
S219 IP Harness, approx. 5 cm from DLC Breakout

5221 ................................ IP Harness, approx. 40 cm from Instrument Cluster

Breakout
5222 ................................ IP Harness, approx. 20 cm from Inflatable Restraint Switch

Breakout
5227 ................................ L F Seat Harness, approx. 5 cm from Power Seat Lum bar
Switch Breakout
5228 ................................ R F Seat Harness, approx. 5 cm from Power Seat Lum bar
Switch Breakout
S231 (4.3L) ...................... Engine Harness, approx. 13 cm from E G R Valve Breakout,

S231 (5.0L, 5.7L) ................ Engine Harness, approx. 16 cm from E G R Valve Breakout,
S231 (6.5L) ........................ Engine Harness, approx. 8 cm from Fuel Heater Breakout
S231 (7.4L - A/T)............... Engine Harness,approx. 18 cm from E G R Valve Breakout
5231 (7.4L - M /T )............... Engine Harness, approx. 7 cm from E G R Valve Breakout
S232 (5.0L - H D , 5.7L - H D ).. Engine Harness, approx. 10 cm from E G R Valve Breakout
S232 (5.0L - L D , 5.7L - LD)... Engine Harness, approx. 27 cm from E G R Valve Breakout
5 2 3 3 .................................. Crossbody Harness, approx. 25 cm from S D M Breakout
S235 (D iesel)..................... IP Harness, approx. 4 cm from Steering Colum n Harness

Breakout

Breakout
5236 (D iesel)....................... IP Harness, approx. 10 cm from Steering Colum n Harness,

near P100
5236 (G as).......................... IP Harness, approx. 12 cm from Steering Colum n Harness,

near P100
5237 ................................ R F Seat Harness, approx. 4 cm from Power Seat Lum bar
Switch Breakout
5238 ................................ Crossbody Harness, approx. 20 cm from S D M Breakout
5 2 4 1 ................................ L F Seat Harness, approx. 4 cm from Power Seat Lum bar

Switch Breakout
5242 ................ :............... IP Harness, approx. 12 cm from Inflatable Restraint Sw itch

Breakout
5 2 4 3 ................................ H V A C Harness, approx. 4 cm from Recirculation D oor

5244 ................................ H V A C Harness, approx. 8 cm from Recirculation D oor

S246................................................... Crossbody Harness, approx. 22 cm from LF Door Harness

Breakout

5 2 4 7 ................................ Crossbody Harness, approx. 6 cm into L H D oor Harness
Breakout
5 2 4 8 ................................ Crossbody Harness, approx. 10 cm from L F D oor Harness

Breakout
5249 (Suburban/Utility)......... Crossbody Harness, approx. 4 cm from L H D oor Harness

5250 (Suburban/Utility).......... Crossbody Harness, approx. 8 cm from L H D oor Harness

5251 ................................ Crossbody Harness, approx. 13 cm right of L F D oor

5252 (Suburban/Utility)......... Crossbody Harness, approx. 4 cm from C 210 Breakout,

toward L H D oor Harness Breakout
5253 (Suburban/Utility).......... Crossbody Harness, approx. 6 cm from IP Harness

Breakout, toward D oor Lock Relay Breakout
5254 (Suburban/Utility).......... Crossbody Harness, approx. 12 cm from C 210 Breakout,

toward Power Am plifier Breakout
5255 (Crew C a b )................. Crossbody Harness, approx. 20 cm from C 210 Breakout,

S255 (Pickup/Extended Cab).. Crossbody Harness, approx. 5 cm from C231 Breakout,

toward IP Harness
5255 (Suburban/Utility).......... Crossbody Harness, approx. 18 cm from C 210 Breakout,

5256 (2-Door
Utility/Pickup/Extended

Suburban)........................ Crossbody Harness, approx. 19 cm from C 210 Breakout,
5256 (Crew C a b )................. Crossbody Harness, approx. 1 cm from D oor Lock Relay
5257 (Crew C a b ).................. Crossbody Harness, approx. 8 cm left of D oor Lock Relay
S257 (Pickup/Extended C ab). Crossbody Harness, approx. 5 cm from C231 Breakout,

5257 (Suburban/Utility).......... Crossbody Harness, approx. 5 cm from C231 Breakout,

toward D oor lock relay Breakout
5258 (2-Door U tility)............. Crossbody Harness, approx. 12 cm from Seat Belt Switch

5 2 5 9 ................................ Crossbody Harness, approx. 7 cm into Seat Belt Switch,

toward C299
S262 (Suburban/Utility).......... Crossbody Harness, approx. 25 cm from Seat Belt Switch

S263 (4-Door
Utility/Suburban/Crew Cab)... Crossbody Harness, approx. 32 cm from Seat Belt Switch


S265 (Suburban/Utility)......... Crossbody Harness, approx. 8 cm from L F D oor Breakout
S 2 6 7 .................................. IP Harness, approx. 4 cm from Instrument Cluster Breakout
Breakout
S269 (6.5L, L D ) ................... Engine Harness, approx. 11 cm from IP Harness Breakout
S269 (6.5L, H D ) .................. Engine Harness, approx. 29 cm from IP Harness Breakout

S 2 7 0 .................................. IP Harness, approx. 13 cm from P100
S 2 7 2 .................................. IP Harness, approx. 4 cm from A uxiliary Power Outlet
Breakout
S 2 7 4 .................................. R H Heated Seat Harness, approx. 10 cm from Heated Seat
S 2 7 5 .................................. R H Heated Seat Harness, approx. 5 cm from Heated Seat
toward C 298 Breakout
toward C 298 Breakout

S280 (D iesel)....................... IP Harness, approx. 5 cm from D L C Breakout
5285 (Z56 - 6J1).................... In Auxiliary Power Center Harness
5286 (Z56 - 6J1)................ In A uxiliary Power Center Harness
5287 (Z56 - 6J1)................ In A uxiliary Power Center Harness
5288 (Z56 - 6J1)................ In Auxiliary Power Center Harness
5289 (Z56 - 6J1)................ In Auxiliary Power Center Harness
5 2 9 8 ................................ IP Harness, approx. 24 cm from Instrument Cluster


Breakout, toward P100
5302 ................................ Selectable 4 W D Harness, approx. 10 cm from Transfer Case

Relay Breakout, toward Front Axle Switch
5303 ................................ Power Lum bar Seat Jumper, approx. 20 cm from R H Power
Seat Breakout, toward C299






S 3 1 2 .................................. Illuminated Vanity M irror Jumper Harness, approx. 4 cm

5314 (K 3 0 0 )........................ Selectable 4 W D Harness, approx. 5 cm from Transfer Case

Relay Breakout, toward Front A xle Switch
5315 ................................ Taillamp Extension Harness, approx. 17 cm from Fuel Pump

S316 (Suburban/Crew
Cab/Utility)..................... Illuminated Vanity M irror Jumper Harness, approx. 11 cm
S317 (G as)......................... Taillamp Extension Harness, approx. 10 cm from Fuel Pump

S317 (D iesel)..................... .. Taillamp Extension Harness, approx. 10 cm from Fuel Pump

S 3 1 8 ................................. .. Taillamp Extension Harness, approx. 10 cm from Fuel Pump

S319 (G as)......................... .. Taillamp Extension Harness, approx. 7 cm from Fuel Pump

and Sender Breakout, toward balance Fuel Pump Balance
M odule Breakout
S322 (Suburban/Crew
Cab/Utility)..................... .. Dom e Lam p Harness, approx. 25 cm from C411, toward
Dom e Lam p

w/Overhead C on sole )........ .. Dom e Lam p Harness, approx. 15 cm from C H M S L

w/o Overhead Console)..... .. Dom e Lam p Harness, approx. 9 cm from C H M S L Breakout,
toward C411

w/o Overhead Console)......... Dom e Lam p Harness, approx. 7 cm from C H M S L Breakout,
toward C411
S 3 2 4 ................................. .. Taillamp Extension Harness, approx. 10 cm from G 404

S 3 2 5 ................................. .. Taillamp Extension Harness, approx. 5 cm from Fuel Pump

S400 (w /Auxiliary A / C ).......... Auxiliary A/C Harness, approx. 17 cm from Blow er M otor
S401 (w /Auxiliary A / C )........,. Auxiliary A/C Harness, approx. 23 cm from Blow er M otor
S401 (w /Auxiliary H V A C )..... . Auxiliary H V A C Harness, approx. 13 cm from Blow er

S402 (w /Auxiliary A / C )........ . Auxiliary A/C Harness, approx. 7 cm from Blow er M otor
Resistor Breakout, toward Blow er M otor Relays
S403 (w /Auxiliary H V A C )..... . Auxiliary H V A C Harness, approx. 7 cm from Blow er M otor

S410 (2-Door U tility )........... . Front-to-Rear Body Harness, approx. 37 cm from R R Door
Breakout

Suburban)........................ . Front-to-Rear Body Harness, approx. 12 cm from R R Door
S411 (Chassis C ab ).............. Taillamp Harness, approx. 33 cm from Taillamp Extension

Harness Breakout

S411 (Fleetside/Stopside)...... Taillamp Harness, approx. 17 cm from Taillamp Extension
5411 (Suburban/Utility).......... Taillamp Harness, approx. 7 cm from Taillamp Trailer Tow



5412 (Fleetside/Stepside Taillamp Harness, approx. 23 cm from Taillamp Extension

w/Dual Rear W heels)......... Harness Breakout, toward R H Taillamp


5414 (Fleetside/Stepside)........ Taillamp Harness, approx. 10 cm from Taillamp Extension

5415 ................................ License Lam ps Harness, approx. 14 cm from L H License

Lamp, toward Taillamp Harness Breakout
5416 ................................ License Lam ps Harness, approx. 4 cm from Taillamp

5417 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 34 cm from Front

Dom e Lam p Breakout, toward C301 Breakout

Suburban)........................ Front-to-Rear Body Harness, approx. 20 cm into Crossbody
Harness Breakout
S419 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 20 cm from C H M S L

Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 5 cm from C H M S L
Breakout
S421 (Chassis C ab)............... Taillamp Harness, approx. 7 cm from Taillamp Extension


5421 (Suburban/Utility).......... Taillamp Harness, approx. 20 cm from Taillamp Extension


S424 (2- D oor U tility)........... Front-to-Rear Body Harness, approx. 15 cm from C H M S L

Breakout

Suburban)......................... Front-to-Rear Body Harness, approx. 10 cm from C H M S L
Breakout
8A - 2 0 0 ■ 28 ELECTRICAL DIAGNOSIS
D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from C H M S L
Breakout, toward L H D oor Speaker Breakout

w/Rear Heat)..................... Front-to-Rear Body Harness, approx. 14 cm from L R
Speaker Breakout

w/o Rear H eat)................. Front-to-Rear Body Harness, approx. 11 cm from Crossbody
Harness Breakout, toward L H Speaker Breakout

w/o C 6 9 )......................... Front-to-Rear Body Harness, approx. 11 cm from Rear
Dom e Lam p Breakout, toward L R Speaker
S426 (2-Door U tility )............ Front-to-Rear Body Harness, approx. 13 cm from Front


w/Overhead C o n so le )......... Dom e Lam p Harness, approx. 13 cm from C H M S L

w/o Overhead Console)....... Dom e Lam p Harness, approx. 22 cm from C H M S L

w/E55 w/o C 6 9 )................ Front-to-Rear Body Harness, approx. 12 cm from Rear
Breakout

Harness Breakout, toward C409

D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from Rear Dom e
Breakout

w/Rear Heat)..................... Front-to-Rear Body Harness, approx. 7 cm from Rear
Breakout

w/o Rear H eat)................. Front-to-Rear Body Harness, approx. 32 cm into Crossbody
Harness Breakout

w/o C 6 9 ).......................... Front-to-Rear Body Harness, approx. 65 cm into Crossbody
Harness Breakout

D o o rs)............................. Front-to-Rear Body Harness, approx. 7 cm from L H Door
Breakout

w/o Rear H e at)................. Front-to-Rear Body Harness, in Crossbody Harness
Suburban)......................... Front-to-Rear Body Harness, approx. 7 cm from Rear Dom e
S434 (2-Door U tility)............. Front-to-Rear Body Harness, approx. 7 cm from Front
Breakout

Breakout

Harness Breakout

Suburban)........................ Front-to-Rear Body Harness, approx. 7 cm from Crossbody

w/o C 6 9 )......................... Front-to-Rear Body Harness, approx. 7 cm from Crossbody
Harness Breakout, toward Front Dom e Lam p Breakout

S442 (4-Door U tility/



Regulator................................................................ 6 1 .... 79
S 5 0 2 .................................. Inside L F Door Harness, approx. 4 cm from Tweeter

S 5 0 3 .................................. Inside L F D oor Harness, approx. 25 cm into Outside

Rearview M irror Breakout
S 5 0 4 .................................. Inside L F D oor Harness, approx. 11 cm into W indow
Regulator Breakout

Speaker Breakout, toward L F W indow Regulator
S 5 0 6 .................................. Inside Power Outside Rearview M irror Harness, approx.

7 cm from Power Outside Rearview M irror, toward C501
w /R K E )............................ Inside R F D oor Harness, approx. 8 cm from W indow

5602 .............................. Inside R F D oor Harness, approx. 10 cm from Power
Outside Rearview M irror M otor
5603 (Suburban/Utility w /RKE,


w /R KE)............................ Inside R F D oor Harness, approx. 4 cm from W indow
S604 (Suburban/Utility w /RKE,

BLANK
COMPONENT LOCATION VIEWS
Figure 1— Fog Lamps
FRONT END DISCRIMINATING SENSOR „

VIEW D
Figure 2— Auxiliary Cooling Fan

Figure 3—Battery Wiring, (Typical)

VIEW A
04-10-96
4200VI212
Figure 5— Negative Battery Cable Routing, Gasoline Engines
Legend
(1) Fuse A and Fuse B (5) Engine W iring Harness
(2) Battery (6) Generator
(3) M ega Fuse Block/Cover (7) Fan Shroud
(4) Heater Hoses
1. HORN, RH
2. AUXILIARY COOLING FAN
RELAY
3. FOG LAMP CONNECTOR, RH
4. MARKER LAMP, RH
5. HEADLAMP CONNECTORS (COMPOSITE), RF
6 . PARK AND TURN LAMP, RF
7. ANTENNA
Figure 7— Forward Lamps Harness, RH Side
C102
Cl 00
1. PARK AND TURN LAMP, LF

2. HORN, LH
3. HEADLAMP CONNECTORS
(COM POSITE), LF
4. FOG LAMP CONNECTOR, LH
5. W INDSHEIELD WIPER MOTOR MODULE
Figure 8— Forward Lamps Harness, LH Side
Legend
(1) Underhood Fuse-Relay Center (4) Auxiliary Battery Relay
(2) Auxiliary Lights Relay (Z56 - 5G 4) (5) Forward Lam p Harness
(3) A.I.R. Pump Relay (if equipped) (6) Washer Pump Hose
(7) Remote Battery Stud
Legend
(1) Positive Auxiliary Battery Lead (8) AJC Com pressor Clutch Relay
(2) Electronic Brake Control M odule (E B C M ) (9) Horn Relay
(3) Engine Harness (10) Fuel Pump Relay
(4) Underhood Fuse-Relay Center (11) Forward Lam p Harness
(5) Brake Lam p Relay (12) Vehicle Control M odule (V C M - Gas O nly)
(6) M a x i Fuses (13) A uxiliary Battery
(7) Starter Relay (14) Brake Pressure W arning Switch
C102
C100
1. PARK AND TURN LAMP, LF

2 HORN LH
3. HEADLAMP CONNECTORS
(COMPOSITE), LF
4. FOG LAMP CONNECTOR, LH
5. WINDSHEIELD WIPER MOTOR MODULE
Figure 11— Wiper/Washer Reservoir (Suburban/Utility)
Figure 12— Underhood Lamp

Figure 13—Outside Air Temperature Sensor

Legend
(1) Outside A ir Temperature Sensor
Figure 14A—A.I.R. Pump (L31)

Legend
(1) A.I.R. Pump (L31)
1. THROTTLE POSITION (TP) SENSOR

2 . IDLE AIR CONTROL (IAC) VALVE MOTOR D104
3. ENGINE COOLANT TEMPERATURE CUTOUT SWITCH
4. A/C LOW PRESSURE CUTOUT SWITCH
5. EGR VALVE -
6 . ENGINE COOLANT TEMPERATURE SENSOR
7. A/C COMPRESSOR HIGH PRESSURE CUTOUT SWITCH
VIEW A 03-24-07
4208W0787
Figure 14— 4.3L Engine, LH Side
1. FUEL INJECTOR CONNECTOR

2. M A P . SENSOR
3. IGNITION CONTROL MODULE
4. EGR VALVE
5. CRANKSHAFT POSITION SENSOR
6. GENERATOR CONNECTOR
7. EVAPORATIVE EMISSIONS PURGE
SOLENOID VACUUM SWITCH
8 . ENGINE HARNESS
9. EVAPORATIVE EMISSIONS CANISTER
PURGE SOLENOID
10. IGNITION COIL CONNECTOR
03-17-97
4208W0788
Figure 15— 4.3L Engine, RH Side
1. ENGINE HARNESS
2. FUEL PUMP OIL PRESSURE SW ITCH AND SENDER
3. KNOCK SENSOR CONNECTOR
4. CAMSHAFT POSITION SENSOR
03-19-97
4208W0799
Figure 16—4.3L Engine, Rear View
5.0 AND 5.7L ENGINE
1. M A P . S E N S O R
2. EVAPORATIVE EMISSIONS CANISTER
PURGE SOLENOID
3. FUEL INJECTORS CONNECTOR
4. EVAPORATIVE EMISSIONS
PURGE SOLENOID VACUUM SWITCH
5. CRANKSHAFT POSITION SENSOR
6. GENERATOR CONNECTOR
7. IGNITION CONTROL MODULE
8 . IGNITION COIL CONNECTOR
0 3 -1 7 * 9 7
4208W0790
Figure 17— 5.0L & 5.7L Engines, RH Side
1. THROTTLE POSITION TP SENSOR

2. IDLE AIR CONTROL VALVE MOTOR
3. ENGINE HARNESS
4. ENGINE COOLANT TEMPERATURE SENDER
5. A/C HIGH PRESSURE CUT OUT SWITCH
6. A/C COMPRESSOR HOSE
7. EGR VALVE
8 . ENGINE COOLANT TEMPERATURE SENSOR
9. A/C COMPRESSOR CLUTCH
10. A/C COMPRESSOR VIEW A 03-i>-ty
4208W0791
Figure 18—5.0L & 5.7L Engines, LH Side

2. FUEL PUMP OIL PRESSURE
SWITCH AND SENDER
3. HEATED OXYGEN SENSOR
CONNECTOR
4. ENGINE HARNESS
5. KNOCK SENSOR
Figure 19— 5.0L & 5.7L Engines, Rear View

Figure 20— 7.4L Engine, RH Side
Legend
(1) Idle A ir Control (IA C ) Valve M otor (5) A ir Injection Reaction Pump
(2) Engine Coolant Temperature Sender (6) Throttle Position (TP) Sensor
(3) Generator Connector (7) Starter M otor
(4) Crankshaft Position Sensor
1. EQR VALVE
2 . INTAKE AIR TEMPERATURE (I.A.T.) SENSOR
3. MASS AIRFLOW (MAF) SENSOR
4. A/C COMPRESSOR CYCLING SWITCH
5. EVO SOLENOID VIEW A 03-24-97
4208W0793
Figure 21— 7.4L Engine, LH Side
1. IGNITION COIL
3. FUEL PUMP OIL PRESSURE SWITCH
AND SENDER
VIEW A 03-18-97
4. KNOCK SENSOR 4209W0794
Figure 22— 7.4L Engine, Rear View

1. FUEL INJECTOR CONNECTORS

2 . GENERATOR CONNECTOR
3. TURBO
4. GLOW PLUG CONNECTOR (LH SIDE)
5. W A T E R -IN -F U E L SENSOR VIEW A
03-18-87
4208W0795
Figure 23— 6.5L Diesel Engine, RH Side
1. WASTEGATE SOLENOID 5
2. EXHAUST QAS RECIRCULATION VENT
3. EXHAUST GAS RECIRCULATION SOLENOID
4. GLOW PLUGS
6 . A/C COMPRESSOR CLUTCH
Figure 24— 6.5L Diesel Engine, LH Side
Figure 25— 6.5L Diesel Engine, Rear View

1. WASTEGATE SOLENOID 5
2. EXHAUST GAS RECIRCULATION VENT
3. EXHAUST GAS RECIRCULATION SOLENOID
4. GLOW PLUGS
6 . A/C COMPRESSOR CLUTCH
Figure 26— 6.5L Diesel Engine, Fuel Injection Pump (L56)
1. INTAKE AIR TEMPERATURE (IAT) SENSOR ^

2 . TURBO PRESSURE SENSOR M „
03-18-07
4208W0799
Figure 27— 6.5L Diesel Engine, Top View

Figure 28—6.5L Diesel Engine, Crankshaft Position Sensor

1. FRONT AXLE SW ITCH

2. FRONT AXLE ACTUATOR
3. TRANSFER CASE RELAY (TYPICAL V IE W - DIESEL ENGINE SHOWN) 04-11-96
4206V1231
Figure 30— Transfer Case Relay
1. HEATED OXYGEN SENSOR CONNECTORS

2. PARK/NEUTRAL POSITION SWITCH
3. VEHICLE SPEED SENSOR
03-19-97
4206W0901
Figure 31— Electronic 4-Speed Automatic Overdrive Transmission (4L60E) LH

1. HEATED OXYGEN SENSOR CONNECTORS

3. TRANSFER CASE SWITCH
4. TRANSFER CASE
04-11-96
_________________________________________________ ___________________ ________ 1
4* * V1*38
3
2
Figure 32— Electronic 4-Speed Automatic Overdrive Transmission W/Sel. 4WD (4L60E) LH
ELECTRICAL DIAGNOSIS 8 A - 201 - 25
1. ENGINE HARNESS
CONNECTORS
4. TRANSMISSION CONNECTOR (C122)
5. PARK/NEUTRAL POSITION SWITCH 4
6 . AUTOMATIC TRANSMISSION INPUT SHAFT SPEED SENSOR
Figure 33— Electronic 4-Speed Automatic Overdrive Transmission (4L80E) LH
1. ENGINE HARNESS
CONNECTORS
4. TRANSFER CASE SYNCRONIZER
6 . TRANSMISSION CONNECTOR (C122)
7. PARK/NEUTRAL POSITION SWITCH
8. AUTOMATIC TRANSMISSION INPUT SHAFT SPEED SENSOR 03-20-97
4206W0903
Figure 34— Electronic 4-Speed Automatic Overdrive Transmission W /4W D (4L80E) LH

Figure 35— Automatic Transfer Case
Legend
(1) Transfer Case Encoder M otor (4) Transfer Case
(2) Engine Harness (5) Vehicle Speed Sensor
(3) Selectable 4 W D Indicator Lam p Harness (6) Transm ission
1. ENGINE HARNESS
3. BACK UP LAMP SWITCH
CONNECTOR
Figure 36— 5-Speed Manual Transmission (MW 3 L31 & L29)

1. ENGINE HARNESS
CONNECTORS
4. TRANSFER CASE SYNCRONIZER
(1/2 TON, 3/4 TON)
6. TRANSFER CASE 6
7. TRANSFER CASE SWITCH (1 TON)
Figure 37— 5-Speed Manual Transmission W /4W D (MW 3)
Figure 38— 5-Speed Manual Transmission (MG5 L35 & L30)

Figure 39— 5-Speed Manual Transmission W /4W D (MG5 L35 & L30)
Legend
(1) O xygen Sensor Harness (3) Catalytic Converter
(2) Frame Crossmember (4) Ground Strap - Catalytic Converter to R H Frame R ail
Figure 41— Electronic Brake Control Module

1. CRUISE CONTROL MODULE

2. REAR LAMP HARNESS
3. ENGINE HARNESS
4. WINDSHIELD WIPER MOTOR MODULE
Figure 42— Cruise Control Module

Figure 43— Instrument Panel Wiring, LH (Rear View)
Legend
(1) Headlamp and Panel Dim m er Switch Connector (3) Instrument Cluster Connector
(2) IP Fuse Block
1. CONVENIENCE CENTER
2. AUDIO ALARM MODULE
3. FOG LAMP RELAY
4. DRL RELAY
5. TURN/HAZARD FLASHER
6. PARK BRAKE WARNING SWITCH
Figure 44— Convenience Center

Figure 45— Instrument Panel Wiring, LH (Rearview)
Legend
(1) Automatic Transfer Case Control M odule (4) Convenience Center
(2) IP Harness (5) IP Reinforcement
(3) D R L M odule
Legend
(1) Radio (3) Tum/Hazard Flasher W iring
(2) Speaker
Figure 47— Overspeed Warning Alarm System Wiring

Legend
(1) Overspeed W arning Alarm
1. UNDERHOOD FU S E -R E LA Y CENTER
2. VEHICLE CONTROL MODULE (VCM)
3. ELECTRONIC BRAKE CONTROL
MODULE (EBCM)
4. CRUISE CONTROL MODULE 08-01-96
4206V1244
Figure 48— Vehicle Control Module (VCM) Gasoline
1. LOW COOLANT LEVEL

INDICATOR MODULE
2 . VEHICLE SPEED SENSOR
BUFFER (VSS)
3. POWERTRAIN CONTROL
MODULE (PCM)
4. LOW COOLANT LEVEL
SENSOR
Figure 49— Powertrain Control Module (PCM) Diesel

Figure 50— Interior Lamp Control Module, Remote Control Door Lock Receiver and TCCM
Legend
(1) Remote Control D oor Lock Receiver M odule (3) Transfer Case Control M odule
(2) Interior Lam p Control M odule
Legend
(1) Inflatable Restraint Sensing and Diagnostic M odule (2) L F Door Sill
Figure 52— EVO/Passlock Module

Legend
(1) EVO /Passlock M odule
Legend
(1) D oor Lock Relay (4) Accelerator Pedal Position M odule (Diesel)
(2) Power Am plifier (5) Clutch Pedal Position Switch
(3) Power Am plifier Relay
Figure 5 4 — Auxiliary Power Center
Legend
(1) A u xiliary Pow er Center (3) Courtesy Lam p,LH
(2) Courtesy Lam p, R H (4) IP Compartment B ox Lam p
Figure 55— Data Link Connector (DLC)
Figure 56— Instrument Panel Wiring, Inflatable Restraint IP Module, RH

Legend
(1) Daytim e Running Lam ps (D R L ) Diode (4) Brake/Transmission Shift Interlock Solenoid
(2) Daytim e Running Lam ps (D R L ) M odule (5) Stoplamp Switch
(3) Ignition Switch
Legend
(1) IP Harness (3) R F D oor Jamb Switch
(2) Emergency Vehicle Front Lam p Relay (Z56)
8 A - 201 - 46 ELECTRICAL DIAGNOSIS
Figure 60— Spotlamp Wiring (Z56 Police Package)

Legend
(1) Spotlamp W iring (Z56 Police Package)
1. INFLATABLE RESTRAINT
STEERING WHEEL MODULE
2. S.I.R. CONNECTOR
3. WIPE/WASHER SWITCH (PART
OF MULTIFUNCTION LEVER)
4. KEY - IN WARNING BUZZER
SWITCH
5. HORN SWITCH
6. STEERING WHEEL POSITION
SENSOR
Figure 61— Inflatable Restraint Steering Wheel Module, Steering Column Wiring
C222
1. CROSSBODY HARNESS
2. IP HARNESS
Figure 62— A Pillar Wiring, LH

Figure 63— IP Wiring, Center (Rear View)
Legend
(1) Radio Connector (7) Remote C D Player / Auxiliary Power Center (Z56)
(2) W indow Wiper/Washer Switch, Rear (8) Auxiliary Speaker Harness (Z56)
(3) Cargo Lam p Switch (Pickup) (9) Auxiliary Power Center Harness (Z56)
(4) A u x ilia ry H eater/H V AC Fan Sw itch (Suburban) / (10) Auxiliary Heater Control Switch
Inflatable Restraint IP M odule Switch (Pickup) (11) A uxiliary Grille Lam p Harness (Z56)
(5) Transfer Case Select Sw itch / Automatic Transfer Case
Select Switch / Fog Lam p Switch
(6) Radio
Legend
(1) Blow er Resistor (4) M ode D oor M otor
(2) Powertrain Control M odule (P C M - Diesel O nly) (5) Blow er M otor Relay, H igh
(3) Temperature D oo r M otor
Legend
(1) Emergency R o o f Lam p Switch
ILLUMINATION LAMP
Figure 67— Selectable Four-Wheel Indicator Wiring

Figure 68— Overhead Console
Legend
(1) Auxiliary H V A C Control Logic M odule (3) Universal Transmitter Switches (Z M 9 / U G 1)
(2) Auxiliary H V A C Control Module, Rear (4) Reading Lam ps, Overhead Console
(5) Auxiliary H V A C Control Module, Front
1. ELECTROCHROMATIC REARVIEW
MIRROR WITH COMPASS
2. SUNVISOR, LH
4. SUNVISOR, RH
Figure 69— Electrochromatic Rearview Mirror with Compass Wiring

Legend
(1) Crossbody Harness (5) Convenience Center
(2) Steering Colum n Support Brace (6) Inside Rearview M irro r / Illum inated Vanity M irror
(3) Power Am plifier Harness
(4) D oor Lock Relay (7) IP Harness
(8) Spotlamp Harness (Z56)
Figure 73— Rear Speakers (Regular Cab)

Figure 74—Rear Speakers (Extended Cab)

Figure 75— Rear Speakers (Crew Cab)
Figure 76— Rear Window Defogger Grid(AII Except Suburban/Utility)

Figure 77—Rear Dome Lamp

Legend
(1) W iring Harness (4) Dom e Lam p Lens
(2) Dom e Lam p Connector (5) W indshield
(3) Dom e Lam p (Z56)
C601
C501 (LH Opposite)
P600
(P500 Opposite)
C208LH
C215 RH
C206LH
C214RH
C209LH-
RH SHOWN
(LH SIMILAR)
Figure 79— Front Door Wiring, RH side
Legend
(1) Rear W indow Lockout Switch (4) Courtesy Lam p
(2) Door Lock Switch (5) Power W indow M otor
(3) D oor Lock M otor (6) Speaker
(7) Power Outside Rearview Mirror, R H
P800
(P700 Opposite)
C498LH
C496RH
C499LH
C497RH
Figure 80— Rear Door Wiring, RH side
Legend
(1) Power W indow Switch (4) Speaker
(2) D oor Lock M otor (5) Power W indow M otor
(3) Courtesy Lam p, R H (L H Opposite)
Figure 81— Power Seat Wiring
Legend
(1) Front Tilt M otor (7) Seat Harness Connector
(2) Forward/Back M otor (8) Crossbody Harness
(3) Heated Seat Element (9) Seat Riser
(4) Rear Tilt M otor (10) Power Seat Lum bar Switch
(5) Seat Harness (11) Power Seat Adjuster Switch
(6) Power Seat Lum bar M otor (12) Heated Seat M odule
Figure 82— Emergency Vehicle Roof Lamp Wiring Harness (Z56)
Legend
(1) B Pillar R o o f B ow (3) Emergency Vehicle R oof Lam p W iring Harness
(2) Dom e Lam p Bracket (4) R H B Pillar
Figure 83— Power Seat Wiring Harness
Figure 84— B-Pillar Wiring

Legend
(1) Auxiliary Low Blow er Relay (5) Auxiliary Blow er M otor
(2) Auxiliary M edium Blow er Relay (6) Auxiliary Temperature D oor M otor
(3) Auxiliary H igh Blow er Relay (7) Auxiliary M ode Door M otor
(4) Auxiliary Blow er Resistor
Figure 86— Auxiliary Air Conditioning Wiring, Rear (Tahoe/Yukon)
Legend
(1) R H C Pillar (5) Rear A/C Harness
(2) Front to Rear Harness (6) Blow er Resistor
(3) Blow er M otor (7) Blow er Relays
(4) Rear A/C Plenum
Figure 87— Liftgate Release Motor

1. CLEARANCE LAMP, LF/RF

2. PRIMARY FUEL TANK
3. CLEARANCE LAMP, LR/RR
4. FUEL GAUGE SENDER (W/DUAL TANKS - DIESEL)
(DUAL TANKS - GAS)
5. FUEL PUMP BALANCE RELAY
6 . FUEL PUMP BALANCE MODULE
7. FUEL PUMP (DUAL TANKS DIESEL)
Figure 89— Clearance Lamps (With Dual Rear Wheels)
04-10-96
4206V1273
Figure 90— CHMSL and Cargo Lamp (Except Suburban/Utility)

Figure 91—CHMSL and Cargo Lamp Wiring (Except Suburban/Utility)

Figure 93—Rear Wiper/Washer
Figure 94— Endgate Marker Lamps

Figure 95— Rear Frame Grounds
Legend
(1) Ground Strap - L R Body to L H Frame R ail End (4) Rear D oor Frame
(2) Ground Strap - Fuel Tank F ill Pipe to L R Body (5) Ground G 400-Bolt
(3) Fuel Tank F ill Pipe
Figure 96— Trailer Wiring
C409
1. TAIL/STOP - TURN LAMP, LH

2. TA IL/STO P-TU R N LAMP, RH
3. B A C K -U P LAMP
4. SECONDARY FUEL GAUGE SENDER
5. FUEL TANK PRESSURE SENDER
6 . SECONDARY FUEL PUMP
Figure 97— Rear Lamps Wiring (Chassis Cab)

201 - 74 ELECTRICAL DIAGNOSIS
8A -
Figure 98—License Lamps (Pickup, Without Rear Bumper)
1. TAIL/STOP - TURN LAMP, RH (LH OPPOSITE)

2. BACKUP LAMP, RH (LH OPPOSITE)
Figure 99— Tail and Stoplamp Harness

Q 403
Q410
CAM PER W IR IN G
C 409
G 403
G 403
C 409
CAM PER AND

TRAILER W IR IN G
04-10-96
4208V1282
Figure 100— Camper and Trailer Wiring
P911
V IE W A
1. LH CARGO DOOR CONTACTOR

04-10-96
4200V I283
Figure 101— LH Cargo Door Wiring
1. RH CARGO DOOR CONTACTOR

2. DOOR LOCK MOTOR, CARGO
3. DOOR JAMB SWITCH, CARGO
(PART ON CONTACTOR)
Figure 102— RH Cargo Door Wiring

SUBURBAN SHOWN
(UTILITY TYPICAL)
08-13-96
1. DOOR LOCK CONTROL MODULE 4206V3294
Figure 104— Door Lock Control Module
06-13-08
1. LAST DOOR LOCK SWITCH 4206V3286
Figure 105— Last Door Lock Switch

HARNESS CONNECTOR FACES
IN - LINE CONNECTOR C100
12146331
CONN 36F M/P 150,180, 630
LTQRY
C A V ITY W IR E C O L O R W IR E S IZ E CKT D E S C R IP T IO N
A1 W HT .8 17 S T O P L A M P S W IT C H O U T P U T (P IC K U P )
A1 RED .5 542 F U S E O U T P U T -B A T TE R Y -TY P E II F U S E (S U B U R B A N /U T IL IT Y )
A2 PN K .35 1020 IG N IT IO N F E E D - OFF, R U N , C R A N K (A/T)
A3 ORN 2 1440 F U S E O U T P U T -B A T TE R Y -TY P E III FU S E
A4 DK G R N .8 29 H O R N F EED
A4 DK G R N 1 392 R EA R W IN D O W W A S H E R P U M P M O T O R F E E D (S U B U R B A N /U TIL ITY )
A6 RED .5 42 F U S E O U T P U T -B A T TE R Y -TY P E II F U S E
A7 RED .5 142 F U S E O U T P U T -B A T TE R Y -TY P E II FU S E
A8 RED 3 242 F U S E O U T P U T -B A T TE R Y -TY P E II F U SE
B1 LT BLU 2 20 S T O P LA M P FE E D
B2 W HT .35 1294 EV O S O L E N O ID F E E D
B3 BRN .35 1295 E V O S O L E N O ID O U T P U T
B5 DK G R N .5 389 V E H IC L E S P E E D SIG N A L (G A S)
B6 N O T USED
B7 PPL .5 1807 S E R IA L DATA C L A S S 2
B8 ORN 1 1040 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E (S U B U R B A N /U TIL ITY )
C1 BLK .5 28 H O R N RELAY O U T P U T - C O IL
C2 PPL .5 30 FU E L G A U G E S E N S O R S IG N A L (G A S)
C2 YE L .8 1737 T R A N S M IS S IO N M O U N T E D N E U TR A L S A F E T Y S W IT C H O U T P U T -
PA R K /N EU TR A L (D IE S E L)
C3 BRN .8 25 C H A R G E IN D IC A TO R LAMP O U T P U T
C4 G R Y/B LK 1 1596 W A TER H EA TER C O N T R O L S O L E N O ID O U T P U T (S U B U R B A N /U TIL ITY )

C4 P P L /W H T .5 821 V S S S IG N A L (D IE S E L)
C5 OK G R N 5 822 V S S R E T U R N (D IE S E L)
C6 T A N /W H T .5 33 BRAKE W A R N IN G IN D IC A TO R LAM P O U T P U T
C7 PNK .8 139 F U S E O U T P U T -IG N IT IO N l-T Y P E III F U S E
C8 LT G R N .5 867 ABS FA ILU R E IN D IC A TO R LA M P O U T P U T
D1 T A N /W H T .5 799 D IA G N O S T IC S IG N A L-A B S (D IE S E L)
02 LT BLU/BLK .5 396 C R U IS E C O N T R O L S IG N A L -E N G A G E D (A/T)
D2 B R N /W H T .5 379 C R U IS E C O N T R O L , C L U T C H PEDAL S W IT C H O U T P U T (M /T)
D2 Y E L/B LK .5 1827 V E H IC L E S P E E D S IG N A L -128,000 P U L S E S P E R M ILE (D IE S E L)
03 LT G R N .8 24 B A C K U P LA M P F E E D
D4 DK G R N /W H T .5 817 V E H IC L E S P E E D S IG N A L -4000 P U LS E S P E R M ILE (GAS)
D4 DK BLU .35 5 07 G LO W P L U G IN D IC A T O R LAMP S IG N A L (D IE S E L)
D6 B LK /W H T 1 1695 F O U R W H E E L D R IV E F R O N T W H E E L LO C K TELLTALE F E E D
D7 LT G R N 1 66 A IR C O N D IT IO N IN G S W IT C H O U T P U T
D8 BRN .35 441 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
E1 P P L/W H T .5 1035 S TA R TE R RELAY F E E D -C O IL (M /T)
E1 PPL .5 806 F U S E O U T P U T -C R A N K -T Y P E III F U S E (A/T)
E2 PNK 3 3 IG N IT IO N S W IT C H O U T P U T -IG N IT IO N 1
E3 RED .5 3 42 F U S E O U T P U T -B A T TE R Y -TY P E II F U S E
E5 BRN 1 241 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
E6 G R Y/B LK 1 1596 W A TE R H E A TE R C O N T R O L S O L E N O ID O U T P U T (SU B U R B A N /U TILITY, G A S )
E7 ORN 1 1940 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
E8 W HT 121 T A C H O M E T E R SIG N A L
■8
IN -L IN E CONNECTOR C102
CONN 12M M/P

BLK
C A V IT Y W IR E C O L O R W IR E S IZ E CKT D E S C R IP T IO N
A LT G R N 1 11 H IG H BEAM H E A D LA M P F E E D
C BRN .8 9 PARK LA M P F EED
D LT BLU 1 14 T U R N SIG N A L LA M P F E E D -LH F R O N T
E DK BLU 1 15 T U R N S IG N A L LAM P F E E D -R H F R O N T
F TAN 1 12 LO W BEAM H E A D LA M P F E E D
G DK G R N 1 29 HORN FEED
H BRN .5 718 (ATC O N LY) S E N S O R R E T U R N
J RED .8 228 W IN D S H IE L D W A S H E R P U M P M O T O R F E E D
K DK G R N 1 392 R E A R W IN D O W W A S H E R P U M P M O T O R F E E D
L LT G R N /B L K .5 735 O U T S ID E A M B IE N T T E M P E R A T U R E S E N S O R S IG N A L
M PPL .8 34 (S P O R T S PKG ON LY-B YP) FO G L A M P F E E D

IN - LINE CONNECTOR C105,

FUEL INJECTORS (7.4L ENGINE)
r l
_______ p - '
12065425
CONN 10F M /P 150
BLK
A BLK .5 1744 FU EL IN JE C T O R #1 O U T P U T
B DK B LU /W H T .5 878 FU E L IN JE C T O R #8 O U T P U T
C LT BLU/BLK .5 8 44 FU EL IN JE C T O R # 4 O U T P U T
D PNK/BLK .5 1746 FU EL IN JE C T O R # 3 O U T P U T
E YEL/BLK .5 846 FU EL IN JE C T O R #6 O U T P U T
F B LK /W H T .5 845 FU EL IN JE C T O R #5 O U T P U T
G RED /B LK .5 8 77 F U E L IN JE C T O R # 7 O U T P U T
H LT G R N /B LK .5 1745 F U E L IN JE C T O R #2 O U T P U T
J PNK .8 439 F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E
K PN K .8 439 F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E

IN - UNE CONNECTOR C112

(DIESEL)
CONN 8F M /P 150
BLK
A YEL .5 410 C O O L A N T T E M P E R A T U R E S E N S O R S IG N A L
B YEL .8 573 C R A N K S H A F T P O S IT IO N S E N S O R SIG N A L
C NOT USED
D LT G R N .5 4 32 M A N IFO L D A B S O LU TE P R E S S U R E S E N S O R S IG N A L
E GRY .8 416 R E F E R E N C E VO LTA G E F E E D -5 VO LT R E F E R E N C E
F BLK .8 491 FU EL S O L E N O ID R E T U R N -C L O S U R E
G BLK .5 452 SENSO R RETURN
H TAN .8 472 M A N IFO L D A B S O LU TE T E M P E R A T U R E S E N S O R S IG N A L

g m 0 no m
BUI El 0 0
0 0 0 B I1
12110779
CONN 15M M/P 280
BLK
A DK B LU /W H T .8 259 E N G IN E S H U T O F F S O L E N O ID O U T P U T
B LT BLU .8 1030 IN JE C T IO N T IM IN G S T E P P E R M O T O R F E E D -C O IL A -LO W
C DK BLU .8 1031 IN JE C T IO N T IM IN G S T E P P E R M O T O R F E E D -C O IL A -H IG H
D BLK .8 1032 IN JE C T IO N T IM IN G S T E P P E R M O T O R F E E D -C O IL B-LO W
E BLK .8 1033 IN JE C T IO N T IM IN G S T E P P E R M O T O R F E E D -C O IL B -H IG H
F PNK .8 4 39 F U SE O U T P U T -IG N IT IO N 1-TY P E III F U S E
G B R N /W H T .8 633 C A M S H A F T P O S ITIO N S E N S O R SIG N A L
H ORN .8 1799 C A M S H A F T P O S IT IO N S E N S O R S IG N A L - H IG H R E S O LU T IO N
J PNK/BLK .8 632 C A M S H A F T P O S IT IO N S E N S O R R E T U R N
K YEL .8 1578 F U E L T E M P E R A T U R E SIG N A L
L LT G R N .8 2 60 FU EL S O L E N O ID M O D U LE FE E D
M LT G R N .8 260 FU EL S O L E N O ID M O D U LE FE E D
N GRY .8 474 R E F E R E N C E VO LTAG E F E E D - 5 VO LT R E F E R E N C E
P RED .8 313 F U E L S O L E N O ID C L O S U R E S IG N A L
R BRN .8 104 F U S E O U T P U T -G L O W P L U G -TY P E III F U S E

IN - LINE CONNECTOR C122 (M30)

UGHT DUTY TRANSMISSION
HARNESS SIDE TRANSMISSION SIDE
12160490 12160545
C O N N 20F M /P100W SLD C O N N 20M M /P100S SLD
GRY GRY
A LT G R N .5 1222 S H IF T S O L E N O ID A O U T P U T
B YEL/B LK .5 1223 S H IF T S O L E N O ID B O U T P U T
C R ED /B LK .5 1228 T R A N S M IS S IO N F O R C E M O T O R FE E D
D LT B L U /W H T .5 1229 T R A N S M IS S IO N F O R C E M O T O R R E T U R N
E PNK .5 1020 F U S E O U T P U T -O F F /R U N /C R A N K -T Y P E III F U S E S E N S O R
L YEL/B LK .5 1227 T R A N S M IS S IO N T E M P E R A T U R E S E N S O R S IG N A L
M BLK .5 452 S E N S O R R E T U R N (D IE S E L )
M BLK .5 470 S E N S O R R E T U R N (G A S)
N PNK .5 1224 T R A N S M IS S IO N P R E S S U R E S W IT C H S IG N A L -B IT 1
P RED .5 1226 T R A N S M IS S IO N P R E S S U R E S W IT C H S IG N A L -B IT 3
R DK BLU .5 1225 T R A N S M IS S IO N P R E S S U R E S W IT C H SIG N A L -B IT 2
S W HT .5 6 87 S H IF T S O L E N O ID O U T P U T -3 /2 (LD)
S BRN .5 418 T C C S O L E N O ID O U T P U T -P W M (H D )
T TAN/BLK .5 4 22 T C C S O L E N O ID O U T P U T (LD)
U BRN .5 418 T C C S O L E N O ID O U T P U T -P W M (LD)

IN -L IN E CONNECTOR C122 (MT1)

HEAVY DUTY TRANSMISSION
HARNESS SIDE TRANSMISSION SIDE
12160545
CONN 20M M /P100S SLD
QRY QRY
A LT G R N .5 1222 1-2 S H IF T S O L E N O ID C O N T R O L C IR C U IT
B YEL/BLK .5 1223 2 -3 S H IF T S O L E N O ID C O N T R O L C IR C U IT
C R ED /B LK .5 1228 P R E S S U R E C O N T R O L S O L E N O ID (H IG H )
D LT B LU /W H T .5 1229 P R E S S U R E C O N T R O L S O L E N O ID (LO W )
E PNK .5 1020 IG N IT IO N F U S E F E E D
L YEL/BLK .5 1227 T R A N S M IS S IO N F LU ID T E M P E R A T U R E (T F T ) SIG N A L
M BLK 5 4 52 S E N S O R G R O U N D (D IE S E L )
M BLK .5 470 S E N S O R G R O U N D (G A S )
N PNK .5 1224 P R E S S U R E S W IT C H S IG N A L - BIT 1
P RED .5 1226 P R E S S U R E S W IT C H S IG N A L - BIT 3
R DK BLU .5 1225 P R E S S U R E S W IT C H S IG N A L - BIT 2
S WHT .5 687 S H IF T S O L E N O ID O U T P U T - 2 /3 (LD)
S BRN .5 4 18 T C C S O L E N O ID O U T P U T - P W M (H D )
12059472
ASM CONN 7F M/P MXD SLD
BLK
A TAN .8 1569 T R A N S F E R C A S E LO C K S O L E N O ID O U T P U T
B G R Y /B L K .5 1570 F R O N T A XLE A C T U A TO R O U T P U T
C ORN .8 1640 F U S E O U T P U T -B A T TE R Y -TY P E III FU S E
D G R Y /B LK .5 1694 4 W D S W IT C H S IG N A L -LO W
E BLK 3 1552 T R A N S F E R C A S E M O T O R F E E D -C W
F B LK /W H T .8 1695 4 W D F R O N T W H E E L LO C K TELLTALE F E E D
G RED 3 1553 T R A N S F E R C A S E M O T O R F E E D -C C W
CONN 1 0 M M /P 150 SLD

BLK
A YEL .5 4 00 V E H IC L E S P E E D S E N S O R SIG N A L
B PPL .5 401 V E H IC L E S P E E D S E N S O R R E T U R N
C LT G R N /B LK .5 431 R E F E R E N C E VO LTAG E F E E D - 8 VO LT R E F E R E N C E
D B LK /W H T .5 1554 T R A N S F E R C A S E E N C O D E R S IG N A L R E T U R N
E B R N /W H T .5 1555 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R SIG N A L - C H A N N E L ’P
F R E D /W H T .5 1556 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R SIG N A L - C H A N N E L ’C ’
G DK B LU /W H T .5 1557 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R SIG N A L - C H A N N E L ’A’
H YEL/BLK .5 1558 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L - C H A N N E L ’B’
J LT BLU .5 2221 V E H IC L E S P E E D S E N S O R SIG N A L
K DK G R N .5 9999 V E H IC L E S P E E D S E N S O R R E T U R N

(GAS)
CONN 16M M/P 280 ACT

NAT
A YEL .8 1737 T R A N S M IS S IO N M O U N T E D N E U TR A L S A F E T Y S W IT C H -O U T P U T -P A R K /N E U T R A L
B NO T USED
C NO T USED
D LT G R N .8 275 T R A N S M IS S IO N M O U N T E D /N E U T R A L S A F E T Y S W IT C H O U T P U T - PARK (A /T)
D TAN/BLK .5 456 S H IF T IN D IC A TO R LA M P O U T P U T (M /T)
E PPL .5 4 20 BRAKE PE D A L S W IT C H O U T P U T - T O R Q U E C O N V E R T E R C L U T C H
F BLKW HT 1 451 E N G IN E C O N T R O L M O D U LE G R O U N D
G B LK /W H T .5 771 T R A N S M IS S IO N P O S IT IO N S W IT C H SIG N A L - BIT 1 (A/T)
H YEL .5 772 T R A N S M IS S IO N P O S ITIO N S W IT C H SIG N A L - BIT 2 (A/T)
J GRY .5 773 T R A N S M IS S IO N P O S ITIO N S W IT C H SIG N A L - BIT 3 (A/T)
K WHT .5 776 T R A N S M IS S IO N P O S ITIO N S W IT C H S IG N A L - PAR ITY BIT (A/T)
L DK G R N .5 35 C O O L A N T T E M P E R A T U R E IN D IC A TO R LAMP O U T P U T
M TAN .5 31 O IL P R E S S U R E IN D IC A TO R LAMP O U T P U T
N B R N /W H T .5 419 C H E C K E N G IN E IN D IC A TO R LAMP O U T P U T
P DK G R N .5 1614 A IR IN LE T VALVE M O TO R FEED
R NOT USED
S NOT USED

(DIESEL)
12092249
CONN 23F 280 ACT
WHT
A WHT .8 17 S T O P LA M P S W IT C H O U T P U T
B DK BLU .5 84 C R U IS E C O N T R O L S E T /C O A S T S W IT C H SIG N A L
C G R Y/B LK .5 87 C R U IS E C O N T R O L R E S U M E /A C C E L S W IT C H SIG N A L
D N O T U SE D
E W H T /B LK .35 176 S E R V IC E T H R O T T L E S O O N IN D IC A T O R LAM P O U T P U T
F LT G R N .8 275 T R A N S M IS S IO N M O U N T E D N E U TR A L S A F E T Y S W IT C H O U T P U T - PARK (A/T)
G DK G R N .5 389 V E H IC L E S P E E D S IG N A L -4000 P U LS E S PE R M ILE
H PPL .5 420 BRAKE PEDAL S W IT C H O U T P U T - T O R Q U E C O N V E R T E R C L U TC H
J BRN .5 437 V E H IC L E S P E E D SIG N A L
K BLK/W HT 1 451 E N G IN E C O N T R O L M O D U L E G R O U N D
L YEL/BLK .8 508 W A TER IN F U E L IN D IC A T O R LA M P O U T P U T
M BLK/W HT .5 771 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - BIT 1 (A/T)
M B R N /W H T .5 379 C R U IS E C O N T R O L C L U T C H PE D A L S W IT C H O U T P U T (MAT))
N YEL .5 772 T R A N S M IS S IO N P O S IT IO N S W IT C H SIG N A L - BIT 2 (A/T)
P GRY .5 773 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - BIT 3 (A/T)
R W HT .5 776 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - PAR ITY BIT (A/T)
S LT G R N .8 1478 LO W C O O LA N T S E N S O R SIG N A L
T DK G R N .5 35 C O O LA N T T E M P E R A T U R E IN D IC A TO R LAMP O U T P U T
U TAN .5 31 O IL P R E S S U R E IN D IC A T O R LA M P O U T P U T
V B R N /W H T .5 419 C H E C K E N G IN E IN D IC A T O R LA M P O U T P U T
C A V ITY W IR E C O L O R W IR E S IZE CKT D E S C R IP T IO N
W DK G R N .5 1614 A IR IN L E T VALVE M O T O R F EED
X NOT USED
Y NOT USED
Z NOT USED

(DIESEL)
=)
£ rJA T B T c T D T £ l 5
12064770
CONN 10M M /P 150
NAT
A W H T /B L K .5 1164 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 1
B DK BLU .5 1161 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N S IG N A L 1
C LT BLU .5 1162 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N S IG N A L 2
D BRN .5 1271 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 1
E TAN .5 1274 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 2
F YEL/B LK .5 1275 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 3
G DK G R N .5 1163 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N SIG N A L 3
H PPL .5 1272 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 2
J GRY .5 1273 E L E C T R O N IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 3
K GRY .35 397 C R U IS E C O N T R O L O N S W IT C H O U T P U T


(UPFITTER OPTION)
12064872
CONN 10M M /P 150
BLK
A PNK .8 40 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
B YE L .8 496 P O W E R M IR R O R M O T O R F E E D -C O M M O N
C GRY .8 90 P O W E R M IR R O R M O T O R F E E D -R H H O R IZ O N TA L M O TO R IN D IR E C T IO N
D P P L /W H T .8 889 P O W E R M IR R O R M O T O R F E E D -R H V E R T IC A L M O T O R -D O W N D IR E C T IO N
E BLK .8 150 GROUND
F BRN .8 9 PARK LAM P F E E D
G GRY .8 1690 A U T O M A T IC D A Y /N IG H T M IR R O R S IG N A L -O U T S ID E
H PN K .8 1691 A U T O M A T IC D A Y /N IG H T M IR R O R R E T U R N -O U T S ID E
J ORN .8 267 H E A TE D M IR R O R E L E M E N T F E E D
K N O T USED
A17
12077822
CONN 48M M/P MXD
BLK
A1 W HT .8 17 S T O P L A M P S W IT C H O U T P U T (S U B U R B A N /U TIL ITY )
A2 PN K .8 139 F U S E O U T P U T -IG N IT IO N l-TY P E III F U SE
A3 BLK 3 150 GROUND
A4 NOT USED
A5 NOT USED
A6 DK BLU 1 15 T U R N S IG N A L LA M P F E E D - RH F R O N T
A7 LT BLU 1 14 T U R N S IG N A L F E E D - LH F R O N T
A8 NO T USED
A9 N O T USED
A 10 NOT USED
A11 BLK .5 28 H O R N RELAY O U T P U T - C O IL
A 12 GRY .35 3 97 C R U IS E C O N T R O L O N S W IT C H O U T P U T
A 13 BR N .35 41 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
A 14 DK BLU .35 84 C R U IS E C O N T R O L S E T /C O A S T S W IT C H S IG N A L
A 15 G R Y /B L K .35 87 C R U IS E C O N T R O L R E S U M E /A C C E L S W IT C H S IG N A L
A 16 BLK .8 150 G R O U N D (A/T)
A 17 DK G R N /W H T .8 1135 BRAKE T R A N S M IS S IO N S H IF T IN T E R L O C K S O L E N O ID F E E D (A /T)
B1 R E D /W H T .8 812 R E F VO LTA G E F E E D -1 2 VO LT R E F
B2 BLK .8 150 GROUND
B3 LT G R N .8 80 K E Y R E M IN D E R S W IT C H SIG N A L
CAVITY W IR E C O L O R W IR E S IZ E CKT D E S C R IP T IO N
B4 TAN 5 159 KEY R E M IN D E R S W IT C H O U T P U T
B5 LT BLU .5 1134 PARK BRAKE S W IT C H SIG N A L
B6 NOT USED
C1 WHT 3 1390 IG N IT IO N S W IT C H O U T P U T -O F F /R U N /C R A N K (AIT)
C2 BLK .8 150 GROUND
C3 GRY .35 705 R E F VOLTAGE F E E D 5 VO LT R EF
C4 O R N /B LK .35 1057 SENSO R RETURN
C5 PNK 3 3 IG N IT IO N S W IT C H O U T P U T -IG N IT IO N 1
C6 ORN .5 300 IG N IT IO N S W IT C H O U T P U T -IG N IT IO N 3
D1 YEL 3 5 IG N IT IO N S W IT C H O U T P U T - C R A N K
D2 R ED .5 342 F U S E O U T P U T -B A T TE R Y -TY P E II F U S E
D3 YEL .35 1836 M A G N E T IC RO TATIO N D E T E C T IO N S E N S O R SIG N A L
D4 LT BLU .35 1059 S T E E R IN G W H E E L P O S IT IO N S E N S O R SIG N A L
D5 RED 3 242 F U S E O U T P U T -B A T TE R Y -TY P E II F U S E
D6 BRN .5 4 IG N IT IO N S W IT C H O U T P U T - A C C E S S O R Y
E1 GRY 1 1696 T U R N /H A Z A R D M O D U L E F E E D -S E C O N D A R Y
E2 LT BLU 2 20 S T O P L A M P F E E D (G AS)
E3 PPL 1 92 W IN D S H IE L D W IP E R M O T O R F E E D - H IG H S P E E D
E4 YEL 1 143 F U S E O U T P U T -A C C E S S O R Y -T Y P E III F U S E
E5 BRN , 1 96 W IN D S H IE L D W IP E R S W IT C H S IG N A L - P U L S E DELAY
E6 DK GRN 2 19 S T O P /T U R N L A M P F E E D - RH R EA R
E7 YEL 2 18 S T O P /T U R N LA M P F E E D - LH R EA R
E8 ORN 1 140 B A TTE R Y F E E D
E9 PPL 1 1697 T U R N /H A Z A R D M O D U LE O U T P U T
E 10 NO T USED
E11 LT G R N 1 11 H IG H BEAM H E A D LA M P F E E D
E 12 PPL 1 359 H E A D LA M P F E E D -D A Y TIM E R U N N IN G LA M PS
E 13 YEL 1 10 H E A D LA M P S W IT C H O U T P U T
CONN 10F M /P 150

BLK
A BRN .8 9 PARK LA M P F E E D
B LT G R N .8 24 B A C K -U P LA M P F E E D
C PN K .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
D ORN .8 40 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
E BLK .8 150 GROUND
F NOT USED
Q NO T USED
H NO T USED
J NOT USED
•
K NOT USED
(SUBURBAN/UTILITY)
CONN 16M M/P 280 ACT

BLK
C A VITY W IR E C O L O R W IR E S IZ E CKT D E S C R IP T IO N
A ORN .8 40 F U S E O U T P U T -B A T TE R Y -TY P E III FU S E
B BRN .8 9 PARK LAMP FE E D
C W HT .8 156 C O U R T E S Y LAM P O U T P U T
D NO T USED
E GRY .35 8 IN S T R U M E N T PANEL LAMP FE E D
F W HT .8 17 S T O P LAMP S W IT C H O U T P U T
G PPL .5 328 IN T E R IO R LAM P D EFEA T S W IT C H O U T P U T
H YEL 8 1737 T R A N S M IS S IO N M O U N T E D N E U TR A L S A F E T Y S W IT C H O U T P U T -P A R K /N E U T R A L
J GRY .5 157 IN T E R IO R LA M P O U T P U T
K B LK /W H T .35 1455 K E Y LE S S E N T R Y P R O G R A M SIG N A L
L ORN 1 1840 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E
M BRN .8 341 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
N GRY .5 1690 A U T O M A T IC D A Y /N IG H T M IR R O R S IG N A L -O U T S ID E
P PNK .5 1691 A U T O M A T IC D A Y /N IG H T M IR R O R R E T U R N -O U T S ID E
R ORN 1 1040 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E
S PPL 3 2 93 R EA R D E F O G G E R E L E M E N T FE E D

(PICKUP)
15305551
CONN 10 M /P 150
NAT
A ORN .8 40 F U S E O U T P U T -B A T TE R Y -TY P E III F U SE
B BRN .8 9 PARK LA M P FE E D
C W HT .8 156 C O U R T E S Y LAMP O U T P U T
D B LK /W H T .8 238 SE A T BELT S W IT C H SIG N A L
E GRY .35 8 IN S T R U M E N T PANEL LA M P F E E D
F W HT .8 17 S T O P LAM P S W IT C H O U T P U T
G PPL .5 328 IN T E R IO R LAM P D EFEA T S W IT C H O U T P U T
H D K B L U /W H T .8 149 C O U R T E S Y LAMP
J GRY .5 157 IN T E R IO R LA M P O U T P U T
K B LK /W H T .35 1455 K EY LE S S E N T R Y P R O G R A M ENA BLE SIG N A L

CONN 10F M /P 150

NAT
C A V ITY W IR E C O LO R W IR E S IZ E CKT D E S C R IP T IO N
A DK G R N .5 117 S P E A K E R R E T U R N -R H F R O N T
B GRY .5 118 S P E A K E R R E T U R N -L H F R O N T
C LT G R N .5 200 S P E A K E R F E E D -R H F R O N T
D TAN .5 201 S P E A K E R F E E D -L H F R O N T
E DK BLU .5 46 S P E A K E R F E E D -R H REA R
F LT BLU .5 115 S P E A K E R R E T U R N - RH R EA R
G YE L .5 116 S P E A K E R R E T U R N - LH REA R
H BRN .5 199 S P E A K E R F E E D - LH R EA R
J PNK .8 3 14 R A D IO S IG N A L -O N
K PNK .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U SE

CO NN10F M /P 150
NAT
C A V IT Y W IR E C O L O R W IR E S IZE CKT D E S C R IP T IO N
A W HT .8 156 C O U R T E S Y L A M P -O U T P U T
B LT BLU .5 115 S P E A K E R R E T U R N -R H R EA R
C DK BLU .5 46 S P E A K E R F E E D -R H R EA R
D YE L .5 116 S P E A K E R R E T U R N -L H R EA R
E BRN .5 199 S P E A K E R F E E D -L H REA R
F BLK .8 1576 T R U N K R E LE A S E S W IT C H O U T P U T
G ORN .8 40 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E F E E D
H ORN 1 640 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
J YE L .8 1737 T R A N S M IS S IO N M O U N T E D /N E U T R A L S A F E T Y S W IT C H O U T P U T -P A R K /N E U T R A L
K W HT .8 17 S T O P LA M P S W IT C H O U T P U T
CONN 10F M /P 150

NAT
A ORN .8 40 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E P O W E R M IR R O R M O TO R

F E E D -C O M M O N
B YEL .8 1496 P O W E R M IR R O R M O T O R F E E D - C O M M O N
C GRY .8 90 P O W E R M IR R O R M O T O R F E E D -R H H O R IZ O N TA L M O TO R -LH D IR E C T IO N
D P P L/W H T .8 889 P O W E R M IR R O R M O T O R F E E D -D O W N D IR E C T IO N
E BLK .8 150 GROUND
F BRN .8 9 PARK LAM P F EED
G GRY .5 1690 A U T O M A T IC D A Y /N IG H T M IR R O R S IG N A L -O /S
H PNK .5 1691 A U T O M A T IC D A Y /N IG H T M IR R O R R E T U R N -O /S
J ORN .8 267 H E A TE D M IR R O R E L E M E N T F E E D
K NOT USED
ACCELERATOR PEDAL POSITION MODULE
r ~ \ -----------------
EDHQEDtZl
Vjh r \ J
12065425
CONN 10F M /P 150
BLK
A BRN .5 1271 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 1
B PPL .5 1272 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 2
C LT BLU .5 1162 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N SIG N A L 2
D GRY .5 1274 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 2
E GRY .5 1275 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 3
F DK BLU .5 1161 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N SIG N A L 1
G GRY 5 1164 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N 5 V R E F 1
H NO T USED
J GRY .5 1273 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N R E T U R N 3
K DK G R N .5 1163 E L E C T R IC T H R O T T L E -P E D A L P O S IT IO N SIG N A L 3
ACTIVE TRANSFER CASE CONTROL MODULE
12052107
ASM 32M
BLK
E1 TAN .8 1569 T R A N S F E R C A S E LO C K S O L E N O ID O U T P U T
E2 LT BLU/BLK ,35 1567 S E R V IC E 4 W D A N D IN D IC A T O R LA M P O U T P U T
E3 PNK .35 1561 A W D IN D IC A TO R LAM P O U T P U T
E4 LT G R N /B LK .35 1563 2 W D IN D IC A TO R LAMP O U T P U T
E5 B R N /W H T .5 1555 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L -C H A N N E L P
E6 R E D /W H T .5 1556 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L -C H A N N E L C
E7 YEL/BLK 5 1558 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L -C H A N N E L B
E8 DK B LU /W H T .5 1557 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L -C H A N N E L A
E9 PPL .5 1807 S E R IA L DATA S IG N A L -C LA S S 2 -1 0 4 0 0 B A U D -P R IM A R Y
E 10 BRN .8 241 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
E11 NO T USED
E12 YEL .5 400 V E H IC L E S P E E D S E N S O R SIG N A L
E 13 PPL .5 401 V E H IC L E S P E E D S E N S O R R E T U R N
E 14 BLK/W HT .8 1695 4 W D F R O N T W H E E L LO C K TELLTALE F E E D
E 15 NOT USED
E16 BLK/W HT 1 451 E N G IN E C O N T R O L M O D U L E G R O U N D
F1 P P L/W H T .35 1565 4 'LO' IN D IC A TO R LA M P O U T P U T
F2 TAN/BLK .35 1566 4 ‘H I’ IN D IC A TO R LA M P O U T P U T
F3 BRN .35 1560 N E U TR A L IN D IC A TO R LA M P O U T P U T
F4 G R Y/B LK .5 1570 F R O N T A XLE A C T U A TO R O U T P U T

F5 LT BLU .5 2221 V S S SIG N A L
F6 DK G R N .5 2222 VSS RETURN
F7 G R Y /B LK .5 1694 4 W D S W IT C H S IG N A L -LO W
F8 NOT USED
F9 NOT USED
F10 NOT USED
F11 NOT USED
F12 B LK /W H T .5 1554 T R A N S F E R C A S E E N C O D E R S IG N A L R E T U R N
F13 LT G R N /B L K .5 431 R E F E R E N C E VO LTA G E F E E D -8 VO LT R E F E R E N C E
F14 LT G R N /B L K .35 431 R E F E R E N C E VO LTA G E F E E D -8 VO LT R E F E R E N C E
F15 LT G R N .8 275 T R A N S M IS S IO N M O U N T E D N E U TR A L S A F E T Y S W O U T P U T -P A R K
F16 LT BLU/BLK .35 1693 4 W D S W IT C H S IG N A L

AUXILIARY HEATER AND A/C CONTROL LOGIC MODULE
12047887
ASM CONN 12W P/C EDGBD STD
BLK
A LT BLU .8 733 A IR T E M P E R A T U R E D O O R P O S IT IO N SIG N A L
B DK BLU .8 1199 A IR T E M P E R A T U R E D O O R M O T O R -F E E D
C D K BLU .8 1646 A IR T E M P E R A T U R E D O O R P O S IT IO N S IG N A L -R E A R
0 LT BLU .8 920 R EA R C O N T R O L O U T P U T
E LT BLU .8 919 F R O N T C O N T R O L HEA T IN P U T
F W HT .8 454 GROUND
H BLK .8 150 GROUND
J BRN .8 341 IG N IT IO N F U S E D F E E D
K NO T USED
L OK BLU .8 77 A /C S E L E C T S W IT C H -R E A R
M ORN .8 1923 A /C S E L E C T S W IT C H F R O N T
AUXILIARY HEATER AND A/C

CONTROL SWITCH/MODULE
(FRONT)
12064769
CONN 10F M /P 150
NAT
A GRY .5 8 IP LA M P F E E D
B BLK .8 150 GROUND
C DK BLU .8 1926 A U X IL IA R Y H VA C S W IT C H O U T P U T - LOW
D W HT .8 1924 A U X IL IA R Y H VA C S W IT C H O U T P U T - H IG H
E R ED .8 1925 A U X IL IA R Y H VA C S W IT C H O U T P U T - M E D IU M
F ORN .8 1923 A U X IL IA R Y HVA C S W IT C H F E E D
G BRN .8 341 IG N IT IO N F E E D - F U S E D
H LT BLU .8 733 A IR T E M P D O O R P O S IT IO N S E N S O R S IG N A L
J LT BLU .8 919 F R O N T C O N T R O L HEA T IN P U T

AUXILIARY HEATER AND A/C

CONTROL SWITCH/MODULE
(REAR)
CONN 10F M /P 150

NAT
A GRY .8 8 IP LA M P F E E D
B BLK .8 150 GROUND
C DK BLU .8 1926 A U X IL IA R Y HVAC S W IT C H O U T P U T - LO W
D WHT .8 1924 A U X IL IA R Y HVAC S W IT C H O U T P U T - H IG H
E RED .8 1925 A U X IL IA R Y HVAC S W IT C H O U T P U T - M E D IU M
F ORN .8 1923 A U X IL IA R Y HVAC S W IT C H FE E D (W ITH C 6 9 O NLY)
G BRN .8 341 IG N IT IO N F E E D - F U S E D
H LT BLU .8 733 A IR T E M P D O O R P O S IT IO N S E N S O R S IG N A L - P A S S E N G E R
J LT BLU .8 919 MODE DOOR OUTPUT

BLOWER MOTOR SWITCH, CONNECTOR C2

(FRONT)
CONN 8F M/P 280

BLK
A LT BLU 1 72 B L O W E R S W IT C H O U T P U T -M E D IU M 2
B TAN 1 63 B L O W E R S W IT C H O U T P U T -M E D IU M 1
C YE L 1 60 B L O W E R S W IT C H O U T P U T -L O W
D DK G R N 1 71 A /C S E L E C T S W IT C H O U T P U T
E NO T USED
F NOT USED
G BRN 1 141 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
H ORN 1 52 B LO W E R S W IT C H O U T P U T - H IG H
r y -------------- r " \
H H IZ IIZ IG II
EUZiEiEE]
12065425
CONN 10F M /P 150
BLK
A GRY .35 397 C R U IS E C O N T R O L S W IT C H O N O U T P U T
B DK BLU .35 84 C R U IS E C O N T R O L S W IT C H S IG N A L S E T /C O A S T
C G R Y/B LK .35 87 C R U IS E C O N T R O L S W IT C H S IG N A L R E S U M E /A C C E L
D PPL .5 420 BRAKE PEDAL S W IT C H O U T P U T -T O R Q U E C O N V E R T E R C L U T C H
E B LK /W H T .5 451 E N G IN E C O N T R O L M O D U L E G R O U N D
F BRN .35 41 F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U S E
Q WHT .8 17 S T O P L A M P S W IT C H O U T P U T
H NO T USED
J LT B LU /W H T .5 396 C R U IS E C O N T R O L S IG N A L - E N G A G E D
K DK G R N /W H T .5 817 V E H IC L E S P E E D SIG N A L - 4 0 0 0 P U L S E S PE R MILE

DATA UNK CONNECTOR
CONN 16F M /P 150

BLK
1 NO T USED
2 PPL .5 1807 S E R IA L DATA S IG N A L -C LA S S 2 -1 0 4 0 0 B A U D -P R IM A R Y
3 NO T USED
4 BLK .5 150 GROUND
5 B LK /W H T .5 451 E N G IN E C O N T R O L M O D U L E G R O U N D
6 NOT USED
7 NO T USED
8 B LK /W H T .35 1455 K E Y LE S S E N T R Y P R O G R A M EN A B LE SIG N A L
9 TAN .5 800 S E R IA L DATA S IG N A L - U A R T -8192-B A U D P R IM A R Y
10 NOT USED
11 NOT USED
12 T A N /W H T .5 799 D IA G N O S T IC S IG N A L - A B S
13 ORN .5 1568 D IA G N O S T IC S IG N A L -T R A N S F E R C A S E C O N T R O L M O D U L E
14 DK G R N .35 835 D IA G N O S T IC S IG N A L -E N T E R T A IN M E N T A N D C O M F O R T
15 NOT USED
16 ORN 1 840 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E

EVO/PASSLOCK MODULE
12110259
CONN 16F M/P 100
GRN
A1 BRN .35 1295 E V O S O L E N O ID O U T P U T
A2 NOT USED
A3 W HT .35 1294 EV O S O L E N O ID FE E D
A4 NOT USED
A5 R E D /W H T .8 812 R E F VO LTA G E F E E D -1 2 VO LT R E F
A6 NO T USED
A7 LT BLU .35 1059 S T E E R IN G W H E E L P O S IT IO N S E N S O R S IG N A L
A8 DK GRIM/W HT .5 817 V E H IC L E S P E E D S IG N A L -4000 P U L S E S P E R M ILE
B1 B LK /W H T 1 451 G R O U N D ELM
B2 YEL .35 749 S E C U R IT Y IN D IC A T O R LA M P O U T P U T
B3 PN K .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
B4 PPL .35 1807 S E R IA L DATA S IG N A L -C LA S S 2-1 0 4 0 0 B A U D P R IM A R Y
B5 O R N /B L K .35 1057 SENSOR RETURN
B6 GRY .35 705 R E F VO LTA G E F E E D -5 VO LT R E F
B7 YEL .35 1836 M A G N E T IC RO TATIO N D E T E C T IO N S E N S O R
B8 ORN .35 1740 F U S E O U T P U T -B A T T E R Y S IG N A L -T Y P E III F U S E

FUEL INJECTORS
(4.3L ENGINE)
CONN 12F M /P 100

BLK
A B LK /W H T .5 845 FU EL IN JE C T O R #5 O U T P U T
B PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U SE
C PNK /B LK .5 1746 F U E L IN JE C T O R # 3 O U T P U T
D PN K .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
E PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E
F BLK .5 1744 F U E L IN JE C T O R #1 O U T P U T
G LT G R N /B LK .5 1745 F U E L IN JE C T O R #2 O U T P U T
H PNK .8 4 39 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
J PNK .8 4 39 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
K LT BLU/BLK .5 8 44 FU E L IN JE C T O R # 4 O U T P U T
L PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
M YEL/BLK .5 846 F U E L IN JE C T O R # 6 O U T P U T
FUEL INJECTORS
(5.0L AND 5.7L ENGINES)
CONN 15M M/P 280

BLK
A BLK .5 1744 FU EL IN JE C T O R #1 O U T P U T
B PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E
C PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
D PNK/BLK .5 1746 FU EL IN JE C T O R #3 O U T P U T
E LT BLU/BLK .5 844 FU EL IN JE C T O R #4 O U T P U T
F PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
G PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-TY P E III FU S E
H LT G R N /B LK .5 1745 FU EL IN JE C T O R #2 O U T P U T
J DK B LU /W H T .5 878 FU E L IN JE C T O R #8 O U T P U T
K PNK .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E
L PNK .8 439 IG N IT IO N FU S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
M YEL7BLK .5 846 F U E L IN JE C T O R #6 O U T P U T
N BLK/W HT .5 845 FU EL IN JE C T O R #5 O U T P U T
P PNK .8 439 IG N IT IO N FU S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-T Y P E III FU S E
R PN K .8 439 IG N IT IO N F U S E D F E E D -F U S E O U T P U T -IG N IT IO N 1-TY P E III F U S E
S R ED /B LK .5 877 FU E L IN JE C T O R #7 O U T P U T
HEADLAMP DIMMER SWITCH
12146952
CONN 12F M/P 280
BLK
B GRY .5 157 IN T E R IO R LA M P O U T P U T
C RED 3 42 F U S E O U T P U T -B A T TE R Y -TY P E II FU S E
D PN K .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U SE
E DK G R N .8 44 IN S T R U M E N T PANEL LA M P S D IM M E R S W IT C H O U T P U T
G YE L 1 10 H E A D LA M P S W IT C H O U T P U T
H ORN .8 2 40 F U S E O U T P U T -B A T T E R Y -T Y P E III F U SE
K NOT USED
L PPL .5 328 IN T E R IO R LAMP D E FE A T S W IT C H O U T P U T
M W HT .8 156 C O U R T E S Y LA M P O U T P U T
N P P L /W H T .8 1382 LED D IM M IN G SIG N A L
R BLK .8 150 GROUND
S BRN .8 9 PARK LA M P FE E D
HEATER AND A/C CONTROL SWITCH,

CONNECTOR C l
(iZItZIBED
V
12052856
CONN 4 F M /P 2 8 0
BLK
A ORN 2 1440 B A TTE R Y F U S E D F E E D F U S E O U T P U T -B A T TE R Y -TY P E III FU SE
B BRN 1 141 IG N IT IO N F U S E D F E E D F U S E O U T P U T -IG N IT IO N 3 -T Y P E III F U SE
C BLK 1 150 GROUND
D PPL 2 293 R EA R D E F O G G E R E L E M E N T F EED

HEATER AND A/C CONTROL SWITCH

CONNECTOR C3
me
m e
me
me
me
me
me
me
■ 4?
12160850
CONN 10W P/C
BLK
1 GRY .35 8 IN S T R U M E N T PANEL LAMP F EED
2 BLK .8 150 GROUND
3 DK G R N 1 71 A /C S E L E C T S W IT C H O U T P U T
4 DK G R N .5 1614 A U X C O O L IN G FAN RELAY C O N T R O L
5 BRN 1 141 IG N IT IO N F U S E D F E E D
6 N O T USED
7 G R Y/B LK 1 1596 W A TE R VALVE C O N T R O L
8 LT BLU 1 733 A IR T E M P E R A T U R E D O O R P O S ITIO N S E N S O R SIG N A L
9 W HT 1 4 54 GROUND
10 LT G R N 1 66 A IR C O N D IT IO N IN G S W IT C H O U T P U T
INFLATABLE RESTRAINT SDM
ASM 12M
BLK
1 W H T /B LK .8 1403 S IR IN FLA TO R FEED -PA S S
2 WHT .8 347 S IR IN FLA TO R F E E D -D R IV E R
3 DK G R N .8 348 S IR IN FLA TO R O U T P U T -D R IV E R
4 DK G R N /W H T .8 1404 S IR IN FLA TO R O U T P U T -P A S S
5 TAN .5 800 S E R IA L DATA S IG N A L -U A R T-819 2 B A U D -P R IM A R Y
6 B LK /W H T .8 1751 S IR G R O U N D
7 BRN .8 358 S IR IN D IC A T O R LAM P O U T P U T
8 B LK /W H T .8 238 SE A T BELT S W IT C H SIG N A L
9 YE L .8 1834 S IR F O R W A R D S E N S O R SIG N A L
10 YEL .8 1139 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E -S IR
11 B LK /W H T .8 371 S IR D EFEA T S W IT C H SIG N A L-PA SS
11 N O T U S E D (C R E W CAB)
12 PN K .8 353 S IR D EFEA T IN D IC A TO R LA M P O U T P U T -P A S S
12 N O T U S E D (C R E W CAB)
INSTRUMENT CLUSTER
16
12146397
ASM 32W P/C BOW
BLK
1 BRN .8 358 S IR IN D IC A TO R LA M P O U T P U T
2 ORN 2 1140 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E (Z56)
3 LT BLU 1 14 T U R N SIG N A L IN D IC A T O R LA M P F E E D -L H F R O N T
4 B LK /W H T .5 451 E N G IN E C O N T R O L M O D U L E G R O U N D
5 LT G R N 1 11 H IG H BEAM H E A D LA M P F E E D
6 WHT .8 121 T A C H O M E T E R SIG N A L
7 PNK .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E (M /T )
7 PNK .35 1020 IG N IT IO N F E E D -O F F /R U N /C R A N K -T Y P E III F U S E (A /T)
8 P P L/W H T .8 1382 LED D IM M IN G SIG N A L
9 B LK /W H T .5 771 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - B IT 1
10 GRY .5 773 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - BIT 3
11 YEL .5 772 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - B IT 2
12 W HT .5 776 T R A N S M IS S IO N P O S IT IO N S W IT C H S IG N A L - PAR ITY BIT
13 DK G R N .5 .35 C O O L A N T T E M P E R A T U R E IN D IC A T O R LA M P O U T P U T
14 DK G R N .5 389 V E H IC L E S P E E D S IG N A L - 4 0 0 0 P U L S E S P E R M ILE
15 TAN .5 31 O IL P R E S S U R E IN D IC A T O R LA M P O U T P U T
16 PPL .8 30 F U E L G A U G E S S E N S O R S IG N A L
17 LT G R N /B LK .8 592 D A Y TIM E R U N N IN G L IG H T RELAY O U T P U T - C O IL
18 Y E L/B LK .8 508 W A TE R IN FU E L IN D IC A T O R L A M P O U T P U T (D IE S E L)
19 BRN .8 25 C H A R G E IN D IC A T O R LA M P O U T P U T
CAVITY W IR E C O L O R W IR E S IZ E CKT D E S C R IP T IO N
20 DK BLU .35 5 07 S H IF T IN D IC A T O R LAM P O U T P U T /G L O W P L U G IN D IC A TO R LA M P SIG N A L

(D IE S E L) (M /T W / AJ3)
21 W H T /B LK .35 176 S E R V IC E T H R O T T L E S O O N IN D IC A TO R LA M P O U T P U T (D IE S E L)
22 PN K .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U SE
23 B R N /W H T .5 419 C H E C K E N G IN E IN D IC A T O R LAM P O U T P U T
24 LT BLU/BLK .35 1567 S E R V IC E 4 W D /A W D IN D IC A TO R LAMP O U T P U T
25 YEL/B LK .5 68 L O W C O O L A N T LEVE L IN D IC A TO R LAMP O U T P U T (D IE S E L)
26 YE L .35 749 S E C U R IT Y IN D IC A T O R LAMP O U T P U T
27 LT G R N .5 8 67 ABS FA ILU R E IN D IC A T O R LAM P O U T P U T
28 T A N /W H T .5 33 BRAKE W A R N IN G IN D IC A TO R LAMP O U T P U T
29 GRY .35 8 IN S T R U M E N T PANEL LA M P FEED
30 YE L .8 2 34 SEAT BELT IN D IC A TO R LAMP O U T P U T
31 BLK .5 451 E N G IN E C O N T R O L M O D U L E G R O U N D
32 DK BLU 1 15 T U R N S IG N A L LA M P F E E D -R H F R O N T
POWER AMPLIFIER
12034325
CONN 15M M/P 280
NAT
C1 DK BLU .5 46 S P E A K E R F E E D - R IG H T REA R
C2 LT BLU 8 115 S P E A K E R R E T U R N - R IG H T R EA R
C3 NOT USED
C4 BRN .8 199 S P E A K E R F E E D - L E F T REA R
C5 YEL .8 116 S P E A K E R R E T U R N - L E F T R EA R
C6 TAN .8 1855 S P E A K E R F E E D - R IG H T R EA R M ID R A N G E
C7 NOT USED
C8 NOT USED
C9 RED .8 1955 S P E A K E R R E T U R N - R IG H T R EA R M ID R A N G E
C 10 NOT USED
C11 NO T USED
C 12 TAN .8 1859 S P E A K E R F E E D - L E FT R EA R M ID R A N G E
C 13 ORN .8 360 A M P L IF IE R F E E D
C 14 BLK .8 150 GROUND
C 15 W HT .8 1959 S P E A K E R R E T U R N - L E F T R E A R M ID R A N G E
ELECTRICAL DIAGNOSIS 8 A - 20 2 - 41
POWER DOOR LOCK SWITCH
y iin jiiii)
& & & & &
12084617
CONN 11F M/P MXD
BLK
A BLK 1 150 GROUND
B BLK 1 150 GROUND
C LT BLU 1 195 P O W E R D O O R LO C K RELAY F E E D - LO C K C O IL
D ORN 1 540 F U S E O U T P U T B A TTE R Y T Y P E III F U S E
D ORN 1 640 F U S E O U T P U T B A TTE R Y T Y P E III F U S E (P IC K U P W /O R H E )
E WHT 1 194 P O W E R D O O R LO C K RELAY F E E D - U N L O C K C O IL
F BLK .8 150 GROUND
G NOT USED
H NO T USED
J BRN .8 9 PARK LA M P F E E D
K NO T USED
L YEL 2 343 F U S E O U T P U T - A C C E S S O R Y - T Y P E III F U S E

8 A - 202 - 42 ELECTRICAL DIAGNOSIS
POWER WINDOW AND DOOR

LOCK SWITCH
^ hIH JhhbbI
fo S rfri cS d d h
d r
12084617
CONN 11F M/P MXD
BLK
A W HT 1 194 P O W E R D O O R LOCK RELAY F E E D - U N L O C K C O IL
B LT BLU 1 195 P O W E R D O O R LOCK RELAY F E E D - LO C K C O IL
C TAN 1 294 P O W E R D O O R LOCK M O T O R F E E D - U N L O C K
C W HT 8 194 P O W E R D O O R LOCK RELAY F E E D - U N L O C K C O IL
D ORN .8 640 F U S E O U T P U T - B A TTER Y T Y P E III F U S E
D ORN 1 540 F U S E O U T P U T - B A TTER Y T Y P E III F U S E
E LT BLU .8 195 P O W E R D O O R LOC K RELAY F E E D - LO C K C O IL
E GRY 1 295 P O W E R D O O R LOC K M O T O R F E E D - LOC K
F YE L 2 1307 P O W E R W IN D O W M A S T E R S W IT C H O U T P U T -L O C K O U T
F YEL 2 343 F U S E O U T P U T - A C C E S S O R Y - T Y P E III F U S E
G DK BLU 2 666 P O W E R W IN D O W M O T O R F E E D R IG H T F R O N T W IN D O W - U P
H NOT USED
J LT BLU 2 166 P O W E R W IN D O W M A S T E R S W IT C H O U T P U T - R IG H T F R O N T W IN D O W - U P
K BRN 2 667 P O W E R W IN D O W M O T O R F E E D R IG H T F R O N T W IN D O W - D O W N
L TAN 2 167 P O W E R W IN D O W M A S T E R S W IT C H O U T P U T - R IG H T F R O N T W IN D O W - D O W N
ELECTRICAL DIAGNOSIS 8 A - 2 0 2 - 4 3
RADIO,
CONNECTOR C1
I i— i L J H -*n |
BQDQDD -'QOO0
c CD anaDcniiincniin..„ mununnn CZ3
lfthtS
12047531
CONN 10F M /P100B LK
1 GRY .5 118 S P E A K E R R E T U R N - LF
2 TAN .5 201 S P E A K E R F E E D - LF
3 DK G R N .5 117 S P E A K E R R E T U R N - RF
4 LT G R N .5 200 S P E A K E R F E E D - RF
5 BLK .8 150 GROUND
6 P P L/W H T .8 1382 LED D IM M IN G SIG N A L
7 GRY .35 8 IN S T R U M E N T PANEL LA M P F E E D
8 PNK .5 314 R A D IO O N S IG N A L (S U B U R B A N /U TIL ITY )
9 YEL .5 43 F U S E O U T P U T - A C C E S S O R Y - T Y P E III F U S E
10 ORN .5 1140 F U S E O U T P U T - BA TTER Y - T Y P E III F U S E

8A > 2 0 2 - 4 4 ELECTRICAL DIAGNOSIS
RADIO,
CONNECTOR C2
___ I_______ nri

(iiipiaipiaia
I— UBECDDmiDEnKn DUIEDdllDI I
12065785
CONN 10FM /P 100
GRY
11 NO T USED
12 NOT USED
13 NOT USED
14 NOT USED
15 DK G R N .35 835 D IA G N O S T IC S IG N A L -E N T E R T A IN M E N T A N D C O M F O R T
16 DK G R N /W H T .35 8 17 V E H IC L E S P E E D S IG N A L -4000 P U L S E S P E R M ILE
17 LT BLU .5 115 S P E A K E R R E T U R N - (R R )
18 DK BLU .5 46 S P E A K E R F E E D - (R R )
19 YEL .5 116 S P E A K E R R E T U R N - (LR)
20 BRN .5 199 S P E A K E R F E E D - (LR)

REMOTE CONTROL DOOR LOCK RECEIVER
1919Q 431
CONN 16F M/P 280

BLK
A TAN 2 694 P O W E R D O O R LO C K M O T O R F E E D -D R IV E R D O O R
B W HT .8 194 P O W E R D O O R LO C K RELAY F E E D -U N L O C K C O IL
C BLK .5 28 H O R N RELAY O U T P U T -C O IL
D NO T USED
E ORN 2 540 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E
F ORN .8 640 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
F ORN 2 540 (2W D ) F U S E O U T P U T -B A T TE R Y -TY P E III F U S E
G BLK .8 1576 T R U N K R E LE A S E S W IT C H O U T P U T
H TAN 2 294 (2W D ) P O W E R D O O R LO C K M O T O R F E E D -U N L O C K
J PN K .5 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
K GRY .5 157 IN T E R IO R LA M P O U T P U T
L GRY .5 1455 K EY LE S S E N T R Y P R O G R A M ENA BLE SIG N A L
M NO T USED
N BLK .8 1505 GROUND
P NOT USED
R LT BLU .8 195 G R O U N D -L O C K C O IL
S W HT .8 156 C O U R T E S Y LAM P O U T P U T
8 A - 2 0 2 - 46 ELECTRICAL DIAGNOSIS
TRANSFER CASE CONTROL MODULE

(WIRE ENTRY VIEW)
p/'cJe I----- r E - — l~ J 1 I .. | cT
II 11 II i 1I T m T I T h
LL1 L L □. □...□ . n i l
X T
12045470
CONN 32F M /P 100
NAT
C1 B LK /W H T 1 1695 F O U R W H E E L D R IV E -F R O N T W H E E L LOC K TELLTALE F E E D
C2 LT G R N /B LK .5 431 8V R E F E R E N C E VOLTAGE F E E D -8 VO LT R E F E R E N C E
C3 DK G R N /W H T .5 1559 4 L O W S E L E C T S W IT C H O U T P U T
C4 W HT .5 900 2 H IG H S E L E C T S W IT C H O U T P U T
C5 G R Y /B LK .5 1564 4 H IG H S E L E C T S W IT C H O U T P U T
C6 ORN 1 1640 F U S E O U T P U T -B A T T E R Y -T Y P E III F U S E
C7 NOT USED
C8 PN K .35 39 F U S E O U T P U T -IG N IT IO N 1-T Y P E III F U S E
C9 B LK /W H T .5 1554 T R A N S F E R C A S E E N C O D E R S IG N A L R E T U R N
C 10 BLK .8 150 GROUND
C11 PN K .5 1563 2 H IG H IN D IC A TO R LA M P O U T P U T
C 12 TAN/BLK .5 1566 4 H IG H IN D IC A T O R LA M P O U T P U T
C 13 N O T USED
C 14 P P L /W H T .5 1565 4 L O W IN D IC A T O R LA M P O U T P U T
C 15 NOT USED
C 16 bLk 1 1552 T R A N S F E R C A S E M O T O R F E E D -C W
D1 RED 1 1553 T R A N S F E R C A S E M O T O R F E E D -C C W
02 LT G R N .8 275 T R A N S M IS S IO N M O U N T E D /N E U T R A L S A F E T Y S W IT C H O U T P U T - PARK
D3 ORN .5 1568 T R A N S F E R C A S E C O N T R O L M O D U L E (D IA G N O S T IC S S IG N A L -T R A N S M IS S IO N
M OUNTED)
D4 B R N /W H T .5 1555 T R A N S F E R C A S E P O S IT IO N S W IT C H E N C O D E R S IG N A L -C H A N N E L P
05 R E D /W H T .5 1556 ENCODER CHANNEL C
D6 DK B LU /W H T .5 1557 ENCODER CHANNEL A
D7 YEL/BLK .5 1558 ENCODER CHANNEL B
D8 DK G R N /W H T .35 817 V E H IC L E S P E E D SIG N A L
D9 NO T USED
D10 BLK .8 150 GROUND
D11 NO T USED
D12 BLK 1 150 GROUND
D13 BLK 1 150 GROUND
D14 ORN 1 1640 F U S E O U T P U T -B A T TE R Y -TY P E III F U S E
D15 ORN 1 1640 F U S E O U T P U T -B A T TE R Y -TY P E III F U SE
D16 YEL .5 1737 T R A N S M IS S IO N M O U N T E D /N E U T R A L S A F E T Y S W IT C H O U T P U T -

P A R K /N EU TR A L
8 A - 20 2 - 48 ELECTRICAL DIAGNOSIS
TRANSFER CASE SELECT SWITCH
12064769
CONN 10F M /P 150
NAT
A PN K .35 39 IG N ITIO N F U S E D FE E D
B W HT .5 900 2 H IG H T R A N S F E R C A S E S E LE C T S W IT C H O U T P U T
C G R Y /B LK .5 1564 4 H IG H T R A N S F E R C A S E S E L E C T S W IT C H O U T P U T
D D K G R N /W H T .5 1559 4 LO W T R A N S F E R C A S E S E L E C T S W IT C H O U T P U T
E P P L /W H T .5 1565 4 LO W IN D IC A TO R LA M P O U T P U T
F TAN/BLK .5 1566 4 H IG H IN D IC A TO R LAM P O U T P U T
G PN K .5 901 2 H IG H IN D IC A TO R LA M P O U T P U T
H BLK .5 150 GROUND
J GRY .35 8 IN S T R U M E N T PANEL LAM P F E E D
K NOT USED
ELECTRICAL DIAGNOSIS 8 A - 2 0 2 - 49
IN - L IN E C O N N E C T O R C101 IN - U N E C O N N E C T O R C 107
n.
0Q 0O 0O 0
12162102
A S M 4 M M /P 150 12124107
BLK A S M 6 M M /P 150
BLK
IN - U N E C O N N E C T O R C 103
IN - U N E C O N N E C T O R C110
1 2084180
12129565 A S M 2 M M /P 2 8 0
A S M 4 F M /P 2 8 0 YEL
GRY
(G A S )
12186400
A S M 5 M M /P 2 8 0
BLK
GRY
02-06*97
4208W 0718
IN - L IN E C O N N E C T O R C 120 IN - L IN E C O N N E C T O R C 2 0 3
12129155
C O N N 2 M M /P 2 8 0
BLK BLK
IN - U N E C O N N E C T O R C 2 0 5
GRY
BLK
(0 3 , 4 3 , 5 3)
0 0
0 0
w 12064867
12160482 C O N N 2 F M /P 150
A SM C O N N 4 F M /P 150 BLK
BLK
02-06-97
4208W 0719
IN - L IN E C O N N E C T O R C 2 0 8
IN —U N E C O N N E C T O R C 2 0 6
( 0 6 ,4 3 )
(0 6 ,1 6 )
12064763
A S M 6 M M /P 150
BLK
QRY
12064767
A S M 8 M M /P 150
BLK
BLK
(0 3 ,1 6 , 5 3 )
I
A B C D E F |
U
12066195
C O N N 8 M M /P 2 8 0 12110747
BLK A S M 6 F M /P 2 8 0
QRY
02-06-97
4208W 0720
8A ■ 2 0 2 - 52 ELECTRICAL DIAGNOSIS

IN -U N E CONNECTOR C211
12047663
CONN 2M M /P 150
12064761
BLK
ASM 4M M/P 150
BLK
IN - UNE CONNECTOR C212 IN -U N E CONNECTOR C215
BLK 12064767
ASM 8M M/P 150
BLU

12066195
ASM 8M M/P 280
BLK
BLK
0 2-06-97
4208W0721
w
12065978 1 2015203
ASM 5M M/P C O N N 1F M /P 2 8 0
BLK BLK
A B C D E F
12110748
ASM 6M M/P
12124107
A S M 6 F M /P 150
BLK
12033713
C O N N 1F M /P 2 8 0 BLK
NAT
02-06-97
42O8W0722
IN - L IN E C O N N E C T O R C 2 2 6 IN - L IN E C O N N E C T O R C 2 3 0
12045688
C O N N 8 M M /P 150
BLK
BLK
12047663
C O N N 2 M M /P 150
BLK C O N N 8M M /P 2 8 0
YEL
(0 3 ,1 6 , 5 3 )
YEL
BLK
02-00*97
42O0WO723

IN —UNE CONNECTOR C233
12077918
CONN 2M M/P 280
BLK
BLK
12045813
CONN 4F M/P 150
BLK
12066195
CONN 8M M/P 280
BLK
12045813
CONN 4F M/P 150
BLK
BLU
02-06-97
4206W 0724
J ----------
12064758
C O N N 3 F M /P 1 5 0 12066387
BLK A S M C O N N 2 M M /P 4 8 0
BLK
IN - U N E C O N N E C T O R C 3 0 2 IN - U N E C O N N E C T O R C 4 0 0
(0 6 , W /R E A R H E A T)
15305452
A S M 2 M M /P
LTQ RN BLK
IN - U N E C O N N E C T O R C 3 0 2 IN - U N E C O N N E C T O R C401
(A LL E X C E P T 0 6 W /R E A R H E A T )
12064998 12064762
C O N N 8 F M /P 2 8 0 A S M 6 F M /P 150
BLK GRY
02-07-97
420SW 0725
IN - UNE CONNECTOR C402 IN - UNE CONNECTOR C406
0 E p
08905206 12015271
CONN 4F PAC/ONI CONN 2M M/P 280
BLK BLK
IN -U N E CONNECTOR C404
BLK
IN -LIN E CONNECTOR C405 IN - UNE CONNECTOR C408
12010973
CONN 2M M/P
12033779 BLK
CONN 2F M/P 280
BLK
02-07-97
4208W 0726
8A ■ 2 0 2 - 58 ELECTRICAL DIAGNOSIS

(06,16, 43)
A B C
F E D
BLK 12064763
ASM 6MM/P150
GRY
IN - UNE CONNECTOR C410 IN -LIN E CONNECTOR C450

(SUBURBAN/UTIUTY)
12064761 12015199
CONN 4MM/P150 CONN 2F M/P 280
BLK BLK
IN - UNE CONNECTOR C411 IN - UNE CONNECTOR C496

(03,53)
A B C
F E D
Q
12059558 12064763
CONN 8M M/P 150 ASM 6M M/P 150
BLK GRY
02-07-97
4208W 0727
IN —UNE CONNECTOR 0497 IN - LINE CONNECTOR C601
[EESl
[EH]
rc n re i
i _ r
19064754.
CONN 6M M/P 280 12064766
B IX CONN 8F MI P 150
BLK

ACTIVE TRANSFER CASE MODULE
|~S~] |~e~l [~D~l

A B C
F E D RJ
12052856
CONN 4F 280
BLK
12162105
ASM 6M M/P 150
QRY
ACTIVE TRANSFER CASE SELECT SWITCH,

CONNECTOR C1
CEIB3
U SE]
rmrci
12162104
12064766
ASM 6M M/P 280
CONN 8F M/P 150
BLK
BLK
02-10-97
4208W 0728
AUXILIARY FAN RELAY
ACTIVE TRANSFER CASE SELECT SWITCH,

CONNECTOR C2
12045813
CONN4F M /P150
BLK
MD GRY
A.I.R. PUMP RELAY BLOWER MOTOR RELAY

(LO, MED, HI,)
12034003
rrp
CONN 4F 280 FLXLK SLD CONN 5F M/P 630
MO GRY BLK
BLOWER MOTOR RELAY (HI)

AUXILIARY FAN CONTROL SWITCH
0
0 '
f c f r -
BLK 12110541
ASM 6F 280 FLXLK
BLK
02-10-97
4208W 0729
CLUTCH PEDAL POSITION SWITCH
□ ____Q ,
r t.
12064877
CONN 4F M/P 680 BLK
BLK
DRL MODULE
CARGO DOOR SWITCH

(LAST DOOR LOCK)
gr
I53I53C5][5]
t£ b c £ b c 2 ]c £ b
w
12064998 12191131
CONN 8F M/P 280 ASM 8W P/C EDGBD STD
BLK BLK
DRURADIO OVERRIDE SWITCH
CARGO LAMP SWITCH
12129136
CONN 4F M/P 280 FLXLK
BLK
BLK
02-11-97
4208W 0730
EMERGENCY BEACON LAMP FEED RELAY

FOG LAMP SWITCH
GRY
BLK
FRONT AXLE ACTUATOR

EXHAUST GAS RECIRCULATION (EGR)
VALVE SOLENOID
12186057
ASM CONN 5F M/P 150.2 P2S SLD 12077591
BLK ASM CONN 5F M/P 150 SLD
BLK
FUEL GAUGE ANTI - SLOSH MODULE

FLASHER MODULE
(Z56 ONLY)
0 0 0 0 0 0 0 0
12034003 12010000
CONN 5F M/P 630 CONN 8W EDGBD STD
BLK BLK
02-11*97
4206W0731
FUEL PUMP MOTOR

(4.3L ENGINE)
FUEL GAUGE SENDER
(AUXILIARY FUEL TANK)
r >1
A B C D
V )
12162189
CONN 4F M /P150
BLK 12160482
CONN 4F M/P 150
BLK
FUEL PUMP OIL PRESSURE SWITCH

FUEL PUMP BALANCE MODULE AND SENDER (DIESEL)
12059573 12110293
CONN 6F M/P 280 CONN 3F M/P 150
BLK BLK
FUEL PUMP BALANCE RELAY

FUEL PUMP OIL PRESSURE SWITCH
AND SENDER (GAS)
MD GRY GRY
02-11-97
4206W 0732
8 A - 2 0 2 - 64 ELECTRICAL DIAGNOSIS
FUEL TANK PRESSURE SENSOR HEATED SEAT ELEMENT

(4.3L ENGINE)
G D B 0
12058595
CONN 3F M /P 150 BLK
BLK
GLOW PLUG CONTROL MODULE HIGH M OUNT STOP LAMP

(DIESEL)
@ © @ ^
12047785
CONN 4F M /P 150
12045636 BLK
CONN 4F M /P 280
MD GRY
HEATED OXTGEN SENSOR
ICM
12160482 BLK
ASM 4F M /P 150 SLD
BLK
0 2 H -9 7
4208W 0733
IN -U N E IP FUSE BLOCK
IDLE AIR CONTROL (IAC) VALVE MOTOR
BLK
12129082
MD GRY
INFLATABLE RESTRAINT
FRONT END SENSOR
IN - UNE TO IP FUSE BLOCK
12015664
CONN 4F M/P 630
12160310
CONN 2F M/P 280
YEL
IN - UNE TO SPEAKER/GRILL UGHTS

INFLATABLE RESTRAINT
(Z56 ONLY)
l/P MODULE ENABLE SWITCH
c B A
rJ
□
L_
0000 0
D E F
L r - L _ _ p J
12191470 12146045
CONN 6F M/P 150 ASM CONN 5F M/P 150 SLD
YEL BLK
O 2H -07
4208W0734
8 A - 20 2 - 6 6 ELECTRICAL DIAGNOSIS
IN —UNE TO TURN SIGNAL LAMPS (REAR) LOW ENGINE COOLANT LEVEL

INDICATOR MODULE
12010974
CONN 4M W/P SHD 12004706
BLK CONN 6W P/C EDGBD-STUD
BLK
MODE DOOR MOTOR

INTERIOR LAMP CONTROL MODULE
1 rr-r
DOBO [EDO (ED[ED
EEE 0 0
Uq
12041429
CONN 5F M/P 280
BLK 12040953
CONN 6F M/P
BLK
UNEAR EGR VALVE

OUTSIDE REARVIEW MIRROR MOTOR (W/UG1)
r ......— \
E F G H
DC B A
V_____o ___/
12045688
CONN 8M M/P 150
BLK
MD GRY
02-11-97
4209W 0735
OUTSIDE REARVIEW MIRROR MOTOR (W/O UG1) PNP SWITCH, CONNECTOR C2
12129804
ASM 4F M /P150
CRM
POWER AMPLIFIER RELAY

OUTSIDE REARVIEW MIRROR SWITCH
• n n i«i»i
1A 1 1C 10 1
12065978
12064862
CONN 5M M/P 480
CONN 8F M/P 150 BLK
BLK
POWER DOOR LOCK CONTROL SWITCH
PNP SWITCH, CONNECTOR Cl
1 21 29 8 AO
ASM 7F M/P 150, 280 12048363
MD GRY ASM 8W P/C EDGBD-STD
BLK
02-12-97
4208W 0736
8 A - 20 2 - 6 8 ELECTRICAL DIAGNOSIS
POWER SEAT CONTROL MODULE
POWER DOOR LOCK RELAY

]__ [
[ tg qp qpigi qp ig [
------- 1 S"F H-------
I rh 1
12059561
CONN 6F M/P 280, 480
BLK
BLK
POWER DOOR LOCK SWITCH, MASTER
[ J POWER WINDOW MASTER SWITCH

b d
-[Ms-
c
rT -ir? -ir? -irliiLi ■s'
r r b u t
1_
12084603
CONN 8F M/P MXD
12064998 MD GRY
CONN 8F M/P 280
BLK
POWER SEAT ADJUSTER SWITCH
REAR UFTGATE RELAY
12129136
12066386 BLK
CONN 8F P/G SER
BLK
02-12-97
4208W 0737
REAR WINDOW LOCKOUT SWITCH RECIRCULATION DOOR MOTOR
A B C D innEDOMDinjini
BE □ EES
i ___ r
UJ U_l
0
12066571 12040953
CONN 4F M/P 480 CONN 6F M/P
BLK BLK
REAR WINDOW SWITCH ROOF CLEARANCE LAMP SWITCH
^ C B A 3
in
ui
u.
O
l^ p — r fJ
12064762
CONN 6F M/P 150
BLK
BLK
REAR WINDOW WIPER/WASHER SWITCH
b TAIL AND STOPLAMP SWITCH
c 5 h c 5 b c 2 ]c 5 3 □ □ 0 1 2 0
12065862
12064998 ASM CONN 4F M/P 280
CONN 8F M/P 280 BLK
BLK
0 2 -1 2 -0 7
8 A - 20 2 - 70 ELECTRICAL DIAGNOSIS
TCC/STOPLAMP SWITCH
TRANSMISSION RANGE SWITCH,
CONNECTOR C2
12129804
CONN 4W M /P150
GRY
BLK
VEHICLE SPEED SENSOR BUFFER
TRANSFER CASE RELAY
0 0 (ED (H I ED o o o o
0 B 0 I* ] 11
c
c
r
1
c
c
□
12110539
CONN 5F M/P 150 12066130
BLK CONN 9F M/P 100
NAT
TRANSMISSION RANGE SWITCH, WINDSHIELD WIPER MOTOR

CONNECTOR Cl
12124634
12129840 CONN 5F M/P 280
CONN 7W M/P 150 BLK
GRY
02-12-97
4206W 0739
02-12-07
4206W 0740
LIGHTING SYSTEMS 8B-1
SECTION 8B
LIGHTING SYSTEMS
ON-VEHICLE SERVICE OF EXTERIOR LIGHTING
CARGO/STOPLAMP 6. Gasket from the roof.
REPLACEMENT -► 4- Install or Connect (Figure 1)
Pickup and Cab/Chassis Models 1. Gasket to the roof.

2. Wiring harness to the lamp assembly.
Remove or Disconnect (Figure 1) 3. Lamp assembly to the roof.
4. Lamp assem bly screws.
• M ake sure the headlam p switch is off. 5. Bulb.
6. Lens and screws.
1. Lens screws and lens.
2. Bulb. Tighten
4. Lamp assembly from the roof. • C argo/Stoplam p retaining screws to 2 .0 N-m
5. Wiring harness from the lamp assembly. (17 lb in).
(1) Screw (5) Lamp Harness Assem bly

(2) Cargo/Stoplam p Lens (6) Nut
(3) Lam p Gasket (7) Shield
(4) Bulb
Figure 1—Cargo/Stoplamp Components (Pickup and Cab/Chassis Models)
8B-2 LIGHTING SYSTEMS
CENTER HIGH-MOUNTED COMPOSITE HEADLAMP
STOPLAMP (CHMSL) BULB REPLACEMENT
REPLACEMENT
3 Remove or Disconnect (Figures 3 and 4)
Suburban and Utility Models
• M ake sure the headlamp switch is off.
Remove or Disconnect (Figure 2) 1. Bulbs from the headlamp capsules by reaching in
from the engine compartment and twisting to the
• M ake sure the headlamp switch is off. left.
1. R ear upper garnish molding at headliner.
2. L o w e r re a r of h e a d lin e r to a c c e s s e le c tric a l
C A U TIO N : H alogen bulbs contain a gas under
connector.
pressure. Handling a bulb im properly could
c a u s e it to s h a tte r into fly in g g la ss fra g
m ents. To help avoid personal injury:
• Attach a short piece of wire to the C H M S L con • Turn off the lamp switch and allow the
nector to assist guiding the harness through the bulb to cool before changing it. Leave the
body. switch off until change is complete.
4. C H M S L retaining screws. • Always wear eye protection when chang
5. C H M S L from the vehicle. ing a halogen bulb.
• Handle the bulb only by its base. Avoid
Install or Connect (Figure 2) touching the glass.
• Do not drop or scratch the bulb. Keep
1. Attach harness to guide wire. moisture away.
2. Pull lamp wire through hole in roof panel using • Place the used bulb in the new bulb’s car
guide wire. ton and dispose of it properly.
• Rem ove guide wire.
NO TICE: Avoid touching the bulb or letting
3. C H M S L to the vehicle with screws. it come in contact with anything damp. Oil
from your skin or moisture on the bulb can
Tighten cause the bulb to explode when it is turned
on. If either comes in contact with the bulb,
• C H M S L mounting screws to 2 N.m (17 lb in). clean it with alcohol or a suitable degreaser
4. Electrical connector. and wipe the bulb dry.
5. Headliner.
6. R ear upper garnish molding. 2. Two long screws from the top of the radiator sup
port (Figure 4).
• Pull the headlamp assembly forward.
3. Electrical connector from th e burned out bulb
assembly.
(1) Lamp Assembly

(2) Screw
(3) Nut
(4) Connector
Figure 2— CHM SL Replacem ent (Suburban and Figure 3— Composite Headlamp Assem bly Pin
Utility) Removal
(1) Bulb Assembly (3) Headlam p Assembly

(2) Connector (4) Screw
Figure 4— Composite Headlamp Assembly
-► 4- Install or Connect (Figures 3 and 4) repair and properly adjusted, and should be used in
accordance with the m anufacturer’s instructions. The
1. New bulb assem bly into the headlamp assembly machine using a photoelectric cell or cells to determine
and twist it clockwise. It should seat with the con aim should also include a visual screen upon which the
nector facing down. beam pattern can be projected proportional to its
• M ake sure to replace a high beam bulb with appearance and aim on a screen at 7 .62 m (25 feet).
another high beam and a low beam bulb with The screen should be easily visible to the technician
another low beam. T h e low beam bulb has a who is adjusting the headlamps, and should have hori
gray tip and a yellow gasket at its base. The zontal and vertical reference lines to permit visual
high beam bulb has a red gasket. appraisal of the headlamp beam.
2. Electrical connector to the bulb assembly.
3. Headlam p assembly.
4. Two long screws through the top of the radiator
support and tighten.
COMPOSITE HEADLAMP
ADJUSTMENT
Horizontal and vertical aim ing of each headlam p
assembly is done by two adjusting screws. The screws
are located within the radiator support, and are not easi
ly s e e n . T w o h o les in th e ra d ia to r support for each
headlamp assembly provide access to the recessed
adjusting screws (Figures 5 and 6). Turn the screws
using a T 1 5 torx head bit.
Adjust the headlamps to the specifications required by
state and/or local authorities.
There are three methods for aiming the headlamps:
Visual Headlamp Aim ing Procedure (Preferred)

All equipment for testing headlamps must comply with
the SAE Recom m ended Practice for Headlam p Inspec
tion Equipment.
If a headlamp testing machine is used, it should give (1) Adjusting Screw Location #1
results equivalent to those obtained using the screen (2) Adjusting Screw Location #2
procedure as shown in Figure 7. It should be in good
Figure 5— Adjusting the Headlamps
Headlamp Aim ing by the Screen Method
2
Location
The area should be darkened and large enough to
allow for the vehicle and an additional 7 .62 m (25 feet)
measured from the face of the headlamps to the front of
the screen. Th e floor on which the vehicle rests must be
flat with the bottom of the screen. If the floor is not
level, com pensate as necessary.
Aiming Screen
If a screen is used, it should be at least 1.52 m
(5 feet) high by 3 .66 m (12 feet) wide with a matte white
surface well shaded from extraneous light, and properly
adjusted to the floor. The screen should be moveable
so that it can be aligned parallel with the rear axle of
the vehicle. It should be positioned so that a horizontal
line drawn perpendicular to the centerline of the screen
will pass an equal distance midway between the two
headlamps (Figure 7).
Legend
The screen should be provided with a vertical center-
(1) Horizontal Adjusting Screw line, two laterally adjustable vertical tapes, and one ver
(2) Vertical Adjusting Screw tically adjustable horizontal tape.
Figure 6— Com posite Headlamps Adjusting Screws
Legend
(1) 3.66m (12 ft) (5) Vehicle Centerline
(2) Screen (6) Height to Horizontal Centerline of Lamps
(3) Low Beam Lam p Centerline (7) Reference Line
(4) Horizontal Lamp Centerline (8) 1.52m (5 ft)
Figure 7—Visual Headlamp Inspection and Adjustment
If a regular commercial aiming screen is not available, 9. Adjust the vertical tapes on the screen to match the
the screen m ay consist of a wall having a clear uninter vertical centerline of each low beam lamp. (M ea
rupted area at least 1.83 m (6 feet) high by 3.66 m sure the distance from the centerline of the vehicle
(12 feet) wide. The surface should be finished with a to the centerline of a low beam lamp).
washable no-gloss white paint. 10. Adjust the horizontal tapes on the screen to match
After the aiming screen has been set up and located, the horizontal centerline of each low beam head
paint or tape a reference line on the floor 7 .6 2 m lamp. (M easure the height from the floor to the
(25 feet) from the screen. Th e vehicle should be parked center of a low beam).
with the front of the headlamps directly over this refer 11. Turn on the low beam lamps. Observe the left and
ence line. top edges of the high intensity zone on the screen.
Adjust the headlamps so that:
Headlamp Aiming Procedure A. The top edge of the center of intensity on the
1. Park the vehicle square with the screen and with screen for the low beam is less than 101.6 mm
the headlamps directly over the reference line. (4 inches) above or below the cross section of
2. M ake sure all components are in place, if other the headlamp centerlines.
work has been done on the vehicle. B. The left edge of the center of intensity on the
3. M ake sure the vehicle is on a level surface. screen for the low beam is less than 101.6 mm
4. Stop all other work on the vehicle. (4 inches) to the left or right of the cross section
5. M ake sure the vehicle has one-half tank of fuel or of the headlam p centerlines.
less.
6. Close the vehicle’s doors. Headlamp Aiming Alternative Procedure
7. Rock the vehicle sideways. Tool Required:
8. Line up the centerline of the vehicle with the cen J 2 5 3 00 -A Headlam p Aimer
terline of the aiming screen. This can be done by • Prepare the vehicle.
marking the vertical center of the rear and front 1. M ake sure all components are in place, if other
windows with tape. Use these lines as sight lines to work has been done on the vehicle.
match the centerline of the vehicle with the screen. 2. M ake sure the vehicle is on a level surface.
Legend
(1) Retaining Ring Screw (4) Headlam p Mounting Bracket
(2) Retaining Ring (5) Headlam p Wiring Harness
(3) Headlam p
Figure 8—Sealed Beam Headlamp Components
3. Stop all other work on the vehicle.
4. M ake sure the vehicle has one-half tank of fuel or
less.
5. Close the doors.
6. Rock the vehicle sideways.
7. M ake sure headlamps are turned off.
• Using Headlam p Aim er J 25300-A , adjust the
headlam ps to the specifications required by
state and/or local authorities. Instructions for
tool use accom pany the tool. This kit contains
special adapters for use with composite lenses.
SEALED BEAM HEADLAMP

REPLACEMENT
Remove or Disconnect (Figure 8)

1. Retaining ring screws from the retaining ring.
2. Retaining ring from the headlamp.
3. Headlam p from the headlam p mounting bracket. Legend
4. Electrical connector from the headlamp. (1) Vertical Adjusting Screw
(2) Horizontal Adjusting Screw
-M - install or Connect (Figure 8)
Figure 9— Headlamp Aiming Screw s (Sealed Beam
1. Electrical connector to the headlamp. Headlamps)
2. H eadlam p to the headlamp mounting bracket.
3. Retaining ring to the headlamp.
4. Retaining ring screws to the retaining ring.
SEALED BEAM HEADLAMP

ADJUSTMENT
Tool Required:
J 2 5300-A Headlam p Aimer
Horizontal and vertical aiming of each headlamp
is done by two adjusting screws that move the
mounting bracket against the tension of the coil
spring (Figure 9). These screws are located in the
headlam p bezel area on sealed beam headlamp
models (one above and one to the side of the
headlamp).
Th e adjusting screw directly above the head
lamp is used to adjust the horizontal position while
the screw to the side is used to adjust the vertical
position of the headlamp. ,
Using Headlam p Aim er J 25300-A , adjust the
headlamps to the specifications required by state
Figure 10— Endgate Identification Lamps
and/or local authorities. Instructions for tool use
accom pany the tool. 4. Electrical connector.
T h e headlam ps can also be adjusted using the
screen method, described earlier for composite |+4-| Install or Connect (Figure 10)
h e a d la m p s . F o llo w th e s a m e d ire c tio n s and
observe the sam e tolerances for the aim of the 1. Electrical connector.
beam . 2. Lam p assem bly to the endgate.
3. Two screws.
ENDGATE LAMP REPLACEMENT 4. Lens.
E3 Rem ove o r Disconnect (Figure 10)
T h e lens, lamp, and base must be replaced as one

assembly.
• M ake sure the headlam p switch is off.
1. Lens.
2. Two screws.
3. Lam p assembly.
FOG LAMP ADJUSTMENT FOG LAMP BULB
REPLACEMENT
The fog lamps are bracket mounted to the air dam
and bumper (Figure 11). Remove or Disconnect
Before checking the aim of the fog lamps, prepare the
vehicle.
1. M ake sure all components are in place, if other C A U TIO N : H alogen bulbs contain a gas under
work has been done on the vehicle. pressure. Handling a bulb im properly could
2. M ake sure the vehicle is on a level surface. c a u s e it to s h a tte r in to fly in g g la ss fra g
3. Stop all other work on the vehicle. m ents. To help avoid personal injury:
4. M ake sure the vehicle has one-half tank of fuel or
less. • Turn off the lamp switch and allow the bulb to cool
5. Close the doors. before changing it. L ea v e the switch off until
6. Rock the vehicle sideways. change is complete.
7. M ake sure the vehicle has no load other than the • Always wear eye protection when changing a halo
driver. gen bulb.
Place a screen 7 6 0 mm (2.5 feet) in front of the • Handle the bulb only by its base. Avoid touching
vehicle. Draw a horizontal line at the sam e height as the glass.
the centerline of the lamps (Figure 12). Turn on the fog • Do not drop or scratch the bulb. Keep moisture
lamps. The top edge of the high intensity zone should away.
be 5 to 20 mm (0.2 to 0.8 inches) below the centerline • Place the used bulb in the new bulb’s carton and
of the lamps. dispose of it properly.
Th e fog lamps can be adjusted vertically by turning • M ak e sure the h eadlam p switch and fog lam p
the adjusting screw above the lens on the lamp assem switch are off.
bly. Th e lamps cannot be adjusted horizontally. 1. Two screws and the lens from the front of the lamp
Th e fog lamps can also be adjusted using the screen assembly.
method described in Composite Headlam p Adjustment 2. Bulb by twisting it to the left.
earlier in this section. T h e vehicle should be parked
7.62 m (25 feet) in front of the screen. Using tape, -M - Install or Connect
make a horizontal line on the screen at the sam e height
as the centerline of the lamps. Then turn on the fog 1. Bulb into the lamp assem bly and twist it to the
lamps. The top edge of the high intensity zone should right.
be 101.6 mm (4 inches) below the horizontal centerline 2. Lens and two screws.
of the fog lamps.
Figure 11— Fog Lamps

Legend
(1) Height at Center of Lamps Beam)
(2) R ange in Which Top Edge of High Intensity Zone
3. Parking lamp electrical connector.
is Aimed
4. Screws.
Figure 12— Fog Lamp Aiming Zone
FRONT SIDEMARKER AND
FRONT PARKING LAMP REFLECTOR REPLACEMENT
REPLACEMENT
[4—»| Remove or Disconnect (Figures 15 and 16)
Rem ove or Disconnect (Figures 13 and 14)
• M ake sure the headlamp switch is off. • M ake sure the headlam p switch is off.
1. Screws. 1. Grille. Refer to Grille Replacem ent in Sheet Metal.
2. Parking lamp assembly. 2. Nuts.
3. Electrical connector. 3. Sidem arker and/or reflector lens.
4. Bulbs from the assembly. 4. Bulb from the electrical connector.
-►4- Install or Connect (Figures 13 and 14) [■►4-| install or Connect (Figures 15 and 16)
1. Bulbs to the parking lamp assembly. 1. Bulb to the electrical connector.

2. Lam p assembly. 2. Sidem arker and/or reflector lens.
• Insert tab into grille (sealed beam only). 3. Nuts to the sidemarker.
4. Grille.
SPOTLAMP (POLICE PACKAGE)

|4"»| Remove or Disconnect (Figures 17 through 19)
1. Negative battery cable(s). Refer to Battery Discon

nect Caution in General Information.
2. Spotlamp w edge key screw.
3. Handle from outer tube shaft.
4. Collar.
5. W ire clip.
7. Bracket set screw.
8. Spotlamp and shaft by pulling out of bracket.
9. Spotlamp mounting bracket screws.
10. Mounting bracket and gasket from A pillar.
Figure 13— Parking Lamp Com ponents (Composite)

Figure 15— Sidem arker and Reflector Components

(Composite)
Figure 16— Reflector Com ponents (Sealed Beam)

9. Spotlamp w edge key screw.
■M" Install or Connect (Figures 17 through 19) 10. Negative battery cable(s).
1. Mounting bracket and gasket to A pillar. SPOTLAMP BULB

2. Mounting bracket screws.
Remove or Disconnect
Tighten
• Mounting bracket screws to 15 N-m (11 lb ft). nect Caution in General Information.
3. Spotlamp and shaft through A pillar into mounting 2. Spotlamp bezel retaining screw.
bracket. 3. Spotlamp bulb and bezel from spotlamp housing.
• Rotate spotlamp to upright position pointing for 4. Electrical connectors.
ward. 5. Spotlamp bulb from bezel.
4. Bracket set screw.
+ 4- Install or Connect
• Tighten set screw just enough to hold spotlamp
firmly in upright position.
1. Spotlamp bulb into bezel.
5. W ire clip.
6. Collar.
3. Spotlamp bulb and bezel into spotlamp housing.
4. Spotlamp bezel retaining screw.
8. Handle onto outer tube shaft.
5. Negative battery cable(s) .
(1) Bumper
SPOTLAMP TRAVEL (2) Bulb
ADJUSTMENT (3)
(4)
Lens
Lamp Wiring Harness
Adjust Figure 20— License Plate Lamp (M odels with a Step
Bumper)
1. Loosen bracket set screw.
2. Grasp the spotlamp and rotate slowly inboard until
shaft contacts parkstop.
3. Slow ly rotate spotlam p outboard to a position
5 degrees past vertical, so backstop is in motion
and outer tube shaft is forced to rotate.
4. Tighten bracket set screw enough to prevent outer
shaft tube from rotating while spotlamp is moving
between stop positions.
5. Rotate spotlamp head inboard to position parkstop
so as to prevent spotlamp from coming into contact
with body components.
6. The parkstop of shaft must be positioned so that
the spotlamp can be rotated on its axis and clear
nearest body components by 13mm to 0.5m m (0.5
inch to 0 .02 inch).
7. W hen parkstop has been set, tighten bracket set
screw to prevent spotlamp shaft from being rotated.
8. Adjust spotlamp head clamping screw to allow easy
rotation of spotlamp on shaft, but it must hold spot-
lamp in any adjusted position between parkstop
and backstop. (Total motion of spotlamp head is
approximately 90 degrees.)
Tighten
• Head clamping screw to 3 N-m (27 lb in).
LICENSE LAMP REPLACEMENT

Figure 21— License Plate Lamp (M odels without a
Step Bumper)
1. Lens from the lamp assembly or lamp from the
back of the lens assembly.
2. Bulb.
(1) Lamp Wiring Harness (1) Right Fram e Rail

(2) Lens (2) Lens Assembly
(3) License Plate Bracket (3) Lamp Wiring Harness
(4) Hitch Platform Figure 24— License Plate Lamp (Pickup without a
Figure 22— License Plate Lamp (Pickup with Bumper)
Platform Hitch)
-M - Install or Connect (Figures 20 through 24)
1. Bulb.
2. Lens to the lamp assembly or bulb and wiring to
the back of the lens assembly.
REAR FENDER MARKER LAMP

REPLACEMENT

1. Lamp assembly screws.
2. Lamp assembly from the fender.
3. Electrical connector and bulb from the lamp.
4. Bulb from the socket.
1. Bulb to the socket.

Legend 2. Electrical connector and bulb to the lamp.
3. Lamp assembly to the fender.
(1) Lens
(2) License Plate Bracket
(3) Hitch Platform
Figure 23— License Plate Lamp (Cab/Chassis with
Platform Hitch)
(1) Housing (1) Screw

(2) Nut (2) Lens
(3) Lamp Assembly (3) Housing Assembly
(4) Screw (4) Socket
(5) Bulb (5) Wiring Harness
(6) Bolt (6) Nut
(7) Nut (7) Bulb
Figure 25— Rear Fender Marker Lamps with Dual Figure 26— Roof Marker Lamp
Rear W heels
ROOF MARKER LAMP

REPLACEMENT
1. Lens screws.
2. Lens.
3. Insulator.
4. Bulb.
1. Bulb.
2. Insulator.
3. Lens.
4. Lens screws.
TAIL/STOP/TURNLAMP
REPLACEMENT Figure 27—-Cab/Chassis Tail/Stop/Turnlamps
Cab/Chassis Install or Connect (Figure 27)
Rem ove or Disconnect (Figure 27) 1. Lamp assembly to the bracket.

2. Nuts.
1. Lamp electrical connector from lamp assembly. 3. Electrical connector to the lamp assembly.
2. Nuts from the back of the bracket. 4. Bulb.
3. Lamp assem bly from the bracket. 5. Gasket, lens and four screws.
4. Four lens screws, lens and gasket.
5. Bulb.
Pickup, Suburban, and Utility Models

• Lower the endgate.
1. Two screws retaining the tail/stop/turnlamp assem
bly to the body.
2. Rotate tail/stop/turnlamp assembly from the vehicle.
3. Electrical connector from the assembly.
4. Bulbs from the lamp base.
• The top bulb is a parking lamp.
• The center bulb is a parking, brake, and turn
indicator lamp.
• The lower bulb is a backup lamp.
• Rem ove a bulb by pulling it straight out by the
tabs on the base of the bulb.
-►4- Install or Connect (Figure 28)
1. Bulbs to the lamp assembly. Figure 28— 'Tail/Stop/Turnlamp Assem bly

• Push each bulb straight in.
2. Lamp base to the lens assembly with two screws.
4. Tail/stop/turnlamp assem bly to the vehicle with two
screws.
UNDERHOOD STATIONARY
LAMP REPLACEMENT

2. In-line electrical connector.
3. Screws.
4. Underhood stationary lamp from the hood.
+ 4- Install or Connect (Figure 29)
1. Underhood stationary lamp to the hood.

2. Screws. Figure 29— Underhood Stationary Lamp
3. In-line electrical connector.
4. Negative battery cable(s).
ON-VEHICLE SERVICE OF INTERIOR LIGHTING AND

SWITCHES
ASHTRAY LAMP REPLACEMENT 5. Shield from the lamp assembly.
6. Bulb from the base by pulling it straight out.
Remove or Disconnect (Figure 30) -►4- lnstall or Connect (Figure 30)

1. Bulb into the base by pushing it straight in.
1. Knee bolster. Refer to Instrument Panel and Gaug
2. Shield to the lamp assembly.
es.
3. Lamp assem bly and shield to the top of the ashtray
bracket.
• Squeeze sides together and pull out.
4. Ashtray assembly to the instrument panel.
3. Ashtray assembly by unsnapping retainers.
4. Lamp assembly and shield from the top of the ash
6. Knee bolster.
tray bracket.
ACCESSORY/DOME LAMP AND 2. Electrical connectors.

3. Bezel to the instrument panel.
HATCH RELEASE SWITCH 4. Negative battery cable(s).
REPLACEMENT
DAYTIME RUNNING LAMPS
0 Rem ove or Disconnect (Figures 31 and 32)
(DRL) MODULE AND RELAY
1. N egative battery cable(s). Refer to Battery Discon REPLACEMENT
2. Instrument cluster bezel. Refer to Instrument Clus DRL Module
ter Replacem ent in Instrument Panel and Gauges. Th e D R L module consists of a circuit board in a black
3. Electrical connectors. aluminum case with fins. T h e module breaks out of the
4. Switch from the bezel. instrument panel harness behind the left side of the
• S q u eeze the tangs together at the sides of the instrument panel.
switch to remove it.
|+ + | Remove or Disconnect (Figure 33)
-► 4- Install or Connect (Figures 31 and 32)
• M ake sure the ignition switch and headlam p switch
1. Switch into the bezel by squeezing the tangs at the es are off.
side of the switch and pressing it in to the front of I . K n e e bolster. R e fe r to In stru m e n t P a n e l and
the bezel. Gauges.
Figure 31—Cargo/Dome Lamp Switch Figure 33— DRL Module

2. DRL module from bracket. DRL Relay
4. Module from the vehicle. Remove or Disconnect (Figure 34)
Install or Connect (Figure 33) 1. Negative battery cable(s). Refer to Battery Discon
1. Module to the vehicle. 2. Relay from the convenience center.
3. Knee bolster. Install or Connect (Figure 34)
1. Relay to the convenience center.

DOME LAMP REPLACEMENT
Remove or Disconnect (Figures 35 and 36)

2. Lens.
3. Bulb.
4. Housing screws.
5. Housing assembly or lamp assembly.
7. Bezel.
1. Bezel.
3. Housing assembly or lamp assembly.
4. Housing screws.
5. Bulb.
6. Lens.
(1) Harness Assembly

(2) Bulb
(3) Bezel
(4) Lam p Assembly
(5) Lens Figure 36— Dome/Reading Lamp Replacement
(6) Screw (Utility/Suburban Only)
Figure 35— Dome Lamp Replacement
DOOR JAMB SWITCH
REPLACEMENT
Rem ove or Disconnect (Figure 37)

• Reach up under the instrument panel, squeeze
the switch tangs together, and push the switch
through the side of the instrument panel.
2. Door jam b switch electrical connector.
3. Door jam b switch.
1. Door jam b switch to the electrical connector.

• S q u eeze the switch tangs together, and push
the switch into the side of the instrument panel.
2. N egative battery cable(s).
LIFTGATE JAMB SWITCH Instrum ent Panel

REPLACEMENT
1. N egative battery cable(s). Refer to Battery Discon

2. Switch from vehicle by unthreading.
2. Switch to vehicle.
3. N egative battery cable(s).
SELECTABLE FOUR-WHEEL
DRIVE INDICATOR LAMP
REPLACEMENT
t il Rem ove or Disconnect (Figure 39)

1. Shift lever knob by unscrewing it.
2. Four bezel screws.
3. Transfer case bezel.
4. Bulbs from the sockets by pulling them straight out.
0 Install or Connect (Figure 39)
1. Bulbs into the sockets by pushing them straight in.

2. Bulbs and sockets into the back of the bezel.
3. Bezel to the floor with four screws.
4. Shift lever knob.
Figure 39— Selectable Four-W heel Drive Indicator Lamps
HEADLAMP SWITCH 3. Electrical connectors.

4. Switch by unsnapping.
REPLACEMENT
•+| Remove or Disconnect (Figure 40)
1. H eadlam p switch and/or panel dimmer switch to
1. Negative battery cable(s). Refer to Battery Discon bezel.
nect Caution in General Information. 2. Electrical connectors.
2. Instrument cluster bezel. Refer to Instrument Clus 3. Bezel to the instrument panel.
ter Replacement in Instrument Panel and Gauges. 4. Negative battery cable(s).
EMERGENCY ROOF LAMP

SWITCH (IF EQUIPPED)
1. Negative battery cable(s). R efer to Battery Discon

2. Knee bolster. Refer to Knee Bolster Replacem ent
in Instrument Panel and Gauges.
4. Retainer from rear of faceplate.
5. Switch from faceplate.
Figure 40—Headlamp Switch

Figure 41— Em ergency Roof Lamp Switch Figure 43— Instrument Panel Storage Compartment
Lamp
INSTRUMENT PANEL STORAGE

COMPARTMENT LAMP AND
SWITCH REPLACEMENT

2. Depress switch plunger, and pull switch assembly
downward from the retainer.
4. Shield from switch assembly.
5. Bulb from switch assembly.
+◄ - Install or Connect (Figure 43)
1. Bulb into the socket.

2. Shield to switch assembly.
(1) Switch Assem bly 4. Depress switch plunger and slide the assem bly
(2) Bezel upward into the retainer.
(3) Retainer 5. Instrument panel storage compartment.
(4) Connector
Figure 42— Em ergency Roof Lamp Switch OVERHEAD CONSOLE LAMP
(Continued) REPLACEMENT
a Remove or Disconnect (Figure 44)
1. Switch to faceplate.
2. Retainer.
• Align indexing tab on nut to tab on switch, and
2. Lamp assembly.
slide nut to faceplate until it snaps into position.
A. Push upward against the reading lamp assem
bly and turn it counterclockwise.
4. Knee bolster.
B. Lower the assembly from the console.
3. Bulb and base from the back of the assembly.
4. Bulb from the base by pulling it straight out.
Install or Connect (Figure 44) Remove or Disconnect (Figure 45)
1. Bulb into the base by pushing it straight in. • Lift the cover on the vanity mirror.
2. Bulb and base into the lens and socket assembly. 1. Lamp lens by prying it out.
3. Lamp assembly into the console by pushing it in 2. Lamp bulb by gently prying it out.
and turning it clockwise.
4. Negative battery cable(s). Install or Connect (Figure 45)
SUNSHADE VANITY MIRROR 1. Lamp bulb by pressing it in.

LAMP REPLACEMENT 2 - Lamp ,ens by snapping in.
Th e vanity mirror assembly is an integral part of the

sunshade. If it is dam aged, the sunshade assembly
must be replaced. Only the bulbs can be replaced sepa
rately.
SPECIFICATIONS
Bulb Specifications
Power Rating
Trade at 12.8V, Quantity
Lamp or Bulb No. Watts Pickup Crew Cab Utility | Suburban
Exterior Lights:
Headlamps: 2 Headlam p System H 6054 35/65 2 2 2 2
Headlamps: 4 Headlam p System (Composite) 9006 55 2 2 2 2
Candle Power
Fog Lamp H3 115 2 — — —
Front Marker Lamp 194 2 2 2 2 2
Front Park and Turn Lamp 2357N A 30/2 4 4 4 4
Rear Parking Lamp 3057 32-2 2 2 2 2
Rear Stop and Turn Lamp 3057 32-2 2 2 2 2
Backup Lamp 3156 32 2 2 2 2
Backup Lamp (Cab/Chassis Only) 1156 32 2 2 — —
R ear Park, Stop, and Turn Lamp (Cab/Chassis
Only) 1157 32-3 2 2 — —
Fender Clearance Lamp 194 2 4 4 — —
Roof M arker Lamp 194 2 5 5 — 5
C H M S L Bulb 921 32 1 1 — —
License Plate Lamp 194 2 2 2 2 2
Underhood Lamp 93 15 1 1 1 1
Reel Lamp 232 10 1 1 1 1
Interior Lights:
Dome Lamps 211-2 12 1 2 2 2
Reading Lamps 211-2 12 2 4 4 4
Roof Console Lamps 168 3 — 2 2 2
Courtesy Lamp 1003 15 2 2 2 2
Heater or A /C Control Lamp 194 2 1 1 1 1
Four W heel Drive Indicator 161 1 1 1 1 1
Four W heel Drive Shift Lever 194 1 1 1 1 1
Instrument Panel Compartment Lamp 194 2 1 1 1 1
Ashtray Lamp 194 2 1 1 1 1
Sunshade Vanity Mirror 74 0.7 — 4 4 4
Instrument Panel Lights
Transmission Indicator (PRNDL) 161 1 1 1 1 1
Daytime Running Lights Indicator! 74 .7 1 1 1 1
Charging System Indicator Lamp 74 .7 1 1 1 1
Instrument Cluster G age 194 .2 4 4 4 4
Illuminating Lamps W. Tach 194 .2 6 6 6 6
Headlam p Beam Indicator 74 .7 1 1 1 1
Directional Signal Indicator 74 .7 2 2 2 2
Brake Warning Indicator 74 .7 1 1 1 1
Safety Belt Warning 74 .7 1 1 1 1
Check G ages Indicator 74 .7 1 1 1 1
Malfunction Indicator (“Service Engine Soon”) 74 .7 1 1 1 1
Malfunction Indicator (“Service Throttle Soon”) 74 .7 1 1 1 1
Upshift Indicator 74 .7 1 1 1 —
ABS Warning Indicator 74 .7 — — 1 1
W ait Lamp* 74 .7 1 1 — —
Low Coolant Lamp* 74 .7 1 1 — —
Service Fuel Filter Lamp* 74 .7 1 1 — —
‘Diesel only TCanadian Vehicles only T2857

Application N-m Lb ft Lb in
Cargo/Stoplamp Mounting Screws 2 — 17
C H M S L Mounting Screws 2 — 17
Head Clamping Screw 3 — 27
Mounting Bracket Screws 15 11 —
SPECIAL TOOLS
F9468
BLA N K
INSTRUMENT PANEL AND GAUGES 8C-1
SECTION 8C
INSTRUMENT PANEL AND GAUGES

GENERAL DESCRIPTION
ELECTROSTATIC DISCHARGE INSTRUMENT CLUSTER
(ESD) NOTICE T h e instrum ent cluster contains a high-torque type
electric speedometer. The electro-mechanical gauges
M any solid state electrical components can be dam are individually plugged into socket-type metal connec
aged by Electrostatic Discharge (ESD ). Som e will dis tors in the cluster case.
play a label but many will not (Figure 1).
INSTRUMENT PANEL HARNESS

NOTICE: In order to avoid possibly damag This harness is located along the upper back edge of
ing any components, observe the following: the instrument panel. It starts from the convenience
1. Body movement produces an electrostatic
center, which is located at the left side of the instrument
charge. To discharge personal static elec panel, and goes up the left side of the instrument
tricity, touch a ground point (metal) on the p a n e l, th e n a c ro s s to th e right s id e of th e cab
vehicle. This should be done any time you:
(Figures 5 through 8).
• Slide across the car seat. As the harness is routed across the instrument panel,
• Sit down or get up.
various circuits branch off to the switches, indicators,
• Do any walking.
and cluster. The harness is held in place with bendable
2. Do not touch exposed terminals on com
clips.
ponents with your finger or any tools.
Other harnesses are carried along the sam e supports.
Remember, the connector that you are
These harnesses consist of wiring for the power door
checking might be tied Into a circuit that
locks, power windows, radio, heater, and air condition
could be damaged by Electrostatic Dis
ing (Figures 5 through 8).
charge.
3. When using a screwdriver or similar tool
to disconnect a connector, never let the HEATER AND AIR
tool come In contact with or come between CONDITIONING HARNESS
the exposed terminals.
4. Never Jump, ground, or use test equipment The harness begins at the convenience center and
probes on any components or connectors branches up to the heater and air conditioning control
unless specified In diagnosis. When using unit (Figure 5). It then branches to the blower motor and
test equipment, always connect the ground relays. Refer to Heater, Ventilation, and Air Conditioning
lead first. for further information.
5. Do not remove the solid state component
from Its protective packaging until you are
ready to Install the part.
6. Always touch the solid state components
package to a ground before opening. Solid
N O TIC E
state components can also be damaged If:
• They are bumped or dropped.
• They are laid on any metal work bench
es or components that operate electri
c a l l y , s u c h a s a TV, r a d i o , o r
oscilloscope.
INSTRUMENT PANEL
T h e instrument panel is designed to permit the remov CO NTENTS SENSITIVE
al of all control switches from the driver’s side. The TO
standard instrument cluster is equipped with gauges
STATIC ELECTRICITY chhooioa
(Figures 2 and 3).
Figure 1— Electro-Static Discharge Label

8C-2 INSTRUMENT PANEL AND GAUGES
Figure 2— Instrument Cluster with Tachometer (Gasoline Models)
Figure 3— Instrum ent Cluster with Tachometer (Diesel Models)

Figure A— Instrument Cluster with Tachometer (Police Package)
SEAT BELT ALARM FUSE BLOCK AND

Th is system activates a w arning lam p for about CONVENIENCE CENTER
75 seconds and a buzzer for about 8 seconds when the
The instrument panel fuse block is located behind a
ignition switch is turned to the RUN position and the
pull cover on the left end of the instrument panel.
driver's seat belt is not buckled. The warning lamp will
This fuse block contains fuses and circuit breakers for
be constant for the first 20 seconds, then flash for the
individual circuits within the vehicle (Figure 13).
remaining 55 seconds. The buzzer only turns on, and
The underhood fuse/relay center (Figure 14) contains
will stay on when the drivers seat belt is not fastened
both minifuses® and m axifuses®, as well as some
during the 8 second period. The warning lamp and
relays for the vehicle. Refer to Engine Controls, Trans
buzzer sequence of operation is as follows:
mission Diagnosis and Electrical Diagnosis Manual for
1. D R IV E R ’S SEAT BELT U N FA S TE N E D - Turn information on individual circuit routing.
the ignition switch to the RUN position. The Th e convenience center is located just below the
warning lamp illuminates constantly for 20 sec instrument panel on the driver’s side. It contains individ
onds, then flashes for the remaining 55 sec ual relays such as the seat belt and ignition key alarm,
onds. The buzzer turns on and stays on for and flasher (Figure 15).
8 seconds, then turns off. If the driver’s seat
belt buckle is fastened before the 8 seconds is ENGINE CONTROL SWITCH
over, the buzzer will turn off and the lamp will
remain on for the balance of the time delay.
(IG NITIO N SWITCH)
2. D R IV E R ’S SEAT BELT FA STEN ED - Turn the The ignition switch is located on the steering column’s
ignition switch to the RUN position. The warning right side, just below the steering wheel. The electrical
lamp will turn on and the buzzer stays off. At switching portion of the assembly is separate from the
the end of 75 seconds the warning lamp turns key and lock cylinder. However, both are synchronized
off. If the driver’s seat belt buckle is unfastened and work in conjunction with each other through the
prior to 8 seconds, the buzzer will turn on for actuator rod assembly.
the balance of the 8 second delay. For a complete description of the key, lock cylinder,
and actuator rod assembly, refer to Steering Column
Unit Repair.
8 0 -4 INSTRUMENT PANEL AND GAUGES
Legend
(1) Instrument Cluster Connector (8) Forward Lamp Harness
(2) Headlam p Switch Connector (9) Forward lamp Connector (SIR Content)
(3) Door Switch Connector (10) Transfer Case Connector
(4) Courtesy Lamp (11) Rear Lamp Harness Connector
(5) D R L Module (12) W S W Connector
(6) Parking Lamp Switch (13) Cruise Control Connector
(7) Convenience Center (14) Clutch Switch Connector
Figure 5— Instrument Panel Harness (Left Side)
ELECTRIC SPEEDOMETER VEHICLE SPEED SENSOR

T h e electric speedom eter drive replaces the mechani CALIBRATOR MODULE
cal drive for all C /K applications. Integrated circuits con
The Vehicle Speed Sensor (VSS) calibrator module is
trol th e a ir core s p e e d o m e te r and s te p p e r motor
a solid-state device that is used to change the signal
odometer. Th e speedom eter and odometer receive a
from the speed sensor to a digital signal. The V S S
signal from the vehicle speed sensor calibrator module
calibrator module will change the signal from the speed
that is generated by the vehicle speed sensor. For diag
sensor to a signal containing 4 00 0 Pulses Per Mile
nostic information, refer to Engine Controls, Transmis
(PPM ) for the instrument cluster. The vehicle speed
sion Diagnosis, and Electrical Diagnosis Manual.
sensor calibrator module is matched to the final drive
and tire size of each vehicle. It must be replaced with
VEHICLE SPEED SENSOR the proper module to match the final drive and tire size
of that vehicle. If the final drive or tire size is changed
T h e Vehicle Speed Sensor (V S S ) is a perm anent
for any reason, the module must also be changed to
m agnet signal generator located on the transmission or
continue to produce an accurate speedometer/odometer
transfer case output shaft housing. The vehicle speed
reading. T h e incorrect m odule will also affect the
sensor sends an analog signal proportional to the pro
anti-lock brakes, Vehicle Control Module (V C M ), and the
peller shaft speed. This signal goes to the vehicle
cruise control module. For diagnostic information, refer
speed sensor calibrator module. For diagnostic informa
to Engine Controls, Transmission Diagnosis, and Elec
tion, refer to Engine Controls, Transmission Diagnosis,
trical Diagnosis Manual.
and Electrical Diagnosis Manual.
(1) Instrument Panel Harness Connector (4) Stoplamp Switch

(2) Steering Column Harness (5) Stoplamp Switch Connector
(3) Instrument Panel Harness
Figure 6— Instrument Panel Harness (Steering Column Support)
FUEL GAUGE CHECK GAUGES LAMP

Th e fuel gauge is an electrical instrument that m ea This indicator lamp is standard on all vehicles. This
sures an electrical current from a variable resistor in the lamp comes on when the engine coolant temperature is
fuel tan k. T h e v a ria b le re sis tan c e is controlled by a too high or the engine oil pressure is too low. If this
float. W hen the fuel tank is full, the resistance is high. lamp should come on, check the gauges and refer to
The fuel gauge pointer is moved to its maximum posi Coolant Temperature G auge Diagnosis and Oil Pressure
tion, which is FULL on the gauge face. For diagnostic G au ge Diagnosis in Engine Controls, Transmission
information, refer to Engine Controls, Transmission Diagnosis, and Electrical Diagnosis Manual.
Diagnosis, and Electrical Diagnosis Manual.
Fuel Gauge Sender

COOLAMT TEMPERATURE
GAUGE
The fuel gauge sender is attached to the top of the
fuel tank. The sender is retained with a cam lock ring. A The coolant temperature gauge is an electrical gauge
seal is used between the tank and sender. which measures current from a water temperature send
The sender will have two or three pipes attached to er in the cylinder head. The sender is located in the
hoses. O ne pipe is for the fuel feed line. The second is middle of the cylinder head on the driver’s side for the
connected to the vapor canister. T h e third pipe is used 4.3, 5.0, 5.7, and the 7 .4 liter engines. Th e 6.5 liter
as a fuel return line to the fuel tank. On some senders, diesel has the coolant temperature sender at the front of
a short pigtail connector lead is used, while on others, the cylinder head. Refer to Figures 30, 32 and 34. For
the connector attaches directly to the sender. For diag diagnostic information, refer to Engine Controls, Trans
nostic information, refer to Engine Controls, Transmis mission Diagnosis, and Electrical Diagnosis Manual.
sion Diagnosis, and Electrical Diagnosis Manual.
VOLTMETER
The voltmeter measures the voltage level of the elec
trical system. The voltmeter uses an internal shunt. For
diagnostic information, refer to Engine Controls, Trans
mission Diagnosis, and Electrical Diagnosis Manual.
CHARGING SYSTEM WARNING

SYSTEM
The charging system warning system consists of an
indicator lamp with one side of the bulb connected to
the generator and the other side to the ignition. Refer to
Charging Systems in Engine Electrical.
MALFUNCTION INDICATOR
LAMP (MIL)
The Malfunction Indicator Lamp (MIL), appearing as
the Service Engine Soon warning on the instrument
cluster, is part of the computerized engine control sys
tem. Refer to the Engine Controls, Transmission Diag
(1) Steering Column Connector nosis, and Electrical Diagnosis Manual.
(2) Instrument Panel Harness Support Bracket
(3) Inflatable Restraint IP Module Connector BRAKE WARNING SYSTEM
(4) D S IR Connector The brake warning system consists of a differential
(5) Instrument Panel Harness switch which is mounted on the brake combination
Figure 7— Instrument Panel Harness valve, and the indicator lamp which is mounted in the
(DSIR/Inflatable Restraint IP Module Service instrument cluster. Refer to Brakes for more information.
Disconnect)
ELECTRONIC PRNDL
LOW COOLANT LAMP Vehicles with automatic transmissions have an elec
tronic PR N D L. The system utilizes signals from the
This indicator lamp comes on when a low coolant Neutral Safety Back Up (NSB U) switch on the side of
condition exists. The warning lamp is controlled by a the transmission. Signals from this switch determine
low coolant module. Refer to Engine Controls, Trans which LED ’s in the electronic PR N D L will light. Since
mission Diagnosis, and Electrical Diagnosis Manual for the system is entirely electronic, there is no adjustment.
diagnostic information. For diagnostic information, refer to Engine Controls,
T ra n s m is s io n D ia g n o s is , and E le c tric a l D ia g n o s is
OIL PRESSURE GAUGE Manual.
The oil pressure gauge is an electrical gauge which

m easures current from an oil pressure sender in the
engine block. Th e oil pressure sender is located at the
rear of the engine block on the drivers side for the 4.3,
5.0, 5.7, and the 7.4 liter engines. It is located in the
middle of the intake manifold on the 6.5 liter engine.
Refer to Figures 28 through 33. For diagnostic informa
tion, refer to Engine Controls, Transmission Diagnosis,
and Electrical Diagnosis Manual.
Legend
(1) Radio (7) Fog Lamp Switch
(2) Radio Connector (8) Electrical Accelerator Connector
(3) R ear W iper Switch (9) Ashtray Lamp Connector
(4) R ear Cargo Lamp Switch (10) Auxiliary Power Connector
(5) Inflatable Restraint IP Module Switch (11) Cigarette Lighter Connector
(6) E S T C Switch (12) Auxiliary Power Connector
Figure 8— Instrument Panel Harness (Center)
ON-VEHICLE SERVICE
ELECTROSTATIC DISCHARGE
(ESD) NOTICE
M any solid state electrical components can be dam
aged by electrostatic discharge (ESD ). Som e will dis
play a label but many will not (Figure 1).
Legend
(1) Inflatable Restraint IP Module (4) Cross Body Harness Connector
(2) Engine Harness (5) Instrument Panel Compartment Lamp Wiring
(3) Courtesy Lamp (6) Door Jamb Switch
Figure 9—Instrument Panel Harness (Right Side Diesel)
Legend
(1) Inflatable Restraint IP Module (5) Engine Harness
(2) Inflatable Restraint IP Module Connector (6) Cross Body Harness Connector
(3) Inflatable Restraint IP Module Bracket (7) Door Jamb Switch
(4) HVAC Harness Connector
Figure 10— Instrument Panel Harness (Right Side Gasoline)
Legend
(1) P S IR M odule Assembly (5) Engine Harness
(2) P S IR Module Connector (6) Cross Body Harness Connector
(3) P S IR Bracket (7) Door Jam Switch
(4) HVAC Connector
Figure 11—Instrument Panel Wiring (Right Side)
Figure 12—Alarm Module Figure 13—Instrument Panel Fuse Block

Figure 14— Underhood Fuse/Relay Center

NOTICE: In order to avoid possibly damag
ing any components, observe the following:
1. Body movement produces an electrostatic
charge. To discharge personal static elec
tricity, touch a ground point (metal) on the
vehicle. This should be done any time you:
• Slide across the car seat
• Do any walking.
2. Do not touch exposed terminals on com
ponents with your finger or any tools.
Remember, the connector that you are
checking might be tied Into a circuit that
could be damaged by Electrostatic Dis
charge.
3. When using a screwdriver or similar tool
to disconnect a connector, never let the
tool come In contact with or come between
the exposed terminals.
4. Never Jump, ground, or use test equipment
probes on any components or connectors Figure 16— Instrument Cluster Bezel
unless specified In diagnosis. When using
test equipment, always connect the ground
lead first.
INSTRUMENT CLUSTER
5. Do not remove the solid state component REPLACEMENT
from Its protective packaging until you are
ready to Install the p art
6. Always touch the solid state components |<-+| Remove or Disconnect (Figures 16 and 17)
package to a ground before opening. Solid
state components can also be damaged If: 1. Negative battery cable. Refer to Battery Disconnect
• They are bumped or dropped. Caution in General Information.
• They are laid on any metal work bench 2. Instrument cluster bezel. Th e bezel is retained by
es or components that operate electri
four clips across the top edge and four clips across
c a l l y , s u c h a s a TV, r a d i o , o r
the bottom edge.
oscilloscope.
• On vehicles equipped with tilt wheel, move to
the lowest position. O n vehicles without tilt
wheel it may be necessary to lower the column.
INSTRUMENT PANEL FUSE
BLOCK REPLACEMENT

2. Fuse block cover. The cover is on the left end of
the instrument panel.
3. Fuse block.
A. Screw at bottom of fuse block.

B. Push fuse block in at the bottom. It will pivot
clear of two mounting tabs at the top of the fuse
block. Push the fuse block back and away from
the instrument panel.
C. Mark the fuse block and the wire locations for
reassembly.
4. W ires from the fuse block.

Figure 17— Instrum ent Cluster Replacement 5. Fuse block from the vehicle.
3. Electrical connections for headlamp switch, dimmer 6. Fuses from the block.
control and accessory switches.
4. Four screws retaining instrument cluster. I-H -I Install or Connect (Figure 13)
5. Instrument cluster from vehicle.
1. Fuses to the block.
• Keep fingers and other foreign objects away
2. Fuse block to the vehicle.
from the flexible circuit connections.
3. Wires to the fuse block in their original locations.
4. Fuse block to the instrument panel.
A. Place the two tabs at the top of the fuse block
1. Press instrument cluster into instrument panel. onto the tabs of the instrument panel.
2. Instrument cluster hold-down screws. B. Push the bottom of the fuse block into place
3. Electrical connections for headlamps, dimmer con from behind the block. Align the screw hole and
trol and accessory switches. attach the retaining screw.
4. Instrument cluster bezel.
5. Fuse block cover to the instrument panel.
INSTRUMENT CLUSTER BULB

REPLACEMENT
1. Instrum ent cluster. R efer to Instrum ent Cluster

Replacem ent in this section.
2. Bulb and base assembly by turning 1/2 turn to the
left. Refer to Lighting Systems for bulb identifica
tion.
+«• Install or Connect (Figures 16 and 17)
1. Bulbs to the cluster by inserting the socket and

bulb assembly into the cluster and twisting to the
right.
2. Instrument cluster.
TRANSMISSION INDICATOR
(PRNDL) REPLACEMENT (1) Bracket
T h e electronic P R N D L is serviced as part of the (2) Harness
instrument cluster assembly. Refer to Instrument Cluster (3) Cover
Replacem ent in this section. Figure 18—12 Volt Power Supply
CONVENIENCE CENTER
REPLACEMENT

2. Wiring connectors at the front of the convenience
center.
• Label the wires for reassembly.
3. Convenience center from the bulkhead connector.
• Disengage the tabs at the upper left and lower

right posts. Th e tabs clip into the bulkhead con
nector, and separate the bulkhead connector
from the convenience center.
4. Wiring connectors from the rear of the convenience

center.
• Label the connectors for reassembly. Figure 19—Ashtray
5. Convenience center from the vehicle.

CUPHOLDER REPLACEMENT
1. Convenience center to the vehicle.
2. Wiring connectors to the rear of the convenience 1. Slide cupholder out.
center in their original locations. 2. R em o v e knee bolster. R e fe r to K n ee Boltster
3. Convenience center to the bulkhead connector. Replacement in Interior Trim.
• Engage the post tabs of the convenience center 3. Rem ove cupholder retainer from underneath by
to the bulkhead connector. twisting retainer to the left.
4. Remove cupholder.
4. Wiring connectors to the front of the convenience
center in their original locations. +◄ - Install or Connect (Figure 20)
1. Slide cupholder onto m etal track in instrument
12-VOLT POWER SUPPLY panel.
2. Install cupholder retainer from underneath by twist
Remove or Disconnect ing retainer to the right.
3. Slide cupholder in and check for alignment.
1. Remove front cover. 4. Install knee bolster.
2. Remove power supply from instrument panel.
3. Rem ove electrical connector.
-►4- Install or Connect
1. Install electrical connector.

2. install into instrument panel.
3. Install front cover.
ASHTRAY REPLACEMENT
1. Rem ove electrical connectors.

2. Rem ove ashtray retainer inserts from underneath.
3. Rem ove ashtray from instrument panel.
■ M- Install or Connect (Figure 19)
1. Install ashtray up to instrument panel.

2. Install ashtray retainer.
3. Install electrical connectors. Figure 20—Cupholder
Figure 21— IP Pivot Bolts
ROLLING INSTRUMENT PANEL INSTRUMENT PANEL

COMPARTMENT ASSEMBLY
1. Rem ove left and right lower instrument panel pivot
bolts (Figure 21).
1. Roll instrument panel. Refer to Rolling Instrument
2. C enter support screw (Figure 22).
Panel in this section.
3. Pivot instrument panel.
2. Rem ove four nuts retaining the instrument panel
compartment assembly to the carrier.
|-H -| Install or Connect (Figures 21 and 22) 3. Rem ove instrument panel compartment from instru
ment panel.
1. Pivot instrument panel forward.
2. Install center support screw (Figure 22).
3. Install left and right lower instrument panel pivot
bolts (Figure 21).
(Vehicles over 8600 GVW)

INFLATABLE RESTRAINT IP
MODULE REPLACEMENT
• Disable the SIR system, refer to Disabling the SIR

System in Restraints.
1. Roll forward the instrument panel, refer to Rolling
Instrument Panel in this section.
2. The fasteners attaching the inflatable restraint IP
module to the mounting bracket.
3. The inflatable restraint IP module from the front of
the instrument panel, taking care to keep a firm
hold of the module.
4. The yellow 2-w ay electrical harness connector at
the left side of the mounting bracket.
5. The Connector Position Assurance (CPA) from the
yellow 2-w ay electrical harness connector.
6. The inflatable restraint IP module yellow pigtail con
Figure 24— Inflatable Restraint IP Module Mounting nector from the yellow 2-w ay electrical harness
Bracket connector.
7. The inflatable restraint IP module from the instru
ment panel.
CAUTION: W hen you are carrying an unde

ployed inflator m odule:
• Do not carry the inflator module by the
wires or connector on the inflator module.
from you.
W hen you are storing an undeployed inflator
m odule, m ake sure the bag opening points
aw ay from the surface on w hich the inflator
m odule rests. W hen you are storing a steer
ing colum n, do not rest th e colum n with the
bag opening facin g dow n and the colum n
vertical. Provide free space for the air bag to
expand in case of an accidental deploym ent.
O therw ise, personal injury m ay result.
-► <- Install or Connect
1. The inflatable restraint IP module yellow pigtail con

(1) Fastener nector to the yellow 2 -w a y elec trical harness
(2) Instrument Panel connector.
(3) Inflatable Restraint IP Module 2. The Connector Position Assurance (CPA).
(4) Inflatable Restraint IP Module yellow 2-w ay 3. The yellow 2-w ay electrical harness connector to
connector the mounting on the left side of the mounting
(5) Bolt bracket.
4. The two new retainer J-clips to the mounting brack
(6) Retainer Clip
et.
Figure 25— Inflatable Restraint IP Module 5. The inflatable restraint IP module to the mounting
(Vehicles up to 8600 GVW) bracket through the front of the instrument panel,
using the two retainer J-clips to hold the inflatable
Install or Connect (Figure 23) restraint IP module in position.
6. The fasteners to the inflatable restraint IP module.
1. Install instrument panel compartment into instru
ment panel. Tighten
2. Install four nuts to retain instrument panel compart
ment assembly to the carrier. • The fasteners to 10 N.m (89 lb in).
3. Roll instrument panel back into place and secure. 7. Roll forward the instrument panel.
Refer to Rolling Instrument Panel in this section. • Enable the SIR system, refer to Enabling the SIR
INSTRUMENT PANEL 5. Coolant reservoir tank.
6. Antenna lead-in and grommet.
ASSEMBLY REPLACEMENT 7. Knee bolster. Refer to Knee Bolster Replacement
in Interior Trim.
Remove or Disconnect 8. Steering shaft pinch bolt.
(Figures 16 through 29) 9. Left and right sill plate front screw.
10. Left and right hinge pillar trim panels (Figure 28).
11. Brake release handle from the cable.
• Clip releases handle from cable.
2. Disable SIR system. Refer to Disabling the SIR
12. Reaction plate assembly.
13. Tie bar.
3. Three relay center bolts from underside of wheel
14. 8-w ay column connector.
opening.
15. 48-w ay connector retainer to access two lower col
4. Bulkhead connector.
umn nuts.
• Two screws retaining convenience center to
16. Shift cable (automatic transmission).
cowl.
17. Steering column from the vehicle.
• Cruise control harness (if equipped).
18. Shift levers.
• Forward lamp harness.
A. Transfer case knob by pulling straight up.
• R ear lamp harness.
• F o u r w h e e l d riv e m o d e ls m u s t b e in
• S IR system harness.
4-LO range.
• Relay center.
B. Manual transmission (if equipped).
19. Left and right lower IP pivot bolts (Figure 21).
Figure 26— IP Auxiliary Storage Compartments Figure 28— Hinge Pillar Trim Panel
Figure 27—IP Storage Compartment Figure 29—Instrument Cluster Trim

20. IP storage compartment door. 29. Park brake cable clip.
21. IP storage compartment (Figure 27). 30. Both air outlet deflectors.
• S queeze compartment to release. 31. Inflatable Restraint IP Module mounting bracket
22. IP attaching bolts through storage com partment (Figure 24).
door. 32. IP storage compartment door check strap.
23. Center support screw (Figure 22). 33. IP storage compartment door striker.
24. Three upper IP support screws.
25. IP from the cowl. Install or Connect (Figures 16 through 29)
26. Park brake release cable.
27. Electrical connectors (as necessary). 1. IP storage compartment door striker.
. SDM 2. IP storage compartment door check strap.
. HVAC 3. Inflatable Restraint IP M odule mounting bracket
• 22-w ay engine harness (Figure 24).
• Stoplamp switch 4. Both air outlet deflectors.
• V S S calibrator module 5. Parking brake cable.
• Clutch or Brake release switches 6. Side window defogger outlets.
• Electronic accelerator (Diesel) 7. Courtesy lamp switch and electrical connector.
• HVAC control cables (if equipped). 8. J u m p e r h a rn e s s to re m o te p la y b a c k d e v ic e
28. IP from the vehicle. (if equipped).
At this point, IP removal is complete. Continue with 9. Harness to IP.
the next step if replacing or refinishing the IP. 10. Ground screw.
1. Accessory switch(es) as necessary (Figures 38 and 11. Fuse panel and courtesy lamp switch.
12. Harness retainer to accessory switches.
39).
2. Instrument cluster bezel (Figure 16). 13. Data Link Connector (DLC)
3. Headlam p switch. • Slide in and attach one screw.
4. HVAC control assembly. 14. Low coolant module (diesel only).
A. Electrical connectors. 15. IP storage compartment lamp.
B. Cables (if equipped). 16. Rosebud retainers on right side of IP for harness.
5. Instrument cluster screws. 17. Four nuts retaining IP compartment assembly to
6. Instrument cluster. the carrier, vehicles over 8 6 0 0 G V W (Figure 23).
7. IP auxiliary storage com partm ent (if equipped) 18. Inflatable R estraint IP M odule, vehicles up to
(Figure 26). 860 0 G V W (Figure 25).
8. IP cupholder. Refer to Cupholder Replacement in 19. Retaining clips from Inflatable Restraint IP Module
this section (Figure 20). or IP compartment assembly.
9. Ashtray assembly. Refer to Ashtray Replacement in 20. Antenna lead-in.
this section (Figure 21). 21. Air distributor duct to IP.
10. Radio from carrier. 22. Two air distributor duct screws.
11. Two air distributor duct screws. 23. Radio to carrier.
12. Air distributor duct from IP. 24. Ashtray assembly (Figure 19)
. Squeeze clips from front of IP to release duct. 25. IP cupholder (Figure 20).
13. Antenna lead-in. 26. IP auxiliary storage com partm ent (if equipped)
14. Retaining clips from Inflatable Restraint IP Module (Figure 26).
or IP compartment assembly. 27. Instrument cluster with four screws.
15. Inflatable Restraint IP Module, refer to Inflatable 28. HVAC control assembly.
Restraint IP Module Replacem ent in this section. 29. Headlam p switch.
16. Four nuts retaining the IP compartment assembly 30. Instrument cluster bezel (Figure 16).
to the carrier, vehicles over 8 6 0 0 G V W (Figure 23). 31. Accessory switch(es) as necessary (Figures 38
17. Rosebud retainers on right side of IP forward and 41).
harness. 32. IP to vehicle.
18. IP storage compartment (Figure 27). • Rest IP on lower pivot studs.
• Squeeze compartment to release. 33. Electrical connectors (as necessary).
19. IP storage compartment lamp. 34. Park brake release cable.
• Slide to release. 35. IP to the cowl.
20. Low coolant module (diesel only). 36. Three upper IP support screws.
21. D ata Link Connector (DLC). 37. Center support screw (Figure 22).
• O ne screw and slide out. 38. IP attaching bolts through storage com partment
22. Harness retainer to accessory switches. door.
23. Fuse panel and courtesy lamp switch. 39. IP storage compartment.
24. Ground screw. 40. IP storage compartment door.
25. Harness from the IP. 41. Left and right lower IP pivot bolts (Figure 21).
26. J u m p e r h a rn e s s to re m o te p la y b a c k d e v ic e 42. Shift levers (if equipped).
(if equipped). • Manual transmission
27. Courtesy lamp switches. • Transfer case
28. Side window defogger outlets. 43. Steering column to vehicle.
44. Shift cable (automatic transmission). 5. Four screws retaining the module to the V C M .
45. 4 8-w ay connector and screw built onto steering 6. Module from the vehicle.
column.
46. 8-w ay column connector. -► 4- Install or Connect (Figure 30)
47. Tie bar with four nuts.
48. Reaction plate assembly. 1. Module to VC M with four mounting screws.
49. Brake release handle to cable. 2. V C M to retaining tabs.
50. Left and right hinge pillar trim panels (Figure 28). 3. Electrical connectors to V C M and module.
51. Left and right sill plate front screws. 4. IP storage compartment.
52. Steering shaft and bolt. 5. Negative battery cable.
53. Knee bolster.
54. Coolant reservoir tank.
55. Bulkhead connector.
INFLATABLE RESTRAINT IP
56. T hree relay center bolts to underside of wheel MODULE SWITCH
opening.
REPLACEMENT
57. Enable S IR system. Refer to Enabling the SIR
System in Restraints. O n reg ular cab (0 3 m odels) and e x ten d ed cab
58. Negative battery cable. (53 models) a switch is provided to enable the passen
ger side air bag when no rear facing child seat is being
VEHICLE SPEED SENSOR used. In the O F F mode, the passenger side air bag will
not deploy. This feature is intended to reduce the risk of
REPLACEMENT injury to infants in rear facing child seats. The switch is
R efer to V eh icle S p e ed S en so r R ep la ce m e n t in located in the lower opening of the vertical switch trim
Transmissions. plate.
4 -+
VEHICLE SPEED SENSOR Remove or Disconnect (Figure 31)
CALIBRATOR MODULE 1. Instrument panel trim bezel. Refer to Instrument

REPLACEMENT Cluster Replacement in this section.
2. Switch from lower opening of switch plate panel.
2. IP storage compartment.
2. Switch into lower opening of switch plate panel.
3. Electrical connectors from V C M and module.
3. Instrument panel trim bezel. Refer to Instrument
4. V C M from retaining tabs.
Cluster and Indicator Lamp Replacem ent in this
section.
Figure 30—-Vehicle Speed Sensor Calibrator Module

Replacement
COOLANT TEMPERATURE
SENDER REPLACEMENT
Remove or Disconnect (Figures 35, 37 and 39)

2. Coolant.
3. Sender connector.
4. Sender.
■ M- Install or Connect (Figures 35, 37 and 39)
1. Sender.
3. Coolant.
OIL PRESSURE SENDER

(1) Fitting
REPLACEMENT (2) Oil Pressure Sensor
(3) Shield
Tool Required:
(4) Oil Pressure Sensor
J 35749 Oil Pressure Sending Unit Socket
(5) Fitting
(6) Coolant Temperature Sensor
Figure 32— Coolant Temperature and Oil Pressure
Senders (4.3L Engine)
(Figures 32 through 33)
Gas Engines

2. Sender using J 35749.
0 Install or Connect (Figures 32 through 37)
1. Sender using J 35749.

Diesel Engines
|+ + | Remove or Disconnect (Figures 33 and 34)

2. Turbo cover. (1) Fitting
3. Reposition fuel filter/water separator. (2) Oil Pressure Sensor
4. Sender connector. (3) Shield
(4) Oil Pressure Sensor
5. Sender using 1 1/16 inch crows foot wrench, or
(5) Fitting
equivalent.
(6) Coolant Temperature Sensor
Figure 33— Coolant Temperature and Oil Pressure
Senders (5.0L and 5.7L Engines)
Legend
(1) Oil Pressure Sender (1) Coolant Temperature Sender
Figure 34— Oil Pressure Sender (7.4L Engine) Figure 35— 'Temperature Sender (7.4L Engine)
+4- Install or Connect (Figures 33 and 34) |*44] Install or Connect (Figure 38)
1. Sender using 1 1/16 inch crows foot wrench, or 1. Module to instrument panel.
equivalent. 2. Electrical connector.
2. Sender connector. 3. IP storage compartment.
3. Reposition fuel filter/water separator. 4. Negative battery cable.
4. Turbo cover.
ENGINE CONTROL SWITCH
LOW COOLANT MODULE (IGNITION SWITCH)
REPLACEMENT REPLACEMENT
R efer to Steering W heel and Colum n On-Vehicle
Service.

ACCESSORY SWITCH
Caution in General Information. REPLACEMENT
2. IP storage compartment.
4-4 Remove or Disconnect
4. Module from instrument panel by pulling straight
(Figures 39 through 41)
out.

Legend
(1) Oil Pressure Sender (1) Coolant Temperature Sender
Figure 36— Oil Pressure Sender (6.5L Engine) Figure 37— Coolant Temperature Sender
(6.5L Engine)
2. Instrum ent cluster bezel (Figure 16). R efer to

Instrument Cluster Replacem ent in this section.
3. Electrical connection.
4. Switch from bezel.
[•»<-| Install or Connect (Figures 39 through 41)
1. Switch to bezel.
2. Electrical connection.
3. Instrum ent cluster b eze l (Figure 16). R efer to
Instrument Cluster Replacem ent in this section.
Legend
(1) Module, Low Engine Coolant
(2) Connector, Instrument Panel Harness
Figure 38— Low Coolant Lamp Module
Figure 40-—Accessory Switch Replacement (cont)

SPECIAL TOOLS
BLANK
CHASSIS ELECTRICAL 8B-1
SECTION 8D
CHASSIS ELECTRICAL
GENERAL DESCRIPTION
HORN SYSTEM The functions of the eight wires are:
• Orange— 30 amp fused battery feed
T h e horn system starts at the fuse block with the • Blue— An auxiliary circuit for electric trailer
horn/dome fuse (Figure 1). The circuit goes from the brakes.
fuse block to the horn relay in the underhood conve • Brown— Tail and license lamps
nience center. At the horn relay, the circuit splits; one • Light Green— Backup lamps
branch goes through the relay coil to the horn switch in • Dark Green— Right turn signal and stoplamp
the steering column, and the other goes through the • Yellow— Left turn signal and stoplamp
relay contacts to the horn. • W hite (Heavy G age)— Ground
W hen the horn switch is closed, it provides a ground • W hite (Light G age)— Center High-Mounted Stop
path for the horn relay coil. Current flows into the relay Lamp
coil, closing the contacts, allowing the horn to sound. This option does not include a connector at the end of
For diagnosis of the horn system, refer to the Engine the harness. It must be wired after production by a
Controls, Transmission Diagnosis, and Electrical Diag qualified technician.
nosis Manual. Attach the trailer harness wiring to the trailer. Then
strap it to the vehicle fram e rail in such a way that
enough slack is left in the harness to prevent bending,
CAMPER AND TRAILER WIRING binding, or breakage of the wiring. Do not allow the
Two trailer harnesses are available: heavy-duty trailer harness to drag on the ground. Tape or strap the trailer
towing (U Y 7) and camper (UY1). portion of the harness (if used) to the tongue of the
Th e option U Y7 trailer harness is for heavy-duty tow trailer. This will prevent the harness from dragging on
the ground.
ing applications. A 30-am p fused battery feed wire and
W hen the harness is not being used, wrap it together
auxiliary circuit routes from the cowl-mounted junction
and bind it with a tie strap to keep it from being dam
block, along the body side rail, to the rear bumper
aged. Store the harness behind the rear bumper on the
crossmember. The harness for the brake/parking lamps
fuel tank strap with a band or tie strap.
is spliced from the rear lamp harness. The harness is Th e second wiring harness option is the UY1 camper
located at the rear bumper crossmember and is bound wiring harness, and it is stored under the vehicle. The
with a plastic strap (Figures 2 and 3). The wiring har harness is located inside the fram e rail and is even with
ness is wrapped with tape to prevent short circuits. the front of the pickup box on the drivers side.
Figure 2—Trailer Harness Routing (Pickup)

8D-2 CHASSIS ELECTRICAL
This harness is for the brake/parking lamps and an
auxiliary power feed. This option uses a single harness
and a connector using five wires.
The functions of the wires are:
• Dark Blue— A 30-am p fused auxiliary power cir
cuit. The other end of this wire is taped to the
wiring near the junction block on the cowl.
• Dark Green— Right turn signal and stoplamp
• Light Green— Backup lamps
• Yellow— Left turn signal and stoplamp
• Brown— Taillamps
• W hite— Ground
Route the trailer harness wiring between the frame
and bumper, or cam per and body, in such a w ay that
enough slack is left in the harness to prevent bending,
binding, or breakage of the wiring. Do not allow the
harness to drag. Tape or strap the trailer portion of the
harness (if used) to the vehicle. This will prevent the
harness from dragging.
W hen the wiring is not being used, wrap the harness
together and bind it with a tie strap to keep it from being
dam aged. (Suburban and Utility)
ON-VEHICLE SERVICE
HORN REPLACEMENT install or Connect (Figure 4)
Remove or Disconnect (Figure 4) 1. Horn to the vehicle.

2. Horn attaching bolt.
Tighten
Caution in Cautions and Notices.
2. Grille to radiator support filler panel for access (left
• Horn attaching bolt to 25 N-m (18 lb ft).
horn only).
4. Grille to radiator support filler panel (if removed).
4. Horn attaching bolt.
5. Horn from the vehicle.
CHASSIS ELECTRICAL 8D-3
(1) Horn (2) Horn Attaching Bolt

Figure A— Horn Replacement
SPECIFICATIONS
Application N.m Lb ft Lb in
Horn Attaching Bolt 25 18 —
8D-4 CHASSIS ELECTRICAL
BLANK
_____________ W INDSHIELD WIPER/WASHER SYSTEM 8E1 -1
SECTION 8E1
WINDSHIELD WIPER/WASHER
SYSTEM
GENERAL DESCRIPTION
WIPER/WASHER SYSTEM windshield inside the fresh air plenum. The transmission
transfers rotary motion from the wiper motor into recipro
The windshield wiper/washer system consists of a cating motion at the transmission drive shafts.
perm anent magnet, positive-park wiper motor assembly The wiper motor is sealed. No service parts are
(Figure 1), a transmission assembly, wiper arm and blade available. Replace the motor if service is required.
assemblies, a washer pump mounted on the side of a The delay module is also sealed and attached di
washer solvent container, and a turn signal-type wiper/ rectly to the wiper motor. It is replaced as a unit during
washer switch assem bly with detents. The wiper motor is service.
equipped with RFI (radio frequency interference) sup
pression. WIPER/WASHER OPERATION
Th e wiper motor drives a crank arm that attaches to
The electronic circuit board controls all the timing
individual transmission links for both the right and left
and washer commands. W hen the wash button is pushed
sides. The transmission links are mounted in front of the
for more than 1 second, washer solvent is sprayed on the
windshield as long as the button is held. This is accom pa
nied by wiper activity that continues for about 6 seconds
after the button is released.
Rotating the wiper switch to the “LO” or “H I” speed
position closes the respective brush circuit and the wiper
motor runs at that speed.
Rotating the wiper switch to the “DELA Y” mode
operates the wiper motor intermittently. Th e delay can be
varied by rotating the switch back and forth.
For immediate wiping activity, rotate the wiper switch
to the “M IS T ” position. W iping will continue as long as the
switch is held.
Figure 2 —Wiper/Washer Motor Circuit Diagrams

8E1-2 W INDSHIELD W PER/W ASHER SYSTEM
VIEW B
VIEW A
Figure 3— W asher Hose Routing (Cowl)
1. GROMMET
2. HOSE, FRONT WASHER
3. CONNECTOR, FRONT
WASHER PUMP HOSE (BLACK)
4. CONNECTOR, REAR
WASHER PUMP HOSE (GRAY)
5. HOSE, REAR WASHER
Figure 4— Washer Hose Routing (Container)

W INDSHIELD WIPER/WASHER SYSTEM 8E1-3
WASHER HOSE ROUTING side of the cowl (Fig ure 4 ). T h e hose continues along
the LH inner fe n d e r to the w a s h e r solvent container.
W a s h e r h ose routing b eg in s at tw o n o z z le s T h e w a s h e r solvent co n tain e r is m ounted w h ere the LH
m ounted to the cowl v en t grille (Figure 3 ). T h e hose is inner fe n d e r m eets the radiator support,
clipped in various p laces to the cowl vent grille, then
exits the cowl a re a through a grom m et on the e ngine
DIAGNOSIS OF THE WIPER/WASHER SYSTEM

WIPER ARM CHATTER W ip er arm s must not be subjected to tem peratures
a bo ve 7 0 °C (1 6 0 °F ). R e m o v e w ip er a rm s before any
If the w ipers ch a tte r or s hudder w hen wiping the painting operations that include the use of an oven to
w indshield, the w indshield a n d /o r inserts m ay need cure the paint.
cleaning. U se a nonabrasive cle a n e r such as Bon A m i®
to clean the w indshield. C ontinue cleaning until w a te r CHECKING WIPER ARM
sheets off the w indshield. U se undiluted windshield PRESSURE
w ip e r/w ash er solvent and a clean, lint-free cloth to
If th e w ipers m iss or s hudder w h en wiping the
clean w ip er inserts.
w indshield, and the w indshield and w ip e r inserts have
b een c le a n e d , th e w ip e r arm p re ss u re should be
C AU TIO N: A void prolonged skin contact w ith
checked. R e fe r to Figure 5. If the w ip e r arm s a re not
w as h e r s o lve n t to avo id dam ag e to yo u r
within the specifications given in Figure 5, they should
s k in . O v e re x p o s u re m a y c a u s e c e n tra l
b e r e p la c e d . R e f e r to “W ip e r A rm A s s e m b ly
n ervous system effe c ts.
R e p la ce m e n t.”
W h e n m arking the w indshield for inside rear view BLADE INSERT SET CHECK
mirror rep lacem en t or any oth er purpose, use only a
R em o ve the w ip e r b lade a ssem b lies from the
w ater-soluble m arker to m a ke m arks on the windshield.
w ip e r arm s. Look down the length of the blade insert
O th er types of m arkers m ay d a m a g e the w ip er inserts.
(Fig ure 6 ). T h e rubber insert that contacts the glass
T h e chem icals that are used to rem ove other types of
must be on th e c e n te r line of the b lade a ssem b ly ± 1 5
m arkers m ay d am ag e the paint, glass, or inserts, or
d eg re es . R e p la ce the insert if n ecessary.
leave a residue on the glass that could lead to chatter.
WIPER MOTOR ASSEMBLY
DIAGNOSIS
A lw ays perform th e “P ulse W ip e r S ystem C h eck”
first as a guide to norm al o peration. T h e n refer to
F ig u re s 7 th ro u g h 16 fo r w ip e r m o to r a s s e m b ly
diagnosis.
v
L
r / - *
A. BLADE ELEM ENT SH O U LD NOT BE BENT

M O R E T H A N 15° IN E IT H E R D IR E C T IO N FR O M
C E N T E R L IN E .
B. E L E M E N T , B L A D E
Figure 5— Checking Wiper Arm Pressure Figure 6— Blade Insert Set Check
8E1 -4 W INDSHIELD WIPER/WASHEB SYSTEM
D IA G N O S TIC P R O C ED U R E S
NOTE: T h e following procedures ass u m e that the technician has checked th e following:
1. Continuity of all harness w ires
2. W ip e r m otor-to-cow l m ounting screw s tight
3. Fuses
4. W a s h e r hoses c lea r
WIPER MOTOR
C H E C K FO R M O T O R O P E R A T IO N B E F O R E R E M O V IN G
F R O M V E H IC L E . D IS C O N N E C T A L L W IR IN G F R O M W IP E R
A N D P E R F O R M T H E F O L L O W IN G C H E C K S IN T H IS O R D E R :
© LO ( 6 ) WASH
12V 12V
NO TE: C o n n ect term in al #3 be C o n n e c t a te s t p u m p (b o tto m -
fo re c o n n e c tin g te rm in a l #4. b o ttle -m o u n t ty p e ) o f p ro v e n
O th erw ise, d a m ag e m ay o ccu r. q u a lity. Do n o t use p u m p fro m
v e h ic le . Test w ash er pum p
s h o u ld p u ls e 9 to 11 tim e s in 15
sec o n d s . Do n o t h o ld th e W A SH
bu tto n fo r lo n g e r th a n 15 sec
o n d s w ith o u t a 2 -m in u te pause.
1. If w iper m otor functions in all ab o v e m odes, go to

W ip e r/W a s h e r Sw itch T es t.
2. If w ip er motor d oes not function in a n y one of the

abo ve m odes, go to th e D iagnosis C h art.
Figure 7— Wiper Motor On-Vehicle Check

W INDSHIELD WIPER/WASHER SYSTEM 8E1 -5
D IA G N O S T IC P R O C E D U R E S (C O N T ’D)
WASHER PUMP
CHECK FOR W ASHER PUMP O P ER A TIO N BEFO RE

REMOVING FROM VEHICLE. REMOVE CONNECTOR AND
APPLY B(+) TO #2 WIRING HARNESS TERMINAL AS
SHOWN.
1. If motor does not run or pump solvent, replace w ash er

pump.
2. If motor runs and pumps solvent, problem is in circuit

board, motor park switch, or wiper switch. R efer to
W ip er/W ash er Switch Tests.
Figure 8— Washer Pump On-Vehicle Check

8E1-6 W INDSHIELD WIPER/WASHER SYSTEM
WIPER/WASHER SWITCH TESTS

DISCONNECT VEHICLE HARNESS CONNECTOR FROM
WIPER MOTOR. PERFORM THE FOLLOWING TESTS USING
A DIGITAL VOLTMETER WITH IGNITION SWITCH "ON."
NOTE: ALL VOLTAGE READINGS TAKEN WITH 1 B+ B+ B+ B+ B+ B+

RESPECT TO VEHICLE GROUND. 2 - - - - C-
C = CONTINUITY BETWEEN TERMINALS. 3 B+ - B+ B+ C C

4 - - - - C -
TO USE WIPER/WASHER SWITCH CHECK 5
CHART, PROBE TERMINALS 1 THROUGH 5
WITH DIGITAL VOLTMETER AND
WIPER/WASHER SWITCH INVARIOUS
POSITIONS.
Figure 9— Wiper/Washer Switch Tests

W INDSHIELD WIPER/WASHER SYSTEM 8JE1-7
PROCEDURE
SYMPTOM NO.
1. Pum p inoperative— w ip er m otor o p erates 1
2. W a s h e r pum ps continuously 2
3. W ip e r m otor inoperative (all m odes) 3
4. “L O ” s p eed only— inoperative in “H I” 4
5. “H I” speed only— inoperative in “L O ” 5
6. O n e speed only— runs the s am e in both speeds 6
7. W ip e r shuts off but blades don’t park 7
8. W ip e rs will not shut off 8
9. Interm ittent inoperation 9
10. W ip e r m otor runs but b lades don’t m ove 10
11. W ip e r parks abo ve park position 11
Figure 10— Symptom Diagnosis Chart
PULSE W IPE R SYSTEM C H E C K

A C TIO N N O R M A L O P ER A TIO N
1. Ignition switch in A C C Y or R U N . 1. W a s h e r sprays windshield until switch is released.

• Hold w a s h e r switch O N for 1 to 2 seconds. W ipers run at low speed and continue to run for
approxim ately 6 seconds after w asher cycle is
com plete, then return to park position.
2. T u rn w ip er switch to D E L A Y (pulse m ode). 2. W ipers m ake one com plete sw eep, then pause for
• A ctivate d elay tim e by turning w ip er switch 0 to 2 5 seconds before making next sw eep.
through d elay range.
3. W ip e r switch in D E L A Y . 3. W a s h e r sprays as long as w asher switch is held
• Push w a s h e r switch O N for 1 to 2 seconds. O N . W ipers run at low speed during spray period
and continue for approxim ately 6 seconds after
spray cycle. W ipers return to pulse mode.
4. Turn w iper switch to LO. 4. W ipers run continuously at low speed.

5. T u rn w iper switch to H I. 5. W ipers run at faster speed.
6. T u rn w iper switch to O F F . 6. W ipers return to park position at low speed.
7. Turn w iper switch to M IS T , then release. 7. W ipers m ake one com plete sw eep at low speed
and park. If switch is held in M IS T , wipers run
continuously at low speed until switch is released.
PROCEDURE 1
PUMP INOPERATIVE
(WIPER MOTOR OPERATES)
CHECK AND/OR REPAIR THE FOLLOWING ITEMS REQUIRED:

1. QUANTITY OF SOLUTION IN SOLVENT CONTAINER.
2. HOSES NOT INCHED, KINKED, OR DAMAGED.
3. HOSES ATTACHED TO CONTAINER PUMP AND NOZZLES. IF
HOSES SEEM LOOSE, CUT OFF 1/2 IN. AND REATTACH.
4. SCREEN AT END OF HOSE INSIDE CONTAINER NOT
PLUGGED.
5. NOZZLES NOT PLUGGED.
WITH IGNITION ON AND REPLACE

MOTOR IN “LO”, CON PUMP
NECT TEST LIGHT LEAD MOTOR.
TO GROUND AT MOTOR
CASE AND BACKPROBE
TERMINAL #2 WHILE
PUSHING “WASH”
BUTTON.
LIGHT OFF LIGHT ON
REPLACE REMOVE COVER AND CHECK

PUMP SPRING CONTACTS. IF SPRING
MOTOR. CONTACTS APPEAR TO BE
MAKING CONTACT, REPLACE
CIRCUIT BOARD &TERMINAL
ASM.
PROCEDURE 2
WASHER PUMPS CONTINUOUSLY
REFER TO SWITCH TESTS, FIG. 6. REPLACE COVER.
Figure 11— Wiper/Washer Diagnosis (1 of 6)

PROCEDURE 3
WIPER MOTOR INOPERATIVE
(ALL MODES)
WITH IGNITION ON AND WIPER ON “HI”, CONNECT TEST LIGHT m
LEAD TO GROUND ON VEHICLE AND BACK PROBE TERMINAL #4.

8E 1-10 W INDSHIELD WIPER/WASHER SYSTEM
PROCEDURE 4
“LO” SPEED ONLY; n
□ lr 0 .
'm H f
INOPERATIVE IN “HI”
DISCONNECT WIRE HARNESS FROM MOTOR. CONNECT 12V (+)
FROM VEHICLE BATTERY TO “HI” SPEED TERMINAL #4.
©
WIPER RUNS WIPER DOES

IN “HI." NOT RUN.
REPAIR OPEN WIRE REPLACE

FROM WIPER TERMINAL MOTOR.
NO. 4 TO SWITCH OR
REPLACE SWITCH.
PROCEDURE 5 f m i- l m l)
“HI” SPEED ONLY; -----------1
INOPERATIVE IN “LO” w m
DISCONNECT WIRE HARNESS FROM MOTOR. CONNECT 12V (+)

FROM VEHICLE BATTERY TO “LO” SPEED TERMINAL #3. ©
WIPER RUNS WIPER DOES

IN “LO.” NOT RUN.
REPAIR OPEN WIRE FROM REPLACE

WIPER TERMINAL #3 TO MOTOR. LO
SWITCH OR REPLACE
SWITCH.
PROCEDURE 6
ONE SPEED ONLY: RUNS THE
SAME IN “LO” AND “HI”
DISCONNECT WIRE HARNESS FROM MOTOR AND OPERATE IN

“LO” AND “HI.”
WIPER OPERATES PROBLEM IS

CORRECTLY. STILL PRESENT.
REPAIR WIRING BETWEEN REPLACE

SWITCH AND WIPER OR MOTOR.
REPLACE SWITCH.
WINDSHIELD WPER/WASHER SYSTEM 8E1 -11
PROCEDURE 7
W IPER SHUTS OFF BUT
BLADES DON’T PARK
DISCONNECT W IRE HARNESS FROM MOTOR. CONNECT JUMPER

FROM TERMINAL #2 TO #3 AND 12V (+) TO TERMINAL #1.
W IPER RUNS W IPER DOESN’T RUN

AND PARKS. OR DOESN’T PARK.
SWITCH IN “OFF” POSITION.

CHECK FOR CONTINUITY BETWEEN REPLACE CIRCUIT
TERMINALS #2 AND #3 ON HARNESS. BOARD.
NO CONTINUITY CONTINUITY WIPER RUNS WIPER

AND PARKS. DOESN’T RUN
OR DOESN’T
PARK.
REPAIR OPEN WIRE REPAIR OPEN WIRE
FROM TERMINAL #3 TO FROM TERMINAL #1
TO FUSE BLOCK. REPLACE
SWITCH OR REPLACE
MOTOR.
SWITCH.
PROCEDURE 8
WIPER WILL NOT
SHUT OFF
DISCONNECT W IRE HARNESS FROM MOTOR. CONNECT JUMPER

FROM TERMINAL #2 TO #3 AND 12V (+) TO TERMINAL #1.
WIPER WIPER STILL

PARKS. RUNS.
REPLACE REPLACE
SWITCH. MOTOR.


W INDSHIELD WIPER/WASHER SYSTEM 8E1 -13

8E1-14 W INDSHIELD WIPEB/WASHEB SYSTEM
O N -VEH IC LE SER VIC E

W IPER ARM ASSEMBLY WIPER BLADE ASSEMBLY AND
REPLACEMENT INSERT REPLACEMENT
R em ove o r D is co n n ec t (F ig u re 18)
m Im p o rta n t
• B efo re rem oving on e or both arm and b lade 1. W ip e r b lade assem b ly from w ip e r arm .
a s s e m b lie s , u s e a s u ita b le m a rk e r on th e A. Push in button of w ip er b lade a ss em b ly clip
w indshield to indicate proper park position to aid in and rem ove w ip er b lade a s s em b ly from inside
reinstallation. radius of w ip e r arm .
B. Bring w ip er arm out through opening in w iper
R em o ve o r D is co n n ec t (F ig u re 17) b lade assem bly.
2. W ip e r b lade insert by pulling out through w iper
1. W a s h e r hose. b lade assem b ly claw s.
2. Lift the w ip er arm a ss em b ly from w indshield, then
pull retaining latch. Im p o rta n t
3. A rm ass em b ly from transm ission drive shaft.
• Insert m ust be replaced if rem oved.
In s tall o r C o n n e c t (F ig u re 17)
In stall or C o n n ect (F ig u re 18)
1. Position w ip er arm ass em b ly on the drive shaft, so
th at the w ip er b lade aligns with the m ark m ade 1. W ip e r b la d e in s e rt in w ip e r b la d e
b efo re rem oval. assem bly.
• S e a t the arm ass em b ly on the drive shaft, • Slide w ip er b lade insert through w ip er blade
then press in retaining latch. a s s e m b ly c law s until c la w is locked into
2. W a s h e r hose. notches in w ip e r b la d e insert.
2. W ip e r b lade a ss em b ly on w ip e r arm .
In s p e c t W ip e r O p eratio n
• C h ec k w ip e pattern and blade tip park position.
3. C L IP , W IP E R B L A D E A S S E M B L Y
4. BUTTO N
5. C L A W , W IP E R B L A D E A S S E M B L Y
1. L A T C H , R E T A IN E R
6. IN S E R T , W IP E R B L A D E
2. A R M , W IP E R
7. N O T C H , W IP E R B L A D E IN S E R T
Figure 17— Wiper Arm Attachment F ig u re 18— W ip e r B la d e A s s e m b ly a n d In s ert

R e p la c e m e n t
W INDSHIELD WIPER/WASHER SYSTEM 8E 1-15
C IR C U IT BOARD AND W IPER TRAN SM ISSIO N
TER M IN A L ASSEMBLY REPLACEMENT
ASSEMBLY REPLACEMENT
B R em ove o r D is c o n n e c t (F ig u re 2 0 )
E3 R em ove o r D is c o n n e c t (F ig u re 19) 1. Wiper arm assemblies. Refer to “Wiper Arm

Assembly Replacement.”
2. Cowl vent grille,
2. Wiper motor electrical connector.
3. Loosen bracket to crank arm nuts.
3. Cover screws.
4. Transmission brackets from the wiper motor crank
4. Cover.
arm.
5. Circuit board and terminal assembly by lifting up
5. Transmission to cowl bolts.
on terminal.
• Note the position of the right and left
B In s ta ll o r C o n n e c t (F ig u re 19)
transmission links for reassembly.
6. Transmission assembly from the vehicle.
1. Circuit board and terminal assembly.
In s ta ll o r C o n n e c t (F ig u re 2 0)
NOTICE: Refer to the Fastener Notice in the
NOTICE: For steps 2 and 4, refer to the Fastener
GENERAL INFORMATION SECTION. N otice in the GENERAL IN FO R M A TIO N
SECTION.
2. Cover and three screws.
1. Wiper transmission assembly to the vehicle.
T ig h te n
2. Transmission to cowl bolts.
• Screws to 2.6 N*m (23 lbs. in.).
T ig h te n
3. Wiper motor electrical connector.
4. Negative battery cable. • Bolts to 7 N«m (62 lbs. in.).
3. Transmission brackets to the wiper motor crank
arm.
T ig h te n
• Drive link nuts to 5 N«m (44 lbs. in.).

4. Cowl vent grille.
5. Wiper arm assemblies. Refer to “Wiper Arm
WIPER MOTOR ASSEMBLY

REPLACEMENT
[» R em ove o r D is co n n ec t (F ig u re s 17 an d 2 0)

2. Wiper arm assemblies.
• Lift the wiper arm into the servicing position,
and move the latch into the open position
before removing the wiper arm (Figure 17).
4. Electrical connector from the motor assembly.
5. Drive link brackets from the wiper motor crank
arm. DO NOT REMOVE THE CRANK ARM.
• Loosen the nuts and slide the brackets off
the crank arm.
8E 1-16 W INDSHIELD WIPER/WASHER SYSTEM
1. S C R E W S , 7 N*m (6 2 L B S . IN .)
2. M O T O R , W IP E R
3. N U T , 5 N«m (4 4 LB S. IN .)
4. BRACKET
5. T R A N S M IS S IO N , W IP E R
6. B O L T , 7 N*m (62 LB S. IN .)
F ig u re 20— W ip e r T ra n s m is s io n an d M o to r A s s e m b ly R e p la ce m e n t
6. Wiper motor screws and wiper motor assembly 4. Electrical connector to the wiper motor.
from the vehicle. 5. Cowl vent grille.
6. Wiper arm assemblies.
In s ta ll o r C o n n e c t (F ig u re s 17 and 20) • Place the wiper arms on the transmission
drive shafts and lock them into place with the
NOTICE: For steps 2 and 3, refer to the Fastener latch (Figure 17).
N o tice in the GENERAL IN FO R M A TIO N 7. Negative battery cable.
SECTION.
WIPER/WASHER SW ITCH
1. Wiper motor assembly to the vehicle.
2. Wiper motor screws. ASSEMBLY REPLACEMENT
The wiper/washer switch assembly is part of the
T ig h te n steering column assembly.
• Screws to 7 N«m (62 lbs. in.).
3. Drive link brackets to the wiper motor crank arm.
• Assemble the brackets in the order shown in
Figure 20. (Right side linkage closest to the
wiper motor).
m T ig h te n
Drive link nuts to 5 N»m (44 lbs. in.).

WASHER SOLVENT CONTAINER

AND PUMP REPLACEMENT
R em ove o r D is co n n ec t (F ig u re s 21 and 22)

2. Storage compartment and storage compartment
tray.
3. Two bolts.
4. Hoses from front and rear washer pump hose
connectors.
5. Vehicle harness connector from washer solvent
container harness connector.
6. Washer solvent container from vehicle.
7. Cover from washer solvent container.
8. Two hoses and two connectors from pumps and
container.
9. Two pumps and seals from container.
10. Filler neck and two seals from container.
11. Mounting grommet from container.
In s ta ll o r C o n n e c t (F ig u re 2 1)
1. Three isolators to washer solvent container.

2. Mounting grommet to container.
3. Filler neck and vent seals on container.
4. Filler neck on container.
• Lubricate filler neck with washer solvent to
ease installation.
5. Two pump seals in container. 1. B O LT, 6 N m (53 LB S. IN .)
2. C O N TA IN E R , W A SH ER
Im p o rta n t SO LVEN T
3. B O LT, 6 N m (53 LB S. IN .)
• Front and rear w asher pumps are not
4. C O N N EC TO R
interchangeable. Rear washer pump has larger
5. H O SE, REAR W A SH ER
harness connector opening.
(G R A Y C O N N E C TO R )
6. Front and rear washer pumps on container.
6. H O SE, FR O N T W A SHER
• Lubricate pump with washer solvent to ease
(B LA C K C O N N EC TO R )
installation.
7. Hoses and harness connectors to washer pumps.
• Push harness wrap and hoses into the F ig u re 2 1 — W a s h e r S y stem C o m p o n e n ts
channels of the container.

8. Cover on container. 9 Im p o rta n t
NOTICE: Refer to the Fastener Notice in the
• Washer pump hose connectors are color
GENERAL INFORMATION SECTION. coded:
9. Container on vehicle with two bolts. • R E A R -G R A Y
• F R O N T-B LA C K
i T ig h te n
• Bolts to 6 N»m (53 lbs. in.).

11. Hoses to front and rear washer pump hose
connectors.
12. S torage com partm ent tra y and storage
10. V e h ic le h arness c o n n e cto r to w a s h e r solvent compartment.
con tainer h arness connector. 13. Negative battery cable.
8E1 -18 W INDSHIELD WIPER/WASHER SYSTEM
1. N ECK, FILLER
2. SEA L, V EN T
3. ISO LA TO R
4. C O N TA IN ER , W A SHER
S O LVEN T
5. G R O M M ET, M O UNTIN G
6. CO VER
7. SEA L
8. PU M P, FR O N T W A SH ER
9. PU M P, REA R W A SH ER
10. H O SE, REAR W A SH ER
(G R A Y C O N N EC TO R )
11. H O SE, FR O N T W A SH ER
(B L A C K C O N N E C TO R )
12. H A R NESS
13. SEA L, N ECK
F ig u re 2 2 — W a s h e r S y ste m C o m p o n e n ts
SPECIFICATIONS
FASTENER TIGHTENING
ITE M N*m L b s. In .
Washer Solvent Container B o lts................................. 6 53
Circuit Board and Terminal Assembly Cover Screws 2.6 23
Transmission Assembly Drive Link N u ts ................... 5 44
Transmission to Cowl Bolts......................................... 7 62
Wiper Motor to Cowl Screws....................................... 7 62
REARWINDOWWIPER/WASHERSYSTEM 8E2-1
SECTION 8E2
REAR WINDOW WIPER/WASHER
SYSTEM
GENERAL DESCRIPTION
REAR WINDOW SYSTEM OPERATION
WIPER/WASHER SYSTEM The system operates only when the ignition switch
is in the “RUN” or “ACCY” position. There are four electri
The rear window wiper/washer system has a one- cal terminals on the controller assembly of the wiper
speed, permanent magnet, nondepressed-park wiper mo motor assembly (Figures 2 and 3).
tor assembly with a pulse (delay) mode (Figure 1). The When the wiper switch is turned on, battery voltage
wiper motor assembly drives a gear box, that in turn is applied to terminal B of the controller. The motor and
drives a wiper pivot that provides an oscillating output to controller are grounded at terminal A. If the delay button
the arm and blade. is pressed, battery voltage is applied to terminals B and D
A controller assembly is retained by the wiper motor at the controller. The operation of the wiper motor will be
bracket and is the only replaceable wiper motor compo pulsed, with about 9 seconds between each wiper sweep.
nent. The controller’s printed circuit board controls all When the wiper switch is turned off, only terminals A
wiper motor functions as determined by the position of the and D are used. Terminal D remains battery positive and
wiper/washer switch. the circuit is completed through terminal A and the closed
park switch terminals. A cam on the wiper motor gear then
opens at the park position and the wiper motor turns off.
CONTAINER-MOUNTED
WASHER SYSTEM
The rear washer pump and solvent container mounts
to the left fender, inside the engine compartment. The
rear window wiper/washer will always run out of solvent
before the windshield wiper/washer does. If the rear
washer fails to operate, try washing the windshield. If you
are able to wash the windshield and not the rear window,
try filling the solvent container.
The washer hose routes from the solvent container,
along the inside of the left frame rail to the rear of the
vehicle (Figure 4). A one-way check valve between the
washer pump motor assembly and the washer hose har
ness allows fluid flow toward the washer nozzle only. A
1. MOTOR, WIPER
2. CONTROLLER ASSEMBLY
3108r3453
Figure 2-Wiper Motor Assembly Components

8E2-2 REAR WINDOW WIPER/WASHER SYSTEM
second check valve is behind the rear bumper, where the wash button is held. When the button is released, ap
hose continues up the right side of the door opening proximately 3 wipes are made without washing activity
frame, across the vehicle to the rear window wiper motor before the wiper motor turns off.
assembly (Figure 5). A “demand” wash will be performed if the wash
Depressing the wash button while the wiper motor button is pressed with the wiper/washer switch in the
operates in either “DELAY” or “ON” completes the washer “OFF” position. The wash action will last until the wash
motor’s circuit to ground, energizing the motor and oper button is released, followed by approximately 3 wipes
ating the washer pump. The pump operates only while the without washing activity before the wiper motor turns off.
DASH SWITCH
3108r3451
F ig u re 3 -W ip e r/W a s h e r M o to r C irc u it D iagram
DIAGNOSIS OF THE REAR

WINDOW WIPER/WASHER SYSTEM
Always perform the System Check first as a guide to to “Wiper/Washer Switch Test.” The wiper motor and
normal operation, then verify that power and ground controller assemblies cannot be repaired. If diagnosis
are at the correct wiper motor term inals. Refer leads to a faulty motor or controller, replace them.
F ig u re 4 -W a s h e r H o se R o u tin g (F ro n t)
REAR WINDOWWIPER/WASHERSYSTEM 8E2-3
SYSTEM CHECK
A C T IO N N O R M A L O P E R A T IO N
1. Slide the rear window wiper switch to the Wiper operates in delay mode. A wipe is
middle position. performed aooroximatelv everv 9 seconds.
2. Slide the rear window wiper switch all the Wiper operates at a constant speed.
way to the right.
3. With wiper running, push wiper switch in. Washer fluid sprays back window until switch
is released. Wiper continues to operate.
4. Slide the rear window wiper switch all the Wiper returns to park position.
way to the left.
T3110
A 7\ \ \
WIPER/WASHER SWITCH TEST
t e r m in a l \
A 0 VOLTS/CONTINUITY TO GROUND
B — B+ B+ —
C — — — B+
D B+ B+ — —
8E2-4 REARWINDOWWIPER/WASHERSYSTEM
ON-VEHICLE SERVICE
W IPER ARM ASSEMBLY WIPER BLADE ELEMENT
B E
R em ove or D isconnect (Figure 6) Rem ove or D isconnect (Figure 6)
1. Washer hose. 1. Wiper blade element by squeezing the element

2. Lift the wiper arm assembly from the glass and pull retainer tabs together, then pull the blade element
the retaining latch. out.
3. Wiper arm assembly from the wiper motor driveshaft.
B Install or C o nnect (Figure 6)
1. Insert the blade element until its retainer is en
1. Wiper arm assembly with the wiper motor in the gaged by the outer claw set.
park position.
A. Install the head of the wiper arm assembly onto Im portant
the serrated wiper motor driveshaft in a posi
• Make sure the blade element is secure in all
tion where the blade will rest in a proper parked
claw sets.
position (blade parallel to the edge of the glass).
2. Check the wipe pattern and compare it to Figure 6.
B. Lift the wiper arm extension and push in the
retaining latch when the head is fully seated
onto the driveshaft. CONTROLLER ASSEMBLY
2. Washer hose, engaging the hose grommet in the
liftglass hole.
REPLACEMENT
B Rem ove or D isconnect (Figures 2 and 7)

W IPER BLADE ASSEMBLY
E
REPLACEMENT 1. Wiper motor assembly. Refer to “Wiper Motor
2. Cover from the wiper motor.
Rem ove or D isconnect (Figure 6) A. Push retainer pin completely out of retainer into
cover using a small pin punch. There are four
1. Wiper blade assembly.
retainers.
A. Insert a screwdriver into the blade retainer slot
B. Remove four retainers and cover. Retainers
over the spring.
should remove easily from cover.
B. Pivot the screwdriver so the blade tip presses
C. Retrieve retainer pins from cover.
downward on the retainer spring, releasing the
pin of the wiper arm.
4. Use a screwdriver to pry the locking tabs of the
| 9 | Im p o rtan t controller assembly free from the slots in the wiper
motor bracket.
• Protect the glass when removing the wiper blade
assembly. B Install o r C onnect (Figures 2 and 7)
1. Press the controller assembly into the wiper motor
bracket so the locking tabs engage both bracket
1. Wiper blade assembly by pressing the pin of the slots.
wiper arm assembly into the blade retainer until the 2. Electrical connectors.
pin is engaged. 3. Cover to the wiper motor.
A. Install cover on wiper motor.
B. Install four retainers in cover.
C. Push four pins into retainers until top surface of
pin is flush with top of retainer.
4. Wiper motor assembly to the vehicle. Refer to
“Wiper Motor Assembly Replacement.”
REAR WINDOW WIPER/WASHER SYSTEM 8E2-5
VIEW A
VIEW B
VIEW C
A. WIPER ARM ASSY. REPLACEMENT 7. WIPER BLADE

B. BLADE ASSY. REPLACEMENT 8. RETAINING SPRING
C. BLADE ELEMENT 9. SCREWDRIVER
1. DRIVE SHAFT 10. WIPER ARM PIN
2. WIPER ARM ASSEMBLY 11. BLADE SUPERSTRUCTURE
3. WASHER NOZZLE 12. RETAINER
4. RETAINING LATCH 13. CLAW SET
5. HOSE 14. BLADE ELEMENT
6. GROMMET
F ig u re 6 -W ip e r A rm A ssem b ly, B lade, an d E lem e n t R e p la c e m e n t

8E2-6 REARWINDOWWIPER/WASHERSYSTEM
A. PIN, RETAINER
1. MOTOR ASSEMBLY
2. COVER, WIPER MOTOR
3. RETAINER, WIPER MOTOR COVER
4. BOLT
5. CONNECTOR, WIPER HARNESS
6. RETAINER, WIPER MOTOR
7. NUT, 6 N»m (53 LBS. IN.)
8. WASHER
9. SPACER, WIPER MOTOR
10. NUT, 6 N»m (53 LBS. IN.)
&
3108r2921
F ig u re 7 -W ip e r M o to r A s s e m b ly R e p la ce m e n t
W IPER MOTOR ASSEMBLY NOTICE: Refer to the Fastener Notice in the

GENERAL INFORMATION SECTION.
REPLACEMENT
4. Bolt to the wiper motor.
R em ove or D isconnect (Figure 7)
Tighten
2. Wiper arm assembly. Refer to “Wiper Arm Assem • Nut to 6 N*m (53 lb. in.).
bly Replacement.” 5. Electrical Connector.
3. Cover from the wiper motor. 6. Cover to the wiper motor.
A. Push retainer pin completely out of retainer A. Install cover on wiper motor.
into cover using a small pin punch. There are B. Install four retainers in cover.
four retainers. C. Push four pins into retainers until top surface of
B. Remove four retainers and cover. Retainers pin is flush with top of retainer.
should remove easily from cover. 7. Wiper arm assembly. Refer to “Wiper Arm Assem
C. Retrieve retainer pins from cover. bly Replacement.”
4. Electrical connectors. 8. Negative battery cable.
5. Bolt from the wiper motor.
6. Nut, spacer, and washer.
7. Nut.
WIPER/WASHER SWITCH
8. Wiper motor assembly from the vehicle. ASSEMBLY REPLACEMENT
Install or C onnect (Figure 7) Refer to “Rear Wiper/Washer (Accessory) Switch
Replacement” in the appropriate section.
1. Wiper motor assembly to the vehicle.
2. Washer, spacer, and nut to the right side of the
motor assembly. WASHER PUMP REPLACEMENT
3. Nut to the left side of the motor assembly.
Refer to “Windshield Wiper/Washer System” in
this section.
SPECIFICATIONS
Item N*m Lb. In .
Wiper Motor Mounting B o lt......................................................................... 6 53
Wiper Motor Mounting N u t.......................................................................... 6 53
Accessories Table of Contents 1
SECTION 9
Accessories
Audio System s ................................................... 9A-1 Cruise Control M o d u le ............................................ 9B-1

General Description...........................................9A-1 G as E n g in e s ........................................................... 9B-1
Handling Electrostatic Discharge (ESD) Diesel E n g in e s ....................................................... 9B -2
Sensitive P arts................................................. 9A-1 Multifunction L e v e r....................................................9B -2
Description of Operation.................................. 9A-1 O n/O ff S w itch ..........................................................9B -2
AM/FM Stereo Radio (UM7).........................9A-1 S et/C oast Button....................................................9B -2
AM/FM Stereo Radio with Integral R esum e and Accel R/A Sw itch....................... 9B -2
Cassette Tape Player (UM6)..........................9A-4 D ia g n o s is .........................................................................9 B -3
AM/FM Stereo Radio with Integral Preliminary Inspection............................................. 9B -3
Cassette (ULO) or Compact Disc (UNO)...... 9A-4 Functional C h e c k ....................................................... 9B -3
Theft Deterrent (Theftlock)........................9A-6 O n-V ehicle S e rv ic e ...................................................... 9B -3
Remote Compact Disc Player......................9A-7 Cruise Control C a b le ................................................9B -3
D ia g n o sis............................................................. 9A-8 Cruise Control M o d u le ............................................ 9B-3
Audio System Diagnosis.................................. 9A-8 Engagem ent S w itc h ................................................. 9B -4
On-Vehicle Service..............................................9A-8 S p e c ific a tio n s ................................................................ 9B -7
Radio Replacement...........................................9A-8 F astener Tightening Specifications.....................9B -7
Remote Playback Device Replacement........ 9A-9 PASSLO CK™ S y s te m ..........................................9D-1
Tape Player and Cassette Care......................9A-9 G eneral Description.................................................. 9D-1
Compact Disc Player and Disc C are............. 9A-9 System O p eratio n ......................................................9D-1
Amplifier Replacement..................................... 9A-9 Handling Electrostatic Discharge (E S D )
Speaker Replacement.................................... 9A-10 Sensitive P a rts ..........................................................9D-1
Front Side Door Speakers.........................9A-10 System C o m p o n e n ts ................................................9 D -2
Front Door Armrest Speakers................... 9A-10 P A S S L O C K ™ Lock C y lin d e r......................... 9D -2
Rear Speakers.............................................9A-10 Ignition Sw itch........................................................ 9D -2
Side Door Speakers................................... 9A-12 P asslock™ S e n s o r............................................. 9D -2
Rear Overhead Speakers...........................9A-12 Passlock ™ M o d u le ............................................9D -2
A nte n na s............................................................ 9A-13 S E C U R IT Y Indicator
General Description........................................ 9A-13 (Instrum ent C luster)......................................... 9D -2
D ia g n o sis........................................................... 9A-13 Vehicle Control M odule (V C M )........................ 9 D -3
On-Vehicle Service............................................9A-14 V T D Class 2 C om m unications............................. 9 D -3
Fixed Antenna Replacement..........................9A-14 Scan Tool D iagnosis............................................ 9 D -3
Lead-In Replacement..................................... 9A-15 D ata L is t...............................................................9D -3
S pe cifica tio ns....................................................9A-16 Auto Learn Tim er S ta tu s .............................. 9 D -3
Fastener Tightening Specifications............... 9A-16 Lock O ut Tim er S tatu s................................... 9 D -3
Cruise Control.....................................................9B-1 P ass w o rd ............................................................. 9 D -4
General D escription............................................9B-1 Passlock D ata V o ltage................................... 9 D -4
Cruise Control System..................................... 9B-1 Passlock P o w e r.................................................9 D -4
Gas Engines................................................... 9B-1 S E C U R IT Y Indicator S t a te ...........................9 D -4
Diesel Engines...............................................9B-1 S e lf D ia g n o s tic s ......................................................... 9 D -4
Brake Release Switch...................................... 9B-1 System T e s ts .............................................................. 9 D -4
Gas Engines................................................... 9B-1 Snap S h o t................................................................9 D -4
Diesel Engines...............................................9B-1 R eprogram m ing P rocedures ............................... 9 D -4
Clutch Release Switch..................................... 9B-1 Reprogram m ing Procedure -
Vehicle Speed Signal........................................9B-1 S e ed and K e y ...........................................................9 D -4
Gas Engines................................................... 9B-1 D isclaim er................................................................. 9D -4
Diesel Engines...............................................9B-1 E q u ip m e n t................................................................9D -4
2 Table of Contents Accessories
Conditions...................................................... 9D-4 Conditions For Clearing The DTC............ 9D-22

S teps............................................................. 9D-4 Diagnostic A ids............................................9D-22
Reprogramming Procedure - Auto - Test Description...........................................9D-23
Learn.................................................................9D-5 DTC B2960 - Security System Sensor
Conditions...................................................... 9D-5 Data Incorrect But Valid............................... 9D-25
Steps...............................................................9D-5 Circuit Description....................................... 9D-25
System Electrical Schematics..........................9D-5 Conditions for Setting The D T C ............... 9D-25
Diagnosis ............................................................ 9D-7 Action Taken When The DTC S ets..........9D-25
Diagnostic Trouble Codes................................ 9D-7 Conditions For Clearing The DTC............ 9D-26
Displaying Diagnostic Trouble Codes............. 9D-7 Diagnostic Aids............................................9D-26
Intermittent And Poor Connections................. 9D-7 Test Description.......................................... 9D-26
Troubleshooting Hints....................................... 9D-7 DTC B3031 - Security System Controller In
System Diagnosis..............................................9D-7 Learn Mode.................................................... 9D-28
VTD Diagnostic System C heck...................... 9D-8 Circuit Description....................................... 9D-28
Diagnostic Tables .......................................... 9D-10 Conditions for Setting The D TC ............... 9D-28
DTC B0688 - Security System Indicator Action Taken When The DTC S ets..........9D-28
Circuit High..................................................... 9D-11 Conditions For Clearing The DTC............ 9D-28
Circuit Description........................................9D-11 Diagnostic A ids............................................9D-28
Conditions for Setting The DTC................ 9D-11 Test Description...........................................9D-29
Action Taken When The DTC Sets........... 9D-11 DTC B3033 - Security System Indicates
Conditions For Clearing The DTC............. 9D-11 Tamper............................................................ 9D-32
Diagnostic Aids.............................................9D-11 Circuit Description....................................... 9D-32
Test Description............................................9D-12 Conditions for Setting The D T C ............... 9D-32
DTC B2947 - Security System Sensor Action Taken When The DTC S ets.......... 9D-32
Power Circuit Low......................................... 9D-14 Conditions For Clearing The DTC............ 9D-32
Circuit Description....................................... 9D-14 Diagnostic A ids............................................9D-33
Conditions for Setting The DTC................ 9D-14 DTC C0559 - EEPROM Checksum Error... 9D-34
Action Taken When The DTC S ets..........9D-14 Circuit Description....................................... 9D-34
Conditions For Clearing The DTC............9D-14 Conditions for Setting The D TC ............... 9D-34
Diagnostic A id s............................................9D-14 Action Taken When The DTC S ets..........9D-34
Test Description.......................................... 9D-15 Conditions For Clearing The DTC............ 9D-34
DTC B2948 - Security System Sensor Diagnostic A ids........................................... 9D-34
Power Circuit High........................................ 9D-17 Test Description...........................................9D-35
Circuit Description....................................... 9D-17 DTC U1016 - Loss Of Class 2
Conditions for Setting The DTC................ 9D-17 Communication With V C M ...........................9D-36
Action Taken When The DTC S ets..........9D-17 Circuit Description....................................... 9D-36
Conditions For Clearing The DTC............9D-17 Conditions for Setting The D TC ............... 9D-36
Diagnostic A ids............................................9D-17 Action Taken When The DTC S ets..........9D-36
Test Description............................................9D-18 Conditions For Clearing The DTC............ 9D-36
DTC B2957 - Security System Sensor Diagnostic A ids............................................9D-37
Data Circuit L ow ............................................9D-19 Test Description...........................................9D-37
Circuit Description....................................... 9D-19 DTC U1255 - Class 2 Communication
Conditions for Setting The DTC................ 9D-19 Malfunction..................................................... 9D-38
Action Taken When The DTC S ets........ 9D-19 Circuit Description........................................9D-38
Conditions For Clearing The DTC............9D-19 Conditions for Setting The D T C ............... 9D-38
Diagnostic A id s........................................... 9D-19 Action Taken When The DTC S ets..........9D-38
Test Description...........................................9D-20 Conditions For Clearing The DTC............ 9D-38
DTC B2958 - Security System Sensor Diagnostic A ids............................................9D-38
Data Circuit High........................................... 9D-22 Test Description...............................................9D-39
Circuit Description....................................... 9D-22 O n-V ehicle S ervice ......................................... 9D-40
Conditions for Setting The DTC................ 9D-22 Changing VTD Components..........................9D-40
Action Taken When The DTC S ets........ 9D-22 E V O /P asslo ck M o d u le ..................................... 9D-40
Accessories Table of Contents 3
Engine Coolant Heater ................................... 9E-1 Child Seat Tether Outer Hardware Kit....... 9J-39
General D e scrip tio n ............................................9E-1 Child Restraint Tether Anchor...................... 9J-40
On-Vehicle S ervice..............................................9E-1 D escrip tio n and O p e ra tio n ..............................9J-46
Engine Coolant Heater..................................... 9E-1 Seat Belt System Operation (Description).. 9J-46
S pe cifica tio ns...................................................... 9E-3 Seat Belt System Operation
Fastener Tightening Specifications................. 9E-3 (Police Package).............................................9J-46
Luggage Carrier ................................................. 9F-1 S IR ........................................................................... 9J-47
General D e scrip tio n ............................................ 9F-1 S p e c ific a tio n s .................................................... 9J-47
On-Vehicle S ervice .............................................. 9F-1 Fastener Tightening Specifications..............9J-47
Luggage Carrier Replacement.........................9F-1 Scan Tool Data List....................................... 9J-47
S pe cifica tio ns.......................................................9F-4 Scan Tool Data Definitions............................9J-48
Fastener Tightening Specifications................. 9F-4 GM SPO Group Numbers.............................9J-48
Running Boards ................................................ 9G-1 S ch em atic and R outing D ia g ra m s ................ 9J-49
General Info rm a tio n ........................................... 9G-1 SIR Schematic References.......................... 9J-49
On-Vehicle S ervice............................................. 9G-1 SIR Schematic Icons..................................... 9J-49
Running Board Replacement.......................... 9G-1 SIR Schematics............................................. 9J-49
S pe cifica tio ns......................................................9G-2 C om ponent L o c a to r ......................................... 9J-52
Fastener Tightening Specifications.................9G-2 SIR Components............................................ 9J-52
Restraints ............................................................... 9J-1 SIR Component View s..................................9J-53
Seat Belts .............................................................. 9J-1 SIR Connector End Views
S p e cifica tio n s......................................................9J-1 (Switch and Sensor Views)...........................9J-54
Fastener Tightening Specifications................9J-1 SIR Connector End Views (SDM
Repair Instructio n s............................................. 9J-2 Connector V iew )............................................ 9J-55
Seat Belt Checks (General Checks)..............9J-2 D iag n o stic In fo rm atio n and P ro c e d u re s .... 9J-57
Emergency Locking Retractor Checks...........9J-2 Intermittents and Poor Connections.............9J-57
Seat Belt Service Precautions........................9J-2 SIR General Diagnosis..................................9J-57
Front Seat Belt Replacement (Regular Cab SIR Diagnostic System Check..................... 9J-58
With Bucket Seat)............................................ 9J-3 SDM Integrity Check...................................... 9J-61
Front Seat Belt Replacement (Regular Cab AIR BAG Warning Lamp Comes On
With Bench Seat)............................................. 9J-6 Steady............................................................. 9J-63
Front Seat Belt Replacement (Suburban AIR BAG Warning Lamp Does Not
And Crew Cab).................................................9J-9 Come On......................................................... 9J-68
Front Seat Belt Replacement DTC B1015 Passenger Deploy. Loop
(Utility Model).................................................. 9J-11 Resistance High............................................. 9J-72
Front Seat Belt Replacement (Extended DTC B1016 Passenger Deployment Loop
Cab with Bucket Seat)...................................9J-13 Resistance Low...............................................9J-76
Cab with Bench S eat)...................................9J-16 Open................................................................ 9J-80
Cab with 3rd Door)........................................ 9J-19 Short to GND..................................................9J-84
Front Seat Belt Height Adjuster DTC B1019 Passenger Deploy. Loop
Replacement...................................................9J-23 Short to Voltage............................................. 9J-87
Intermediate Seat Belt Replacement...........9J-24 DTC B1021 Driver Deployment Loop
Rear Seat Belt Replacement (Suburban Resistance High............................................. 9J-90
Removable Rear Seat)..................................9J-27 DTC B1022 Driver Deployment Loop
Rear Seat Belt Replacement Resistance Low.............................................. 9J-94
(2 Door Utility).................................................9J-28 DTC B1024 Driver Deployment Loop
Rear Seat Belt Replacement (Crew Cab).. 9J-30 Short to Ground............................................. 9J-98
Rear Seat Belt Replacement DTC B1025 Driver Deployment Loop
(Extended Cab).............................................. 9J-32 Short to Voltage........................................... 9J-101
Rear Seat Belt Replacement (Extended DTC B1026 Driver Deployment Loop
Cab with 3rd Door)........................................ 9J-34
Rear Seat Belt Replacement DTC B1035 Discr. Sensor Closed or
(4 Door Utility)........................ 9J-36 Short to GND....................................... 9J-108
4 Table of Contents Accessories
DTC B1036 Discr. Sensor Open or AIR BAG Warning Lamp Replacement.... 9J-134
Short to Voltage........................................... 9J-110 Wiring Repair............................................... 9J-134
DTC B1051 Deployment Commanded..... 9J-113 Repairs and Inspections Required
DTC B1053 Deployment Commanded After an Accident......................................... 9J-136
w/Loop Malfunction...................................... 9J-114 Inflator Module Handling, Shipping, and
DTC B1054 Infl Rst IP Module Switch Scrapping......................................................9J-138
CKT Failure...................................................9J-115 Description and O peration........................... 9J-150
DTC B1061 Lamp Circuit Failure...............9J-122 SIR System Operation.................................9J-150
DTC B1071 Internal SDM Failure..............9J-124 SIR System Component Description and
R ep air In s tru c tio n s ......................................... 9J-126 Definitions......................................................9J-151
SIR Service Precautions............................. 9J-126 Special Tools Description........................... 9J-155
Disabling the SIR System .......................... 9J-126 Special Tools and E q u ip m e n t..................... 9J-156
Enabling the SIR System........................... 9J-127 Special Tools.................................................9J-156
General Service Instructions...................... 9J-128 Remote Keyless Entry .................................... 9K-1
Infl Rst Sensing and Diagnostic Module General D e scrip tio n ............................................9K-1
Replacement...................... 9J-129 Functional Operation.........................................9K-1
Infl Rst Instrument Panel Module D ia g n o sis..............................................................9K-2
Replacement.................................................9J-130 On-Vehicle Service.............................................. 9K-2
Infl Rst Front End Discriminating Sensor Transmitter Battery Replacement....................9K-2
Replace................................ 9J-131 Control Module Replacement..........................9K-2
Infl Rst IP Module Switch Replacement...9J-134 Resynchronization............................................. 9K-3
Infl Rst Steering Wheel Module Reprogramming Transmitter............................. 9K-3
Replacement.................................................9J-134
Infl Rst Steering Wheel Module Coil
Replacement.................................................9J-134
AUDIO SYSTEMS 9A-1
SECTION 9A
AUDIO SYSTEMS
AUDIO SYSTEMS
GENERAL DESCRIPTION 1. Body movement produces an electrostatic charge.
To discharge personal static electricity, touch a
The radio receiver mounts in the instrument panel ground point (metal) on the vehicle. This should be
using snap-fit retainers. The receiver and amplifier are done any time you:
an integral design. No remote amplifier is used. The • Slide across the vehicle seat.
available radio systems are as follows: • Sit down or get up.
1. UM7—AM/FM Stereo, Seek and Scan, Clock, 7 FM • Do any walking.
and 7 AM Preset Stations 2. Do not touch exposed electric terminals on compo
2. UM6—AM/FM Stereo, Seek and Preset Scan, nents with your finger or any tools. Remember, the
Auto-Reverse Cassette, Clock, 14 FM and 7 AM connector that you are checking might be tied into
Preset Stations a circuit that could be damaged by electrostatic
3. ULO—AM/FM Stereo, Seek and Scan, Auto-Re discharge.
verse Cassette, Automatic Tone Control, Music 3. When using a screwdriver or similar tool to discon
Search, Clock, Preset Scan, Speed Compensated nect a connector, never let the tool come in contact
Volume, 12 FM and 6 AM Preset Stations with or come between the exposed terminals.
4. UNO—AM/FM Stereo, Seek and Scan, Compact 4. Never jumper, ground, o^ use test equipment
Disc, Automatic Tone Control, Clock, Preset Scan, probes on any components or connectors unless
Speed Compensated Volume, 12 FM and 6 AM specified in diagnosis. When using test equipment,
Preset Stations always connect the ground lead first.
5. RMCD-1—Remote Compact Disc Player 5. Do not remove the solid state component from its
protective packaging until you are ready to install
the part.
HANDLING ELECTROSTATIC 6. Always touch the solid state components package
DISCHARGE to a ground before opening. Solid state compo
nents can also be damaged if:
(ESD) SENSITIVE PARTS
Solid-state electrical components can be damaged by • They are laid on any metal work benches or
electrostatic discharge (ESD). Some will display a label, components that operate electrically, such as a
but many will not (Figure 1). TV, radio, or oscilloscope.
in order to avoid possibly damaging any components,
observe the following: DESCRIPTION OF OPERATION
AM /FM Stereo Radio (U M 7)
N O T IC E Clock
To set the clock:
1. Press the SET pushbutton.
2. Within 5 seconds, press and hold the SEEK right
arrow until the correct minute appears on the
display.
3. Press and hold the SEEK left arrow until the
correct hour appears on the display.
Volum e (VO LUM E)
The radio power switch is integral with the volume
CONTENTS SENSITIVE control. This knob turns the system on and off and
TO controls the volume. To increase volume and turn the
radio on, turn the knob clockwise. To decrease the vol
STATIC ELECTRICITY chhoohia ume or turn the radio off, turn the knob counterclock
wise. The ignition lock cylinder must be in the
Figure 1— E lectro static D ischarge Label ACCESSORY or RUN position for the radio to operate.
9A-2 AUDIO SYSTEMS
Recall (R EC A LL) Scan (SCAN)
If the radio is ON, pressing the volume control will Press both SEEK buttons to listen to a few seconds
alternately cause the display to change from time of day of each radio station. SCAN will light up on the display.
(TOD) to radio frequency display. Display the time with Press the right arrow to tune into the next higher station
the ignition off by pressing the volume control knob. and press the left arrow to tune into the next lower
station. Press VOLUME or both SEEK buttons to stop
Band Sw itching (A M /FM ) scanning.
Depressing the lower knob will change the radio band
between AM and FM. Set (SET) Pushbutton
When the lower knob is depressed, the receiver will Use the SET button in conjunction with the radio sta
tune in the last frequency selected on the opposite tion preset pushbuttons to program radio frequencies
band. The display will indicate the frequency and AM or into the memory locations. See Radio Frequency Preset
FM mode. Pushbuttons in this section for instructions on presetting
radio stations.
Tuning (TU N E)
Rotating the TUNE knob clockwise will increase the Radio Frequency Preset Pushbuttons
AM or FM frequency. Up to 14 stations can be preset into the radio’s memory.
Rotating it counterclockwise will decrease the AM or To preset 4 AM and 4 FM stations:
FM frequency. 1. Tune in the desired station.
2. Press SET pushbutton. SET will appear on the
Treble/B ass (TR EB /B A SS) display.
Slide the TREB lever up to increase the treble
response. If the station is weak or noisy, slide the TREB
lever down to reduce the noise.
Slide the BASS lever up to increase the bass
response. Adjust the BASS lever to give a pleasing
sound to your ear.
B alance (B A L)
Turn the control behind the upper knob to move the
sound to the left or right speakers. The middle position
balances the sound between the speakers.
Fade (FADE)
Turn the control behind the lower knob to move the
sound to the front or rear speakers. The middle position
balances the sound between the speakers.
Seek (SEEK )
Press the right arrow button to tune into the next
station higher in frequency that has sufficient signal
strength to be listenable. Press the left arrow button to
tune into the next station lower in frequency that has
sufficient strength to be listenable. Figure 3— Pushbutton P airing (2 o f 3)
Figure 2—Pushbutton Pairing (1 of 3) Figure 4— Pushbutton Pairing (3 of 3)

AUDIO SYSTEMS 9A-3
3. Press a station pushbutton. The SET on the display Treble/B ass (TR EB /B A SS)
will go out. The radio will then tune in the selected Slide the TREB lever up to increase the treble
station whenever that pushbutton is pressed. response. If the station is weak or noisy, slide the TREB
If electrical power is interrupted (by a blown fuse, lever down to reduce the noise.
discharged battery, service procedure, etc.), the Slide the BASS lever up to increase the bass
station(s) and time of day must be reset. response. Adjust the BASS lever to give a pleasing
To preset 3 additional AM and 3 additional FM sound to your ear.
stations:
1. Tune in the desired station. B alance (BA L)
2. Press SET pushbutton. SET will appear on the Turn the control behind the upper knob to move the
display. sound to the left or right speakers. The middle position
3. Press any two station pushbuttons at the same balances the sound between the speakers.
time (Figures 2 through 4). The SET on the display
will go out. The station will return when the same Fade (FADE)
two pushbuttons are pressed again. Turn the control behind the lower knob to move the
sound to the front or rear speakers. The middle position
Loudness balances the sound between the speakers.
These units contain an auto-loudness feature. This
feature boosts low-frequency audio response to com S eek (SEEK )
pensate for the inability of the ear to hear low-level, Press the right arrow button to tune into the next
low-frequency tones. This compensation varies inverse station higher in frequency that has sufficient signal
ly with the volume control setting. That is, at low volume strength to be listenable. Press the left arrow button to
settings, the low frequencies are boosted much more tune into the next station lower in frequency that has
than at high volume settings. sufficient strength to be listenable.
AM/FM Stereo R adio w ith Integral Cassette Tape S et/E ject (SET/EJEC T) Pushbutton
Player (U M 6) Use the SET/EJECT button in conjunction with the
radio station preset pushbuttons to program radio fre
quencies into the memory locations. See Radio Fre
C lock quency Preset P ushbuttons in this section for
To set the clock: instructions on presetting radio stations.
1. Press tiie SET pushbutton.
2. Within 5 seconds, press and hold the SEEK right Radio Frequency P reset Pushbuttons
arrow until the correct minute appears on the Up to 21 stations (seven AM, seven FM1, and seven
display. FM2) can be preset into the radio’s memory.
3. Press and hold the SEEK left arrow until the To preset 4 AM, 4 FM1, and 4 FM2 stations:
correct hour appears on the display. 1. Tune in the desired station.
2. Press SET pushbutton. SET will appear on the
Volum e (VO LUM E) display.
The radio power switch is integral with the volume 3. Press a station pushbutton. The SET on the display
control. This knob turns the system on and off and will go out. The radio will then tune in the selected
controls the volume. To increase volume and turn the station whenever that pushbutton is pressed.
radio on, turn the knob clockwise. To decrease the vol If electrical power is interrupted (by a blown fuse,
ume or turn the radio off, turn the knob counterclock discharged battery, service procedure, etc.), the
wise. The ignition lock cylinder must be in the station(s) and time of day must be reset.
ACCESSORY or RUN position for the radio to operate. To preset 3 additional AM, FM1, and FM2 stations:
1. Tune in the desired station.
R ecall (RECALL) 2. Press SET pushbutton. SET will appear on the
If the radio is ON, pressing the volume control will display.
alternately cause the display to change from time of day 3. Press any two station pushbuttons at the same
(TOD) to radio frequency display. Display the time with time (Figures 2 through 4). The SET on the display
the ignition off by pressing the volume control knob. will go out. The station will return when the same
Band Sw itching (A M /FM )
two pushbuttons are pressed again.
Press the lower knob to toggle between AM, FM1, Preset Scan (PSC A N )
and FM2. The display indicates the current band. Any stations already stored on the preset pushbuttons
Tuning (TU N E)
can be sampled by the PSCAN mode. Press both
SEEK pushbuttons to scan through each of the preset
Rotating the TUNE knob clockwise will increase the stations. The system will scan through and play each
AM or FM frequency. preset station for a few seconds. Press either SEEK
Rotating it counterclockwise will decrease the AM or button or RECALL to stop scanning through the preset
FM frequency. stations.
9A-4 AUDIO SYSTEMS
Loudness Speed C ontrol Volum e (SCV)
These units contain an auto-loudness feature. This These radios feature Speed Control Volume (SCV).
The volume level automatically adjusts to compensate
feature boosts low-frequency audio response to com
for road and wind noise as you drive. Adjust the volume
pensate for the inability of the ear to hear low-level,
to the listening level you want at any time. As you drive,
low-frequency tones. This compensation varies inverse the volume will change to match the noise present at
ly with the volume control setting. That is, at low volume any particular speed. The volume should always sound
settings, the low frequencies are boosted much more the same level to you as you drive.
than at high volume settings. Each detent on the SCV allows a little more compen
sation at a faster rate.
C assette Tape Player
To Play a C assette Band Sw itching (AM /FM )
To play a tape, the ignition lock cylinder must be in Press the AM/FM pushbutton to toggle between AM,
FM1, and FM2. The display indicates the current band.
ACCESSORY or RUN position and the receiver must be
turned ON. Recall (R ECA LL)
Tapes are end-loaded into these players. Insert the Press the RECALL pushbutton to display the station
tape squarely through the door, exposed tape side of when the radio is on and in the clock mode. When the
the cassette facing the right. When the tape is fully ignition is off, press the RECALL pushbutton to recall
inserted, the AM/FM portion of the radio will turn off and the time of day. RECALL toggles between station and
the tape will begin playing. time of day.
These tape players are built to work best with tapes
Tuning
that are 30 to 45 minutes long on each side. Tape
longer than that are so thin, they may not work well in Press lightly on the TUNE control to release it from its
these players. recessed position. Rotate the TUNE knob to the right to
increase frequency and to the left to decrease frequen
Once the tape is playing, use the upper and lower
cy. Push the control back in to store it while not tuning.
knobs for volume, balance, and fade just as with the
radio. An arrow indicates which side of the tape is being Seek (SEEK )
played. Press the right arrow to tune into the next higher
To fast forward the tape, press SEEK right arrow. The station and the left arrow to tune into the next lower
tape will rapidly advance until you press the SEEK left station and stay there. Audio is muted during SEEK
arrow. operation.
To rewind the tape, press SEEK left arrow. The tape
Scan (SCAN )
will rewind rapidly until you press the SEEK right arrow.
To go from one side of the tape to the other, press the Press and hold SEEK for two (2) seconds. SCAN will
upper knob. appear on the display. Use SCAN to listen to stations
To remove the tape or stop the tape and switch to for a few seconds. Press SEEK again to stop scanning.
Audio is muted during SCAN operation.
radio, press the EJECT pushbutton.
A utom atic Tone Control (ATC)
AM /FM Stereo w ith Integral C assette (ULO) or
The Automatic Tone Control (ATC) feature tailors the
C om pact Disc (UNO) equalization to the type of broadcast being received.
To O perate the Radio Press AUTO TONE to step through the six preset
The ignition lock cylinder must be in the ACCESSO equalization settings of CLASSIC, NEWS, ROCK, POP,
RY or RUN position to operate the radio. Push the PWR JAZZ, or C/W (Country Western). Note the graph and
knob to turn the radio on. words in the display for each press of the pushbutton.
One or more presses of the AUTO TONE pushbutton
C lock will bring up manual (MAN) and return the control of
tone back to the TREB and BASS controls. Any time
To set the clock, push and hold the HR until the that a BASS or TREBLE control is rotated, tone is auto
correct hour appears on the display. Press and hold MN matically set to MAN.
until the correct minute appears on the display. To dis
play the clock with the ignition off, press RECALL or Bass (BA SS)
HR/MN and the time will be displayed for a few sec Depress the BASS control to remove it from its
onds. There is an initial two-second delay before the recessed position. Rotate the BASS control to the right
clock goes into the time-set mode. to increase bass response. If less bass is desired,
rotate the BASS control to the left. This control has a
Volum e (VO L) center detent position. Push the button back in to store
it when not in use. Operation of this control will switch
Rotate the volume control to increase or decrease the the radio’s AUTO TONE feature to MAN.
volume. The faster the VOL knob is rotated, the quicker
the radio goes to maximum volume. The knob is capa
ble of rotating continuously.
AUDIO SYSTEMS 9A-5
Treble (TR EB ) C assette Tape Player (ULO)
Depress the TREB control to remove it from its To Play a Cassette
recessed position; then pull it out to the fully extended Tapes may be played with the ignition ON or OFF. If
position for TREB adjustments. Rotate the TREB control the ignition is ON, but the radio is OFF, the tape will
to the right to increase the treble response. If less treble begin playing. A tape symbol, accompanied by tape
is desired, rotate the TREB control to the left. This con direction arrows, is shown in the center of the graphic
trol has a center detent position. Push the button back display whenever a tape is playing.
in to store it when not in use. Operation of this control Tapes are end-loaded into these players. Insert the
will switch the radio’s AUTO TONE feature to MAN. tape squarely through the door, exposed tape side of
the cassette facing the right. When the tape is fully
S tation Presets inserted, the AM/FM portion of the radio will turn Off
Six pushbuttons store stations in preset memory. You and the tape will begin playing.
can set the pushbuttons for up to 18 stations (six AM, These tape players are built to work best with tapes
six FM1, and six FM2). To store a station in preset that are 30 to 45 minutes long on each side. Tapes
memory: longer than that are so thin, they may not work well in
1. Tune in the desired station, using the TUNE knob these players.
or SEEK. The player automatically senses the tape cartridge for
2. Press TONE to select the graph that best suits the metal or CR02 tape media and presets the pre-empha
type of station selected. sis. For metal tapes, a metal tape indicator will be dis
3. Press and hold one of the six pushbuttons until played. Any time a tape is inserted, the top side is
audio returns (approximately two seconds). selected for play first.
Whenever you press that pushbutton, the preset sta Once the tape is playing, use the volume, balance,
tion will return. The AUTO TONE that you selected will fade, treble, and bass just as with the radio. An arrow
also be automatically selected for that pushbutton. indicates which side of the tape is being played.
Preset Scan (PSC A N ) Previous (PR EV)
Any stations already stored in preset memory can be Press SEEK or PREV to search for the previous
sampled by the PSCAN mode. Press the PSCAN push selection. A minimum three-second blank gap is
button. It will scan each of the presets and stop for a required for proper operation. The tape direction arrow
few seconds. The AUTO TONE setting stored for that blinks during SEEK operation. Audio is muted during
station will be automatically chosen. The tuner will SEEK.
pause momentarily, then continue scanning until
PSCAN or one of the preset pushbuttons is pressed Program (PRO G )
again. PSCAN will appear in the display whenever the Press PROG to play the other side. Tape direction will
tuner is in the PSCAN mode. The channel number reverse.
(P1-P6) will appear momentarily just before the frequen
cy is displayed. Next (NEXT)
Press SEEK or NEXT to search for the next selection.
B alance (BAL) If you hold this pushbutton, or press it more than once,
Depress the BAL control to remove it from its the tape will advance further. NEXT will appear in the
recessed position. Rotate the balance to adjust the display. Audio is muted during NEXT.
sound between the right and left speakers. This control
features a center detent. Push the button back in to Reverse (R EV)
store it when not in use. To rewind the tape, press REV. The tape will rapidly
reverse to the beginning of the tape or until you press
Fade (FADE) the REV pushbutton. The radio will play the last-select
Depress the FADE control to remove it from its ed station during REV operation.
recessed position. Rotate it to adjust the sound between
the front and back speakers. This control features a D olby® Noise Reduction
center detent. Push the button back in to store it when Press the Dolby pushbutton to reduce inherent tape
not in use. noise such as hiss. The Dolby® symbol will appear in
the display.
C lock
To set the clock, press and hold the HR or MIN push Fast Forward (FW D)
button until it begins to change. There will be an initial To fast forward the tape, press FWD. The tape will
two-second delay before the clock goes into the rapidly advance to the end of the tape or until you press
time-set mode. Release the pushbutton when the cor the FWD pushbutton again. The radio will play the
rect time is displayed. The clock may be set with the last-selected station during FWD operation.
vehicle turned off.
9A-6 AUDIO SYSTEMS
Tape/A u xiliary (TA PE/AUX) N ext Selection (N EXT)
To switch between tape and radio, after a tape has Press SEEK up or NEXT to search for the next selec
been installed, press the AM/FM pushbuttons. The radio tion. If you hold this pushbutton, or press it more than
will play. To return to the tape, press TAPE AUX. The once, the disc will advance further. NEXT will appear in
display will show the proper tape direction indicator. the display. Audio is also muted during NEXT.
E ject (EJEC T) Reverse (REV)
To remove the tape, press EJECT. The radio will play. Press and hold REV to return rapidly to a favorite
EJECT may be activated with either ignition or radio passage. This is an audible search at a high rate of
OFF. Cassettes may be loaded with the radio off. speed. Release REV to resume play at normal speed.
CD A dapter Kits Forw ard (FW D)
Although this is not a recommended practice, it is
Press and hold FWD to advance quickly within a
possible to use a CD adapter kit with your cassette tape
player. track. This is an audible search at a high rate of speed.
Release FWD to resume play at normal speed.
The adapter kit cassette should begin playing like a
regular audio cassette tape once inserted. If the cas R ecall (RECALL)
sette immediately ejects, turn the radio off, turn the igni Press RECALL to see what track is playing. Press it
tion on and press and hold the TAPE AUX button until again within five seconds to view elapsed time. Elapsed
the tape icon flashes on the display. Insert the adapter time is displayed in minutes and seconds. Press
cassette again. It will power up the radio and begin RECALL again to return to time of day.
playing. The track number appears when a new track starts to
This override routine will remain active until EJECT is play.
pressed.
Band Sw itching (A M /FM )
Tape C lean Indicator
While a compact disc is playing, pressing the AM/FM
ULO models have an indicator that appears every 50
pushbutton will cancel CD operation and restore radio
hours or so of tape operation, as a reminder that the
capstan and pinch roller need to be cleaned. This operation. The CD symbol will still be displayed, but the
word CD will be replaced by FM1, FM2, or AM in the
cleaning does not require that the tape player be
removed from the vehicle. Refer to Tape Player and display. If the radio is turned off during compact disc
Cassette Care in this section. playback, the disc stays in the player. It will resume
playing at the point where it stopped.
Com pact D isc Player (UNO)
Com pact D isc/A uxiliary (C D /A U X)
To Play a Com pact Disc
Press the PWR knob to turn the system on. Inserting The CD/AUX pushbutton toggles between CD play
a disc will also turn the system on, if the ignition is on. mode and radio operation. When a CD is inserted, it
Insert a disc part way into the slot, label side up. The plays until the AM/FM pushbutton is pressed. Then, the
player will pull it in. Wait a few seconds. The disc CD will cease playback and the radio will play.
should begin to play, and a CD symbol will appear in Ejecting a Com pact Disc (EJEC T)
the display.
If the disc is very hot, or if you’re driving on a very Press EJECT. The disc will eject and the radio will
rough road, a disc may come out or just not play. When play. The disc will start at track 1 when you reinsert it.
the disc player is too hot to play a disc, ERR will appear T h eft D eterrent (TH EFTLO CK )
on the display. Press RECALL to cancel ERR. These radios are equipped with THEFTLOCK theft
When the disc player returns to normal temperature, deterrent which, when enabled, causes the unit to be
the disc should play again. If the disc still will not play, inoperative should it be removed from the vehicle.
check for: The theft deterrent is enabled (SECURE mode) by
• An upside down disc. entering a user-selected code into the unit. This code
• Dirty, scratched, or wet disc. must be re-keyed into the unit following any interruption
• There is too much moisture in the air. If there is, of battery voltage to resume normal operations. When
wait about one hour and try again. battery power is disconnected from a secured radio, the
• The vehicle is operating on a very rough road. radio will not turn on and LOC will appear on the dis
Previous Track (PR EV) play. If the correct code is not entered, the unit will
Press SEEK down or PREV to search for the previous become inoperable and remain in the LOCKED mode.
selection. A minimum three-second blank gap is Any theft deterrent input mode may be exited by cycling
required for proper operation. The direction indicator either the radio power or ignition.
blinks during SEEK operation. Audio is also muted dur A ctivating Theftlock
ing SEEK.
1. Write down any number from 000 to 1999 and keep
Random Playback (RD M ) it in a safe place.
The random playback (RDM) feature allows the tracks 2. Turn the ignition to the ACC or the RUN position.
on the compact disc to be played in random order rath 3. Turn the radio OFF.
er than in sequential order. To stop the random play 4. Press the 1 and 4 pushbuttons together. Hold them
back feature, press RDM. During random playback, a down until— shows on the display.
RANDOM indicator appears in the display.
AUDIO SYSTEMS 9A-7
You are now ready to enter your code. Do not To load a CD into the player, hold the disc with the
wait more than 15 seconds between each step. label side up and insert it carefully into the player (ap
5. Press MIN 000 will appear on the display. proximately halfway), the disc will automatically be
6. Press the MIN pushbutton again to make the last pulled into the player. If the radio is off and the ignition
two digits agree with your code. is on when a CD is inserted, the radio will turn on and
7. Press the HR pushbutton to make the first one or begin playing the CD. It is possible to load and unload
two digits agree with your code. CDs with the ignition off. To load a disc with the ignition
8. Press the AM/FM pushbutton after you have con off, press the EJECT button on the remote player and
firmed that the code matches the one you wrote then insert the disc. To remove the disc, press the
down. REP appears in the display, indicating that EJECT button and remove the disc from the player.
you need to repeat steps 5-7. A disc that had been ejected but is still sitting in the
9. Press AM/FM. This time the display will show SEC. remote CD player will be pulled back into the player
SEC means your radio is secure. after approximately 30 seconds, this protects the disc
NOTE: With the ignition off, the THEFTLOCK and player from damage. The disc will not start playing.
indicator will flash. To remove the disc, press the EJECT button and
remove the disc from the player.
To Unlock T heftlock A fter a Pow er Loss All of the compact disc functions are controlled by the
Enter the user code as follows. Do not wait more than radio buttons except for EJECT. When a disc is in the
15 seconds between steps. player, a CD symbol will appear on the display. When a
disc is playing, the letters CD will appear next to the CD
1. Press MIN, 000 will appear on the display.
symbol in the bottom left comer. The track number will
2. Press the MIN pushbutton again to make the last
also be displayed.
two digits agree with your code.
If the disc comes back out and ERR appears on the
3. Press the HR pushbutton to make the first one or
display, it could be that:
two digits agree with your code.
• The disc is upside down.
4. Press the AM/FM pushbutton after you have con
• It is dirty, scratched or wet.
firmed that the code matches the one you wrote
• There is too much moisture in the air. If there is,
down. SEC will appear in the display indicating that
wait about an hour and try again.
the radio is now operable.
• The vehicle is operating on a very rough road.
If the code is entered incorrectly, SEC will appear on
the display. The radio will remain secured until the cor Previous Track (PREV)
rect code is entered. If the correct code is not available, Press SEEK down or PREV to search for the previous
the dealer will need to Dial Delco or Technical Assis selection. A minimum three-second blank gap is
tance. required for proper operation. The direction indicator
When battery power is removed and later applied to a blinks during SEEK operation. Audio is also muted dur
secured radio, the radio will not turn on and LOC will ing SEEK.
appear in the display. Random P layback (R D M )
D isabling th e Theft-D eterrent Feature The random playback (RDM) feature allows the tracks
on the compact disc to be played in random order rath
Enter the user code as follows; wait no more than er than in sequential order. To stop the random play
15 seconds between steps: back feature, press RDM. During random playback, a
1. Turn the ignition to ACCESSORY or RUN. RANDOM indicator appears in the display.
2. Turn the radio off.
Next Selection (N EXT)
3. Press the 1 and 4 buttons together. Hold them
Press SEEK up or NEXT to search for the next selec
down until SEC appears on the display.
tion. If you hold this pushbutton, or press it more than
4. Press MIN and 000 will appear on the display.
once, the disc will advance further. NEXT will appear in
5. Press MIN again to make the last two digits agree
the display. Audio is also muted during NEXT.
with the user code.
6. Press HR to make the first one or two digits agree R everse (REV)
with the user code. Press and hold REV to return rapidly to a favorite
7. Press AM/FM after you have confirmed that the passage. This is an audible search at a high rate of
code matches the user code you have. The display speed. Release REV to resume play at normal speed.
will show— , indicating that the radio is no longer
secured. Forw ard (FW D)
Press and hold FWD to advance quickly within a
If the code is entered incorrectly, SEC will appear on track. This is an audible search at a high rate of speed.
the display. The radio will remain secured until the cor Release FWD to resume play at normal speed.
rect code is entered. If the correct code is not available,
the dealer will need to Dial Delco or Technical Assis Seek (SEEK)
tance. Press the left arrow while playing a CD to go back to
the start of the current track. It will go back to the
Rem ote Com pact Disc Player current track if more than eight seconds have played.
To Play a Com pact Disc Press the left arrow again to go to previous tracks.
With this option, a single compact disc (CD) can be Press the right arrow to go to the next higher track on
played. the disc.
9A-8 AUDIO SYSTEMS
Random (RA NDO M ) Tape/A uxiliary (TAPE/AUX)
Press PSCAN to enter the random play mode. RAN With a disc loaded in the player and the radio playing,
DOM will appear on the display. While in this mode, the press this button once to play the compact disc. To
tracks on the disc will be played in a random order. If return to playing the radio, press AM/FM. If both a cas
you press SEEK, PREV or NEXT while in the random sette tape and the CD are loaded, press TAPE/AUX to
mode, the previous or next track will be scanned ran switch between the tape and the compact disc.
domly. Press PSCAN again to turn off RANDOM and
return to normal operation. Ejecting a Com pact Disc (EJEC T)
Press the EJECT button on the remote player to eject
R ecall (R EC A LL) the compact disc. The disc will start at track 1 when you
Press RECALL to see what track is playing. Press it reinsert it.
again within five seconds to view elapsed time. Elapsed
time is displayed in minutes and seconds. Press
RECALL again to return to time of day.
The track number appears when a new track starts
to play.
DIAGNOSIS
AUDIO SYSTEM DIAGNOSIS
For information on audio system diagnosis, refer to
Electrical Diagnosis.
ON-VEHICLE SERVICE
RADIO REPLACEMENT |"M-| Install o r Connect (Figure 5)
Rem ove o r D isconnect (Figure 5) 1. Antenna connection.

1. Negative battery cable. Refer to Battery Disconnect 3. Radio by sliding into the instrument panel.
Caution in General Information. • Unit should snap into retainers when fully
2. Instrument panel trim. Refer to Instrument Panel seated.
and Gauges. 4. Instrument panel trim.
3. Release radio retainers using a small screwdriver. 5. Negative battery cable.
4. Radio by sliding forward. • Check component operation.
6. Antenna connection.
Figure 5— Radio R eplacem ent Figure 6 — Using A C leaning C assette

AUDIO SYSTEMS 9A-9
REMOTE PLAYBACK DEVICE in cassette mode. The feature will be canceled and the
timer reset when the eject button is pressed and held
REPLACEMENT for approximately five seconds. When the feature has
been canceled,— appears in the display.
COMPACT DISC PLAYER AND
Caution in General Information. DISC CARE
2. Instrument panel trim. Refer to Instrument Panel No maintenance is required to the compact disc play
and Gauges. er. The use of CD lens cleaner discs is not advised, due
3. Release retainers using a small screwdriver. to the risk of contaminating the lens of the CD optics
4. Electrical connectors. with lubricants internal to the CD mechanism.
5. Playback device. Handle discs carefully. Store them in their original
cases, or other protective cases and away from direct
□ Install or C onnect (Figure 5) sunlight and dust. If the surface of a disc becomes
soiled, dampen a clean, soft cloth in a mild, neutral
1. Electrical connectors. detergent solution and clean it, wiping from the center
2. Playback device. to the edge. Be sure never to touch the signal surface
• Unit should snap into retainers when fully when handling discs. Pick up the discs by grasping the
seated. outer edges, or the edge of the hole and the outer
3. Accessory trim plate. edge.
• Check component operation. AMPLIFIER REPLACEMENT
TAPE PLAYER AND CASSETTE Rem ove o r D isconnect (Figure 7)
CARE
A tape player that is not cleaned regularly can cause Caution in General Information.
reduced sound quality, ruined cassettes or a damaged 2. Electrical connectors, as necessary.
mechanism. Cassette tapes should be stored in their 3. Amplifier from bracket.
cases away from contaminants, direct sunlight and
extreme heat. Install o r Connect (Figure 7)
For the best operation of the cassette tape player, do
not use cassette tapes that are longer than 90 minutes 1. Amplifier to bracket.
in playback time (45 minutes per side). Cassette tapes 2. Electrical connectors, as necessary.
longer than 90 minutes may cause tape slippage or 3. Negative battery cable.
jamming. • Check circuit operation.
Tape Head and C apstan C leaning
There are two parts that are cleaned on a tape player:
the head and the capstan. Since they can be reached
through the tape door, leave the tape player in the vehi
cle. This service should be performed every 50 hours of
operation.
To dean the head and capstan, use a cotton swab
dipped in ordinary rubbing alcohol, or use a cleaning
cassette.
As an alternate way to clean the head and capstan, a
cleaning cassette kit may be purchased (Figure 6). Fol
low the instructions included with the kit to clean the
tape player.
Do not contact the tape head with magnetized tools. If
the head becomes magnetized, cassette sound quality
will be degraded.
No service is performed on tapes. Warranty of these
tapes is handled by the cassette manufacturer, not by
the dealer.
Clean Tape Indicator Feature
The cassette and remote cassette units will remind
the user to clean the cassette head. After 50 hours of (1) Relay
cassette operation, CLN will appear briefly in the display (2) Amplifier
when a cassette is inserted or when the power is cycled (3) Retainer
Figure 7—Amplifier Assembly
9A-10 AUDIO SYSTEMS
SPEAKER REPLACEMENT 3. Screws.
Front S ide Door Speakers Tighten
Rem ove o r D isconnect (Figure 8) • Screws to 2 N-m (18 lb in).

4. Trim panel.
1 . Trim panel. Refer to Trim Panel Replacement in • Check component operation.
Doors. Front Door A rm rest Speakers
2. Screws.
3. Release speaker retainer using a small screwdriver.
4. Speaker.
1. Lift armrest speaker cover at the rear edge.
+4- Install o r Connect (Figure 8) 2. Slide cover back to disengage front retainer.
4. Speaker.
• Rotate speaker to release it.
2. Speaker.
• Speaker should snap into retainer when fully +4* Install or Connect (Figure 9)
seated.
1. Speaker to the cover by rotating.
• Speaker should snap into retainer when fully
seated.
3. Slide cover into front slots.
4. Lower armrest speaker cover to engage retainers.
Rear Speakers
|<-»| Remove or Disconnect (Figures 10 through 14)
1. Speaker grille or rear trim panel. Refer to Trim Pan

el Replacement in Interior Trim
2. Screws.
3. Speaker.
Figure 8— Front Speaker A ssem bly
Figure 10— Rear Speaker (Pickup/C hassis-C ab

Figure 9 — A rm rest Speaker Replacem ent M odels)
AUDIO SYSTEMS 9A-11
Figure 11— Rear Speaker Harness Routing

(Pickup/C hassis-C ab M odels) (Pickup/C hassis-C ab M odels)
-M - Install o r Connect (Figures 10 through 14) ^ Tighten
1. Electrical connectors. • Screws to 2 N.m (18 lb in).

2. Speaker. 4. Speaker grille or rear trim panel.
3. Screws. • Check component operation.
Figure 12—Rear Speaker Harness Routing (Extended Cab Models)

9A-12 AUDIO SYSTEMS
2. Speaker.
3. Retainers.
4. Speaker grille.
• Check component operation.
Rear O verhead Speakers
1. Speaker grille.
2. Roof inner trim panel, if necessary, refer to Interior
Trim.
3. Screws.
4. Speaker from bracket.

Figure 13— R ear S peaker Assem bly (Extended
C ab/C rew Cab M odels) 1. Electrical connectors, as necessary.
2. Speaker to bracket.
Side D oor Speakers 3. Screws.
Rem ove o r D isconnect (Figure 15) S Tighten
1. Speaker grille. • Screws to 2 N-m (18 lb in).

2. Retainers. 4. Roof inner trim panel, if necessary.
3. Speaker. 5. Speaker grille.
4. Electrical connectors. • Check component operation.
Figure 14— Rear Speaker Harness Routing (Crew Cab Models)

AUDIO SYSTEMS 9A-13
Figure 16— R ear O verhead S peaker A ssem bly

(Suburban and U tility M odels)
ANTENNA
GENERAL DESCRIPTION
The fixed mast barbless antenna is designed to with
stand most car washes without damage. It cannot be
adjusted up or down. If the mast becomes slightly bent,
straighten it by hand. The antenna can be replaced if it
becomes severely bent. Antennas must be kept clean
for good performance.
DIAGNOSIS
Disconnect the antenna from the extension cable and nection in the antenna/lead-in system can result in seri
plug in a test antenna. Ground the antenna to the vehi ously reduced radio performance. A poor ground can be
cle chassis. Keep hands off of the antenna. Test radio a reason for excess ignition noise on AM or erratic
reception in an area away from electrical interference audio. Also, make sure lead-in connectors are free of
such as tall buildings, metal structures, power lines, flu dirt and corrosion, and are tightly fastened.
orescent lighting, and power tools. Tune to high and low Possible ground loss or high-resistance ground points
ends of the dial on both AM and FM, checking weak are:
and strong station reception. If reception is okay, the • Antenna upper mounting (loose screws, paint over
problem exists with the antenna and/or its lead-in cable. spray, etc.).
If reception is still poor, refer to Diagnosis earlier in this • Lead-in cable connector at antenna (loose or inter
section. nally corroded).
• Lead-in cable connector at radio (loose or internally
Testing fo r Good G round of A ntenna corroded).
M ounting and Connections • Quick connect connector (corroded).
Poor grounding at the antenna mounting or any con • Missing ground lead.'
9A-14 AUDIO SYSTEMS
M easuring R esistance w ith D igital Volt-O hm m eter
M EASURE RESISTANCE W ITH DIGITAL

VOLT-OHM M ETER
PROBES ON INDICATION (O HM S)*
3 and 4 Less than 0.2
1 and 2 Less than 0.2
2 and 4 Infinite
1 and 3 Infinite
1 and 4 Infinite
2 and 3 Infinite
‘ WHILE MEASURING, WIGGLE LEAD-IN TIP AND
CABLE; INDICATION SHOULD NOT VARY.
T3226
Usually, a broken center conductor of the lead-in

cable will result in no AM and weak FM. In case of
continued reception or noise complaints, always check
the lead-in with an ohmmeter (Figure 17). Fig 17
When checking resistance, wiggle the lead-in tip and
cable. If the readings shown in the accompanying table
Legend
are not obtained, some portion of the lead-in is intermit
tent. Replace the lead-in. (1) Insulator
(2) Insulator
(3) Lead-In Tip
(4) Lead-In Cable
Figure 17— Lead-In Cable Diagnosis
ON-VEHICLE SERVICE
FIXED ANTENNA REPLACEMENT
1. Antenna mast.
2. Nut.
3. Bezel.
4. Antenna cable from extension cable.
5. Screws.
6. Antenna cable assembly.
+<-] Install or C onnect (Figure 18)
1. Antenna cable assembly.

2. Screws.
Tighten
• Screws to 5 N-m (58 lb in).

3. Antenna cable to extension cable.
4. Bezel. Legend
5. Nut.
(1) Radio Antenna
Tighten (2) Antenna Cable Nut
(3) Antenna Bezel
• Nut to 5 N-m (58 lb in). (4) Antenna Cable Assembly
6. Antenna mast. (5) Screw
(6) Antenna Extension Cable
Figure 18—Antenna Assembly
AUDIO SYSTEMS 9A-15
LEAD-IN REPLACEMENT
Rem ove or Disconnect (Figures 19 through 21)
1. Roll out instrument panel. Refer to Instrument Pan

el and Gauges.
2. Extension cable from radio (Figure 19).
3. Extension cable from HVAC duct (Figure 20).
4. Extension cable from antenna (Figure 21).
+«- Install o r C onnect (Figures 19 through 21)
1. Extension cable to radio (Figure 19).

2. Extension cable to HVAC duct (Figure 20).
3. Extension cable to antenna (Figure 21).
4. Roll instrument panel back in place and secure.
Refer to Instrument Panel and Gauges.
Figure 20— A ntenna Extension C able Routing to

HVAC Duct
Figure 21— A ntenna Extension Cable R outing to

(1) Antenna Extension Cable (UM6, UM7) Antenna
(2) Antenna Extension Cable (ULO, UNO)
Figure 19— Antenna Extension Cable Routing to
Radio
9A-16 AUDIO SYSTEMS
SPECIFICATIONS

Antenna Cable Mounting Screw 5 — 58
Antenna Mounting Nut 5 — 58
Front Speaker Mounting Screw 2 — 18
Rear Overhead Speaker Mounting Screw 2 — 18
Rear Speaker Mounting Screw 2 — 18
CRUISE CONTROL 9B-1
SECTION 9B
CRUISE CONTROL
GENERAL DESCRIPTION
CRUISE CONTROL SYSTEM clutch release switch is activated and will interrupt the
voltage supplied to the cruise control circuit in the ECM
Gas Engines and will disengage the cruise module.
The cruise control system associated with gas
engines is made up of the Vehicle Control Module VEHICLE SPEED SIGNAL
(VCM), the cruise control module, the multifunction
lever, and the brake release switch. The cruise control Gas Engines
module contains a stepper motor which is used to
The vehicle speed signal is generated by the Vehicle
change throttle position. The cruise control module
Speed Sensor (VSS), at the transmission and translated
receives commands from the multifunction lever, and
by the VCM.
vehicle speed from the VCM. Based on these input
The VSS mounts to the automatic transmission
commands, and vehicle speed, the cruise control mod
assembly and produces an AC signal. The frequency of
ule will control speed.
this signal is proportional to the transmission output
Diesel Engines shaft speed. The AC signal is sent to the VCM to be
The cruise control system associated with diesel amplified and converted to a digital square wave that
engines is made up of the Powertrain Control Module represents the vehicle speed in terms of Pulses Per
(PCM), the electronic throttle system, the Vehicle Speed Mile (PPM). The VCM provides a 4000 PPM signal.
Sensor Buffer (VSSB), the multifunction lever, and the This 4000 PPM signal is provided to the cruise control
brake release switch. The PCM receives commands module, and speedometer in the instrument cluster.
from the multifunction lever. The PCM also receives
vehicle speed information from the VSSB. Based on Diesel Engines
input commands and vehicle speed, the PCM sends The vehicle speed signal is generated by the Vehicle
information to the electronic throttle system to control Speed Sensor (VSS), at the transmission and translated
vehicle speed. by the Vehicle Speed Sensor Buffer (VSSB).
The VSS mounts to the automatic transmission
BRAKE RELEASE SWITCH assembly and produces an AC signal. The frequency of
this signal is proportional to the transmission output
Gas Engines shaft speed. The AC signal is sent to the VSSB to be
The cruise control module uses an electronic brake amplified and converted to a digital square wave that
switch which contains one normally open and one nor represents the vehicle speed in terms of Pulses Per
mally closed switch contact. These switch contacts are Mile (PPM). The VSSB provides a 4000 PPM signal.
part of the zero adjust brake switch. This 4000 PPM signal is provided to the powertrain
When the brake pedal is depressed, the two brake control module, and speedometer in the instrument
switch contacts change their input state at the cruise cluster.
control module. The cruise control module will then shut
off all cruise control outputs.
Diesel Engines
The powertrain control module uses an electronic Gas Engines
brake switch which contains one normally open and one For gas engine applications, the cruise control module
normally closed switch contact. These switch contacts maintains a desired vehicle speed under normal driving
are part of the zero adjust brake switch. conditions.
When the brake pedal is depressed, the two brake Typical operation is as follows:
switch contacts change their input state at the power- The cruise ON/OFF switch must be in the ON posi
train control module. The powertrain control module will tion. When the SET button is activated the cruise con
then shut off all cruise control outputs to the electronic trol module stores the last vehicle speed input from the
throttle system. VCM into a memory. The stepper motor (part of the
cruise control module) will increase or decrease throttle
CLUTCH RELEASE SWITCH position depending on the load (going up or down a hill)
For vehicles equipped with a manual transmission, to maintain vehicle speed. If the cruise ON/OFF switch
there is a clutch release switch located on the clutch is turned off, or the brake is applied, the cruise control
push-rod. When the clutch pedal is depressed the module will turn off the cruise system.
9B-2 CRUISE CONTROL
Diesel Engines disengages the system, but the set speed is
For diesel engine applications, the PCM takes the retained in memory allowing a RESUME at a later
place of the cruise control module. time.
Typical mode of operation is as follows: • T h e C o a s t (T r im ) F u n c tio n — W hen the
The cruise ON/OFF switch must be in the ON posi SET/COAST button switch is fully depressed, the
tion. When the SET button is activated, the PCM Stores driver can raise or lower the control speed. To
the last vehicle speed input from the VSSB into a mem increase control speed, the driver would accelerate
ory location. The PCM then sends signals to the elec to a new speed and fully depress the switch. The
tronic throttle control system. The PCM controls the VCM releases the previously set speed. Then
electronic throttle to maintain the vehicle speed stored release the button. Upon releasing the button, a
in memory. The electronic throttle is a servo system new speed is set. An increased control speed can
which sends position information to the PCM. The PCM also be more easily set by the RESUME/ACCEL
will increase or decrease throttle position depending on switch as described later. To decrease cruise
the load (going up or down a hill) to maintain vehicle speed, the SET/COAST switch is held in (de
speed. If the cruise ON/OFF switch is switched off or pressed position) to disengage the cruise system,
the brake is applied, the PCM will turn off the cruise and allowing the throttle to return to the idle posi
control system. tion. When the vehicle has slowed to the desired
lower cruise speed, releasing the switch will cause
MULTIFUNCTION LEVER the system to cruise at the new speed.
• The Tap Down Function —For this function to
O N/O FF Sw itch operate, the cruise must be engaged and operat
The ON and OFF position slide switch, located on the ing. Tapping down means quickly pressing the
multifunction lever assembly, controls electrical power to SET/COAST button to the depressed position and
the cruise control system. When the switch is OFF the quickly releasing it, or tapping the button. Do not
system cannot be engaged. When the switch is ON the hold the button in the depressed position or the
system may be engaged by either the SET or RESUME system will revert to the COAST mode. Tap down is
switch at any speed above approximately 40 km/h a function in which cruise speed can be decreased
(25 mph), refer to Figure 1. by 1.6 km/h (1 mph) increments (one tap=1 mph
decrease). The system can tap down to the engage
SET/C O A ST Button speed lockout of 40 km/h (25 mph), below this
The SET/COAST button controls three functions. speed, cruise control will not operate.
• The S et Function —When the SET/COAST switch The accelerator may be depressed at any time to
is depressed and then released, with vehicle speed override the cruise system. Release of the accelerator
above the low speed limit point, and the ON/OFF will return the vehicle to the previous set cruise speed.
switch in the ON position, cruise speed will be set
at the particular speed the vehicle was at when the RESUM E/ACCEL R/A Switch
button was released. Cruise speed will be within ± The RESUME/ACCEL switch controls three functions.
1.6 km/h (1 mph) of actual vehicle speed when • The Resum e Function —If the cruise system has
engaged. The system will cruise until either the been disengaged by depressing the brake pedal, it
ON/OFF switch is moved to OFF, the ignition switch may be reactivated by momentarily holding the
is turned off, and/or the SET/COAST button is RESUME/ACCEL switch. This will cause the vehi
pushed in fully and held. Pushing the brake pedal cle to accelerate to the previously set speed and
cruise at that speed. The resume function will not
work if the cruise ON/OFF switch or the ignition
switch has been cycled since the last time cruise
was active or the vehicle speed is below the low
speed lockout 40 km/h (25 mph).
• T h e A c c e le ra te F u n c tio n — By sliding the
RESUME/ACCEL switch and holding it, the vehicle
will accelerate until the switch is released. The
cruise ON/OFF switch must be on and the vehicle
speed must be above the low speed lockout
40 km/h (25 mph) for this function to operate.
• The Tap Up Function —For this function to oper
ate, the cruise must be engaged and operating.
Tapping up means quickly pressing the slide switch
toward the R/A position and quickly releasing it, or
tapping the lever. Do not hold the lever in the R/A
position or the system will revert to the Accel
mode. Tap up is a function in which cruise speed
can be increased by 1.6 km/h (1 mph) increments
(one tap=1 mph increase). The system cannot tap
up beyond 201 km/h (125 mph).
Figure 1—Multifunction Lever

CRUISE CONTROL 9B-3
DIAGNOSIS
Before beginning diagnosis, make a visual inspection 4. Check Brake Release: Depress the brake pedal.
for the following and repair as needed: The cruise control must release the throttle, allow
ing the vehicle speed to drop. The system must not
PRELIMINARY INSPECTION re-engage when the brake is released.
5. Check Resum e Feature: With the vehicle speed at
• Check G A G E S 20 am p fuse.
approximately 72 km/h (45 mph), slide the cruise
• Check for bare, broken, or disconnected wires.
switch momentarily (less than 1 second) to the R/A
• Check for binding or mis-adjusted cable assembly.
position. The vehicle should accelerate to approxi
• Check for dam aged or mis-positioned brake switch.
mately 89 km/h (55 mph).
If preliminary inspection reveals no problem, follow
the Functional Check.
6 . Check Coast Feature: Depress the S E T push but
ton and hold. Allow the vehicle speed to drop to
8 0 km/h (50 mph) and release the push button.
FUNCTIONAL CHECK Cruise control should hold vehicle speed at approx
Use this procedure to check the operating modes of imately 80 km/h (50 mph).
the cruise control system. Always use this procedure 7. Check A ccelerate Feature: Slide the cruise switch
after repair work has been completed on the cruise to the R/A position and hold. The vehicle speed
system. should begin to increase. Allow th e speed to
1. Slide the turn signal lever cruise switch to the ON increase to 89 km/h (55 mph) and release switch.
position. T h e cruise control should hold the vehicle at
2. Check the Low Speed Inhibit: Drive the vehicle at approximately 89 km/h (55 mph).
32 km/h (20 mph). Depress S E T push button and 8 . Check O ff Sw itch: Turn the turn signal lever cruise
release. Cruise control must not engage. switch to the O F F position. This must disengage
3. Check S et Speed: Drive the vehicle at a steady the cruise control system.
speed of 89 km/h (55 mph). Depress the S E T push If preliminary inspection reveals no solution, refer to
button com pletely and re lea s e. C ruise control Engine Controls, Transmission Diagnosis and Electrical
should engage at approximately 89 km/h (55 mph). Diagnosis Manual.
ON-VEHICLE SERVICE
CRUISE CONTROL CABLE 3. Air cleaner assembly from the vehicle. Refer to the
Engine Controls, Transmission Diagnosis and Elec
Rem ove or Disconnect (Figures 2 through 5) trical Diagnosis Manual.
4. Cable housing from the module housing.
5. Cable bead from the end of the ribbon.
1. Cruise control cable from the throttle lever.
6. Cable from the vehicle.
2. Cruise control cable housing from the retainer on
the bracket.
Install o r C onnect (Figures 2 through 5)
1. Route the cable from the cruise control module to

the throttle lever.
2. Cable bead to the end of the ribbon on the cruise
control module.
3. Cable housing to the cruise control module.
4. Air cleaner assembly to the vehicle. Refer to the
Engine Controls, Transmission Diagnosis and Elec
trical Diagnosis Manual.
5. Cruise control cable housing to the retainer on the
bracket.
6. Cruise control cable to the throttle lever.


2. Air cleaner assembly from the vehicle.
3. Electrical connector at the cruise control module.
Figure 2—Cruise Control Module Ribbon

9B-4 CRUISE CONTROL
4. Nuts retaining the cruise control module to the 4. Electrical connector at the cruise control module.
cowl. 5. Air cleaner assembly to the vehicle.
5. Cruise control cable from the module. R efer to 6. Negative battery cable.
Cruise Control Cable in this section.
6. Cruise control module from the vehicle. ENGAGEMENT SWITCH
The cruise control engagem ent switch is part of the
multifunction lever assembly and is not serviceable by
itself. T h e multifunction lever and switch must be
1. Cruise control module to the vehicle.
replaced as an assembly. For replacement procedures,
2. Cruise control cable to the cruise control module. refer to Steering Column Unit Repair.
Refer to Cruise Control C able in this section.
3. Nuts to retain the cruise control module to the cowl.
Tighten
• Nuts to retain the cruise control module bracket

to the cowl to 5 N-m (44 lb in).
CRUISE CONTROL 9B-5
Legend
(1) Cruise Control C able (2) Accelerator Cable
Figure 4— C ruise Control Cable Routing (7.4L Engines)
9B-6 CRUISE CONTROL
(1) Cruise Control C able (2) Accelerator Cable

Figure 5— C ruise Control Cable Routing (5.0L and 5.7L Engines)
(1) Cruise Control Servo Cable

(2) Cruise Control Module
(3) Cruise Control Module Mounting Screw
Figure 6—Cruise Control Module
CRUISE CONTROL 9B-7
SPECIFICATIONS
Cruise Control Module Bracket to Cowl Retaining Nuts 5 — 44
9B-8 CRUISE CONTROL
BLANK
THEFT DETERRENT SYSTEM 9D-1
SECTION 9D
THEFT DETERRENT SYSTEM

(PASSLOCK)
PASSLOCK SYSTEM
GENERAL DESCRIPTION 3. W hen using a screwdriver or similar tool to discon
nect a connector, never let the tool com e in contact
The PASSLO CK ™ System is designed to prevent
with or come between the exposed terminals.
v e h ic le th e ft by d is ab lin g th e e n g in e u n less th e
4. N e v e r ju m p er, ground, or use tes t e q u ip m en t
P A S S LO C K ™ Lock Cylinder is properly rotated by
probes on any components or connectors unless
engaging the correct ignition key. This system is similar
specified in diagnosis. W hen using test equipment,
in c o n c e p t to th e P a s s k e y S y s te m ; h o w e v e r ,
always connect the ground lead first.
PA SSLO C K ™ eliminates the need for a key mounted
5. Do not remove the solid state component from its
resistor pellet. The components of this system are as
protective packaging until you are ready to install
follows: PA SSLO C K ™ Lock Cylinder, Ignition Switch,
the part.
PA SSLO C K ™ Sensor, PASSLO CK ™ Module, Securi
6. Always touch the solid state component package to
ty Indicator, and Vehicle Control Module (VC M ). W hen
a ground before opening. Solid state components
reference in this section is made to the Vehicle Control
can also be dam aged if:
Module (V C M ), the Powertrain Control Module (P C M ) is
considered the equivalent.
• They are laid on any metal work benches or
components that operate electrically, such as a
SYSTEM OPERATION Radio, T V or Oscilloscope.
Th e PA SSLO C K ™ System is designed to prevent Not all parts that can be dam aged by ESD have an
vehicle operation if the proper ignition key is not used to ESD label. Som e of the components involved in this
start the vehicle. The mechanical key, in normal opera section which can be dam aged by ES D are:
tion, will turn th e P A S S L O C K ™ Lock C ylinder. T h e
• Vehicle Control Module (VC M ).
PA SSLO C K ™ Sensor will relay Passlock D ata to the
• Passlock ™ Module.
Passlock/EVO Module. Th e Passlock/EVO Module will
• Passlock ™ Sensor.
determine the validity of the Passlock D ata and will
• E E P R O M (Electrical Erasable Programmable Read
send a coded password to the Vehicle Control Module
Only Memory).
(V C M ). W h e n th e V e h ic le C o n tro l M o d u le (V C M ) Solid state components also can be dam aged if they
receives the correct code, it will allow the Fuel Injectors
are bumped or dropped, or if they are laid on a metal
to operate normally. work bench or on an electrically operated item such as
a radio, a T V or an Oscilloscope.
HANDLING ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE
PARTS
M any solid state electrical components can be dam NOTICE
aged by Electrostatic Discharge (E S D ). Som e will dis
play a label as shown in Figure 1, but many will not.
N O TIC E:In order to avoid possibly damag

ing any components, observe the following.
1. Body movement produces an electrostatic charge.
ground point (metal) on the vehicle. This should be
done any time you:
• Slide across the vehicle seat.
• Sit down or get up. CO NTENTS SENSITIVE
• Do any walking.
TO
2. Do not touch exposed electric terminals on compo
nents or connectors with your finger or any tools. STATIC ELECTRICITY ch n o w o a
Remember, the connector you are checking might

be tied into a circuit that could be dam aged by Figure 1 - E lectrostatic D ischarge S ensitive Parts
electrostatic discharge. Label
9D-2 THEFT DETERRENT SYSTEM
SYSTEM COMPONENTS security resistors ranging up 13 Kohms, any one may
be installed inside the Passlock ™ Sensor to generate
a unique PASSLOCK ™ code. All ten combinations of
PASSLOCK ™ Lock Cylinder the Passlock ™ Sensor have the sam e part number.
W h e n th e p r o p e r c u t k e y is in s e rte d in th e However, one cannot simply replace the PASSLOCK ™
PA S SLO C K ™ Lock Cylinder, it can be turned clock Sensor and expect the system to operate properly. You
wise rotating a magnet past a stationary hall effect sen must follow the replacement instructions specified in
sor creating Passlock Cylinder D ata which is sent to the Steering Column Unit Repair.
Passlock/EVO Module.
NOTE PASSLOCK ™ Module

The P asslock ™ Lock C ylinder m ust be placed in The Theft Deterrent System ’s logic is contained within
the CRANK position to rem ove it fo r replacem ent. the Passlock/EVO Module. The PASSLO CK ™ Module
will read Passlock Data from the PA SSLO C K ™ Lock
Ignition Sw itch S e n s o r . If th e P a s s lo c k D a t a is c o r r e c t , th e
PASSLOCK ™ Module will Pass Theft and will transmit
T h e lock cylinder and the visible key insert portion of
its coded password to the Vehicle Control M odule
it are located at the upper right side of the steering
(VC M ).
column. T h e electrical switching portion of the assembly
is separate from the key and lock cylinder and is hidden Im portant
inside the steering column. However, both are synchro
nized and work in conjunction through the action of the
Please note, during any Tamper M ode the vehicle
mechanical assem bly between the two.
m ay start; however, the vehicle will quickly stall. If the
P A S SLO C K ™ Module receives the wrong Passlock
PASSLOCK ™ Sensor Data, the V T D will immediately go into its Tam per Mode
T h e P A S S L O C K ™ S e n so r is located inside the in which the vehicle’s fuel injectors will be locked-out for
u p p e r rig h t s id e o f th e s te e r in g c o lu m n . T h e ten (10) minutes as described above. Th e S E C U R IT Y
PA S S LO C K ™ Sensor itself contains two hall effect indicator will flash while the V T D is in Tam per Mode.
sensors. A Tam per Hall effect Sensor on top and a
Security Hall Effect Sensor under it. Both Hall Effect If the Passlock ™ Sensor sends a correct password
Sensors monitor the m agnet of the lock cylinder through to the P A S S LO C K ™ M odule w hen the ignition is
an opening, the Tam per Hall Effect Sensor is physically turned ON, the PASSLOCK Module will send a fuel
p laced on top of th e S e c u rity H all E ffect S e n so r enable signal to the Vehicle Control Module (V C M ). The
enabling it to engage first should an intruder attempt to Vehicle Control Module (VC M ) will not disable fuel due
bypass the PA S SLO C K ™ Sensor by placing a large to any Passlock ™ Module m essage for the remainder
m agnet around that area of the Steering Column. There of that ignition cycle.
is a 2 74 ohms tam per resistor inside the Passlock ™
Sensor. C /K vehicles have a selection of ten different SECURITY Indicator
Th e S E C U R IT Y Indicator is located on the Instrument
Cluster. If the S E C U R IT Y indicator flashes or if it lights
continuously during vehicle operation, refer to the
System Diagnosis located in this section.
(1) P A S S L O C K ™ Lock Cylinder and Key Insert

(2) P A S S L O C K ™ S e n s o r a n d Ig n itio n S w itc h
Location
Figure 2—Steering Column Figure 3—EVO/Passlock Module
VEHICLE CONTROL MODULE VTD CLASS 2
(VCM) COMMUNICATIONS
The Vehicle Control Module (V C M ) is located at the Th e PASSLOCK ™ System requires the Vehicle Con
left rear side of the engine com partm ent near the trol Module (VC M ) and the P A S S LO C K ™ Module to
EBCM . com m unicate various functions in order to operate.
T h e Vehicle Control M odule (V C M ) com m unicates T h ese functions are transmitted over the Class 2 Serial
with the PA SSLO C K ™ Module via serial data over the D ata Line, or circuit 1807. For an explanation of Class 2
C lass 2 S e ria l D a ta Bus, circuit 1 8 0 7 . W h e n the S e ria l D a ta o p e ra tio n , re fe r to C o m p u te r S ystem
PA SSLO C K ™ Module has determined a Passed Theft Diagnosis.
condition, it sends a coded password to the Vehicle
Control M odule (V C M ). Upon receipt of the correct SCAN TOOL DIAGNOSIS
password, the Vehicle Control Module (VC M ) enables
Refer to the Scan Tool O w ner’s Manual for informa
the fuel injection system, allowing fuel delivery to the
tion about the Scan Tool and the various modes.
injectors. P lease note, the Vehicle Control M odule
(V C M ) m ay allow the vehicle to start and quickly stall if DATA LIST
th e re is a p roblem with th e P ass lo c k ™ S e cu rity Th e scan tool can list the PASSLOCK ™ /E V O Mod
System. ule data list. This list shows the status of the hardwired
If a password is not received or is incorrect by the connections m ade to the P A S S LO C K ™ Module and
tim e the engine starts, the Vehicle Control M odule can be very useful in diagnosing the PASSLOCK ™
(V C M ) will enter a Lockout Mode during which it will not system.
allow the vehicle to start. A Lockout is triggered if a
tam per condition exists when other than the correct igni AUTO LEARN TIM ER STATUS
tion key is used to start the vehicle, or if a large magnet The Auto Learn Tim er is used as part of the interac
is placed around the Lock Cylinder in an attempt to tive procedure to allow learning of the Passlock D ata in
bypass the Passlock ™ System. Lack of data from the service (approximately 3 0 minutes).
Passlock ™ Sensor to the Passlock ™ Module triggers
certain D TC s which can also cause this condition . LOCKOUT TIM ER STATUS
The Lockout Tim er is the ten minutes time that the
PASSLO CK ™ Module must go through in the event of
a tam per mode even if the Ignition Switch was turned to
the O F F position.
Figure 4— Instrument Cluster

PASSW ORD SEC U R ITY INDICATOR STATE
T h e Passw ord is a coded m essage sent by the T h e S E C U R IT Y indicator state indicates whether the
PA SSLO C K ™ Module to the Vehicle Control Module PA SSLO C K ™ Module has determined if the Passlock
(V C M ) when the engine is started. Th e V C M then com data has passed. The Passlock ™ Module supplies a
pares the data received with the stored data, if the data ground to the security lamp driver circuit illuminating the
is a match the Vehicle Control Module (V C M ) will keep S E C U R IT Y indicator at the Instrum ent Cluster. Th e
the vehicle running, otherwise will immediately shut the S E C U R IT Y indicator will be O N when any D TC is set or
engine off. if the S E C U R IT Y indicator lamp driver circuit is shorted
to ground. T h e P asslock ™ M odule will flash the
PASSLOCK DATA VOLTAGE S E C U R IT Y indicator when there exists a tam per condi
Th e Passlock signal is an analog input voltage gener tion or the fuel enable lockout bit was set in the last
ated by a voltage divider network. T h e PA SSLO C K ™ status m essage received from the V C M .
M odule determ ines if this voltage value is valid or
invalid.
PASSLOCK POW ER
T h e P A S SLO C K ™ M odule supplies the Passlock
power signal to the Passlock Sensor.
SELF DIAGNOSTICS
SYSTEM TESTS 3. Special Functions (Output Controls) - allows for
outputs of the system to be set at a desired value
System Tests using the scan tool allow for the display (ON or O FF).
of values as actually seen or com manded by the vari 4. C lear Codes - will erase all D TC s stored for the
ous systems (i.e. V C M , SD M , EB C M , or Passlock/EVO system currently selected (Note: If the malfunction
M odule). Th e Test Types available are dependent upon is still present, the D TC may imm ediately reset).
the system selected, but m ay include the following:
1. D ata (Analog Inputs) - displays analog values as SNAPSHO T
seen by the system. T h e Snapshot function is the sam e one used to cap
2. Inputs and Outputs (Digital Inputs) - displays digital ture D TC s for the Vehicle Control Module. Refer to the
values as seen by the system and provides an scan tool instruction manual for more information.
indication of whether the input or output has cycled.
REPROGRAMMING PROCEDURES
REPROGRAMMING PROCEDURE T h e PA SSLO C K ™ Module will set the D TC B3031 -
Module in learn mode, when entering the reprogram
- SEED AND KEY ming procedure. The following is the Seed and Key
Learn Procedure:
DISCLAIM ER
This step by step procedure is intended to augment STEPS
the PA SSLO C K ™ Diagnostic Repair Procedures. Sole 1. C lear all PASSLOCK ™ Module and V C M D T C s t
reliance on this procedure m ay lead to unintended 2. Turn Ignition Off.
results. 3. Replace the Module or sensor (If indicated).
4. Turn th e Ignition S w itch to th e O N p o sitio n ,
EQ U IPM EN T
momentarily rotate it to C R A N K (DO N O T START
• C D - R O M database containing Passlock Seed and V E H IC L E ), and re le a s e it to th e ignition O N
Key algorithm loaded on a computer with class 2 position.
capability. 5. With the T E C H 2 or a Class 2 compatible computer
connected to the Data Link Connector, issue the
• T E C H 2 or a compatible scan tool. P a ss lo c k R e q u e st D e v ic e C o ntrol (C P ID $ A E
$ FE $80).
C O NDITIO NS
6. O bserve the Class 2 response ($7F $AE $ FE $80
T h e following procedure allows relearning of the
$33), to Request Device Control denied and issue
P A S S L O C K ™ M od u le or V e h ic le C ontrol M odule
an Unlock Module Security, (mode $27 01 Request
(V C M ) Learned Data Code when any of the following
Seed and mode $27 02 wx yz Send Key ), to
parts is replaced:
initiate Seed and Key learn sequence. After issuing
1. PA SSLO C K ™ Module
a (mode $27 01) Request Seed , the technician will
2. Passlock Sensor
be required to access a C D -R O M database for the
3. Vehicle Control Module (VC M ) *
algorithm needed to unlock the P A S S L O C K ™
Module or V C M , whichever was not replaced.
7. Now issue the Request Device Control ($AE $ FE 5. Observe the S E C U R IT Y indicator:
$80) and observe the Class 2 response ($E E $FE a. If the Passlock ™ Sensor was replaced, the
$E 1) D evice Control Enabled . T h e S E C U R IT Y S E C U R IT Y indicator will flash for 10 minutes.
indicator should be O N continuously for 10 minutes. b. If the Passlock ™ Module was replaced, the
8. After 10 minutes, the S E C U R IT Y indicator will turn S E C U R IT Y indicator will flash for a few sec
O F F and the module will learn the new component onds, then stay O N for 10 minutes.
on th e n ex t ig n itio n lo ck c y lin d e r c yc le from c. If the V C M was replaced with a new one off the
O FF-to-C R A N K -to-O N (start attempt). shelf, vehicle will start and this procedure may
not be needed. However, if the replacem ent
* If a n ew V e h ic le C o n tro l M o d u le is b e in g V C M w as plugged at a n y other tim e even
installed fo r th e firs t tim e. M anufacturing enable bit momentarily, the S E C U R IT Y indicator will flash
w ill be set and th e Auto learn procedure m ay not be for a few seconds, then stay O N for 10 minutes.
necessary. 6. After 10 minutes of remaining in the ignition ON
position, the S E C U R IT Y indicator will transition
t P asslock related DTCs stored at the Vehicle from flashing to O N briefly and finally OFF.
Control M odule have to be erased. If there are any 7. Turn the Ignition Switch to the O F F position and
pow ertrain related DTCs, record them firs t and refer wait for 10 seconds.
those to the Engine D iagnostics fo r repair. 8. Repeat steps 3 - 6 two more times. The module will
learn the new component on the next ignition lock
NOTE cylinder cycle from O F F -to -C R A N K -to -O N (start
In addition to the tim e involved in perform ing the attempt).
specific steps, the Seed and Key procedure accom
plishes the sam e task in 10 m inutes as the Auto * If a new V e h ic le C o n tro l M o d u le is b e in g
Learn procedure does in 30 m inutes. Either one can installed fo r the firs t tim e. M anufacturing enable bit
be used. w ill be set and the Auto learn procedure m ay not be
necessary.
REPROGRAMMING PROCEDURE
- AUTO LEARN t P asslock related DTCs stored at the Vehicle
Control M odule have to be erased. If there are any
CO NDITIO NS pow ertrain related DTCs, record them firs t and refer
The following procedure allows for anyone to repro those to the Engine D iagnostics fo r repair.
gram the P A S SLO C K ™ Module Learned D ata Code
without any tools (other than the scan tool) when any of SYSTEM ELECTRICAL
the following parts is replaced: SCHEMATICS
1. P A S S LO C K ™ Module
2. Passlock Sensor COM PONENT REFERENCE
3. Vehicle Control M odule (V C M ) * Electrical Diagnosis contains several component loca
The PA SSLO C K ™ M odule will set the D TC B3031 - tion illustrations which will assist in locating the various
Module in learn mode, when entering the reprogram components called out in the diagnostic tables. The
ming procedure. T h e following is the Auto Learn Proce schematics show the wiring shared between the compo
dure: nents in the system. For the detailed removal, replace
ment and adjustment procedure, refer to the appropriate
STEPS
service manual section.
1. Clear all PA S SLO C K ™ Module and V C M D T C s t
2. Turn Ignition Off.
3. Replace the M odule or sensor (If indicated).
4. Turn th e Ig n itio n S w itc h to th e O N p o sitio n ,
momentarily rotate it to C R A N K (DO N O T START
V E H IC L E ), a n d re le a s e it to the ignition O N
position.
n EVQ>1
| PASSLOCK
| MOOULC
03-13-97
J 4208W0608
DIAGNOSIS
DIAGNOSTIC TROUBLE CODES TROUBLESHOOTING HINTS
m Im portant (Perform before beginning
DO NOT replace the PASSLOCK ™ M odule unless
System Diagnosis)
there are no Vehicle Control M odule (VC M ) Diagnos • M ake the following checks before beginning system
tic T ro u b le C o d es (D T C s ) c u rre n t, and a DTC diagnosis.
rem ains current in the P asslock ™ M odule after the 1. Check all fuses by visual inspection.
VTD D iagnostic System C heck table and the corre 2. Ensure that all connectors in system are mated
sponding DTC table have been executed. NEVER correctly.
replace th e PASSLOCK ™ M odule based on H istory 3. Check for open in Class 2 Serial D ata Line
codes. (C K T 1807), refer to Data Link Connector (DLC)
in Electrical Diagnosis
The PASSLOCK™ M odule is connected to the 4. D O N O T replace the PA S SLO C K ™ Module
C lass 2 serial data link and is capable of setting with only History Codes set.
D iagnostic Trouble Codes. The history DTC codes (a • Check for a broken (or partially broken) wire inside
history DTC code is a fau lt th at disappears in the of the insulation which could cause system failure
next ignition cycle but rem ains as a history DTC fo r but prove G O O D in a continuity/voltage check (re
a 100 ignition cycle) can be especially useful in fer to Troubleshooting Procedures in Electrical
diagnosing an interm ittent problem . An explanation Diagnosis).
o f th ese are given below in D iag n o stic Trouble • Check for proper installation of aftermarket elec
Codes (D TC ) Table, fo r a com plete list of Diagnostic tronic equipment which may affect the integrity of
Trouble Codes refer to Com puter System s Diagno their systems (refer to Troubleshooting Procedures
sis. in Electrical Diagnosis).
• Check that all grounds are tight and clean.
INTERM ITTENT AND POOR • Refer to System Diagnosis.
CONNECTIONS SYSTEM DIAGNOSIS

Most intermittent faults are caused by a faulty electri • Perform the V T D Diagnostic System Check table
c a l c o n n e c tio n o r w irin g , a lth o u g h a d a m a g e d below first. If multiple DTCs are present, refer to
Passlock/Electronic Variable Orifice (E V O ) Module can the Displaying Diagnostic Trouble Codes table fol
occasionally be at fault. Refer to Intermittent and Poor lowing this table te perform the appropriate diag
Connections for a detailed explanation of how to locate
nostic procedures ih the order shown.
and repair intermittent conditions.
Icon Icon Definition
ilk Refer to Electrostatic Discharge (ESD) Sensitive Devices in Symbols,

Page 8 A - 3 - 0 .
A Refer to SIR Caution in Symbols, Page 8 A - 3 - 0 .

9 P-8 THEFT DETERRENT SYSTEM____________________
VTD DIAGNOSTIC SYSTEM CHECK

S te p A ctio n V alue Yes No
1 Attempt to start the engine. Go to Step 2 Go to Step
24
Does the engine crank?
2 Does the engine start and stall immediately? — Go to Step 4 Go to Step 3
3 Does the engine start and run OK? — Go to Step 4 Go to Step
22
4 1. Reconnect all previously disconnected components Go to Step 6 Go to Step 5
(If any).
2. Ensure the Ignition Switch is in the R U N position,
engine OFF.
3. Connect a scan tool into the Diagnostic Link Con
nector (DLC).
4. Attempt to establish communication with the Vehicle
Control Module (VC M ).
Does the scan tool communicate with the Vehicle Con

trol Module (VC M )?
5 Refer to D ata Link Connector (DLC) in Electrical Diag Go to Step 6
nosis.
Can communication be established?

6 Attempt to communicate with the Passlock/EVO Module. G o to Step Go to Step 7
17
Does the scan tool communicate with the Passlock/EVO
Module?
7 IN S P E C T Fuse 21 (S E C /S T R G ). Go to Step Go to Step 8
10
Is the fuse open?
8 Inspect Fuse 4 (G A U G E S ) Go to Step 9 Go to Step
11
Is the fuse open?
9 1. Turn the ignition OFF. Go to Step 1 G o to Step
2. Disconnect the 16-way Passlock/EVO Module Con 26
nector.
3. Inspect electrical terminals and connector for proper
fit. Repair as necessary.
4. REPAIR the PN K (39) wire for a short to ground.
W as a repair made?
10 1. Turn the ignition OFF. Go to Step 1 G o to Step
2. Disconnect the 16-way Passlock/EVO Module Con 26
nector.
4. REPAIR the O R N (1740) wire for a short to ground
b e t w e e n f u s e 21 a n d t e r m i n a l B 8 o f t h e
Passlock/EVO Module.
W as a repair made?
11 1. Turn Ignition OFF. Go to Step G o to Step
2. Disconnect the Passlock/EVO Module 16-w ay con 13 12
nector.
3. Check for voltage at terminal B8 of the 16-w ay con
nector to ground.
Is voltage present?
Step Action Value Yes No
12 LOCATE and REPAIR open in O R N 1740 wire between Go to Step 1
Fuse 21 and terminal B8 of the Passlock/EVO Module.
W as a repair made?
13 1. Turn Ignition ON. Go to Step Go to Step
2. Check for voltage at terminal B3 of the 16-way con 15 14
nector to ground.
Is voltage present?
14 LOCATE and REPAIR open in PN K 39 wire between Go to Step 1
Fuse 4 and terminal B3 of the Passlock/EVO Module.
W as a repair made?
15 Inspect for open in BLK/W H T 651 wire between terminal Go to Step 1 Go to Step
B1 of the 16-way Passlock/EVO Module connector and 16
ground.
W as a repair made?
16 1. Turn Ignition OFF. Go to Step 1 Go to Step
2. Disconnect the scan tool from the D ata Link Connec 26
tor (DLC).
4. Inspect Serial Data Line PPL 1807 wire from termi
nal B4 of Passlock/EVO Module to terminal 2 of the
D LC for open.
W as a repair made?
17 1. Turn the ignition OFF. Go to Step Go to Step
2. Key O N . Monitor the S E C U R IT Y indicator at the 27 18
Instrument Cluster for 10 seconds.
3. Using the scan tool, read the Passlock ™ Diagnostic
Trouble Codes.
Are there any DTCs?

18 Did the S E C U R IT Y indicator light at all? — Go to Step Go to Step
21 19
19 1. Key OFF. 1.0v Go to Step Go to Step
2. Disconnect the Instrument Cluster. 20 26
3. Disconnect the Passlock ™ Module.
4. Key O N .
5. Use a D M M to measure the voltage in the Y E L 749
wire at the Passlock ™ Module connector terminal
B2.
Is the measured voltage above the specified value?

20 Repair the Y E L 749 wire for a short to an ignition G o to Step 1
source between the Passlock ™ Module connector ter
minal B2 and the Instrument Cluster connector terminal
26.
Is the repair complete?

21 Th e S E C U R IT Y indicator normally com es ON then goes Go to Step System
O F F after 5 seconds of ignition ON. 25 Operating
Normally.
Is the S E C U R IT Y indicator still O N at this time?
22 Did the engine crank normal? —
G o to Step Go to Step
23 24
23 Check the Spark and fuel delivery systems. Refer to Refer to
Engine Controls. Engine Con
trols
24 Check the Starting and Charging System. Refer to Refer to
Engine Electrical. Engine Elec
trical
25 1. Turn the ignition OFF. G o to Step 1 Go to Step
2. REPAIR short to ground on Y E L 749 wire between 26
terminal B2 of the Passlock/EVO Module and termi
nal 2 6 of the Instrument Cluster.
W as a repair made?
26 1. Turn Ignition OFF. Go to Step 1
2. Reconnect any previously disconnected components.
3. R E P LA C E the Passlock/EVO Module.
4. Perform the Seed and Key Procedure.

27 If multiple D TC s are present, the DTCs should be priori Refer to the Refer to the
tized and diagnosed in the order of importance. D T C table appropriate
following this D TC table.
Is there more than one D T C present? system
check table
and diag
nose DTCs
in the order
shown.
DISPLAYING DIAGNOSTIC TROUBLE CODES (DTCs)

DTCs listed below are prioritized in order of im portance and should be diagnosed in the sam e order.
D IA G NO STIC TRO UBLE CODE EXPLANATION
PA S SLO C K T H E F T D E T E R R E N T T E C H 2 D ISPLAY
U 10 16 Loss O f Class 2 Communication With V C M
U 12 55 Class 2 Communication Malfunction
C 05 59 E E P R O M Checksum Error
B 2947 Security System Sensor Power Circuit Low
B 3033 Security System Indicates Tam per
B 2960 Security System Sensor D ata Incorrect But Valid
B 2957 Security System Sensor D ata Circuit Low
B 2958 Security System Sensor D ata Circuit High
B 2948 Security System Sensor Power Circuit High
B3031 Security System Controller In Learn Mode
B 0688 Security System Indicator Circuit High
DIAGNOSTIC TABLES
i
S215 ■ ■
1 BLK/WHT I 451
i A
(G4S) F \ J / ^ 2 0 0
( 0 » E S E L )K V |/ —
1
i
1 BLK/WHT I 451
P101 SEE CROUNO
DISTRIBUTION
S103I PAGE B A - 1 4 - 8
1 BLK/WHT | 451 1 BLK/WHT j 451
# G103 (GAS) - A G104 (GAS) fc m m J

- - (DIESEL)
DTC B0688
SECURITY SYSTEM INDICATOR CIRCUIT HIGH
Circuit Description Conditions for Clearing the DTC

This circuit supplies ground to the S E C U R IT Y indica • The Passlock ™ Module continuously monitors the
tor at the Instrument Cluster from the Passlock ™ M od signal and moves the D TC from current to history
ule, circuit 749. on the next ignition cycle when the condition caus
ing the fault no longer exists.
Conditions for Setting th e DTC • All P a s s lo c k ™ M o d u le history c od es w ill be
All of the following conditions must be met: cleared after 100 ignition cycles (from O F F to R UN)
• T h e Passlock ™ Module is trying to ground the with no current codes active during the 100 ignition
S E C U R IT Y lamp driver. cycles.
• T h e S E C U R IT Y lamp driver circuit voltage is great • Using a scan tool.
er than 2.85 volts for 0 .15 second.
Diagnostic Aids
Action Taken When th e DTC • W hen the diagnostics direct you to take electrical
m eas u rem e n ts at the W iring H arn ess Junction
Sets Blocks , refer to Power Distribution, in Electrical
• Stores D T C B 06 88 in the Passlock ™ M odule Diagnosis, for terminal assignments of the Wiring
memory. Harness Junction Blocks .
• S E C U R IT Y indicator will never illuminate under any • If the D T C is a history D TC, the problem m ay be
circumstances. intermittent. Try performing the tests shown while
wiggling wiring and connectors, this can often
cause the malfunction to appear.
Test Description
T h e numbers below refer to the numbers on the diag
nostic table.
2. This step checks the power and ground supply to
the instrument cluster.
3. This step determines if there is an open or short to
battery in circuit 7 4 9 between the Passlock ™
Module and the S E C U R IT Y indicator.
DTC B0688 - SECURITY SYSTEM INDICATOR CIRCUIT

HIGH
Step Action Value(s) Yes No
1 W as the V T D Diagnostic System Check performed? Go to Step 2 G o to V TD
Diagnostic
System
Check
2 Key O N . O bserve the Instrument Cluster. R efer to G o to Step 3
Instrument
Are all Gauges and indicators inoperative on the clus- Cluster S ec
ter? tion in Elec
trical
Diagnosis.
3 1. Ensure the scan tool is still connected to the Data Go to Step Go to Step 4
Link Connector. 13
2. Using the scan tool actuate the S E C U R IT Y indicator.
Does the S E C U R IT Y indicator illuminate?

4 1. Key OFF. Go to Step 5 Go to Step 9
2. Rem ove the Instrument Cluster.
3. Connect a test light between the Y E L 7 49 wire at the
Instrument Cluster connector terminal 26 and battery.
4. Key O N . Connect a scan tool to the D ata Link Con
nector.
5. Using the scan tool actuate the S E C U R IT Y indicator.
Does the test light illuminate?

5 Rem ove and inspect the S E C U R IT Y indicator lamp. Go to Step 6 Go to Step 7
Is the lamp open?

6 R eplace the S E C U R IT Y indicator lamp. Go to Step
14
7 Locate and Repair open circuit at the instrument cluster Go to Step Go to Step 8
circuit board leading to the S E C U R IT Y indicator. 14
W as the dam age repairable?

8 Replace the dam aged Instrument Cluster and/or circuit Go to Step
board as necessary. 14

THEFT DETERRENT SYSTEM 9D»13
9 1. Key OFF. 1.0v Go to Step Go to Step
2. Rem ove the scan tool and the test light. 10 11
3. Disconnect the Passlock ™ Module.
4. Use a D M M to measure the voltage in the Y E L 749
wire at the Passlock ™ Module connector terminal
B2.

10 Repair the Y E L 749 wire for a short to battery between Go to Step
the Passlock ™ Module connector terminal B2 and the 14
Instrument Cluster connector.

11 Use a D M M to measure the resistance in circuit 749 10.0 Q Go to Step Go to Step
between the Passlock ™ Module connector terminal B2 13 12
and the Instrument Cluster connector terminal 26.
Is the measured resistance below the specified value?

12 Repair the open Y E L 7 49 wire between the Passlock ™ Go to Step
Module connector terminal B2 and the Instrument Clus 14
ter connector terminal 26.

13 Key OFF. R EP LA C E the Passlock ™ Module. Go to Step
14
Is the procedure done?
14 1. Reconnect all previously disconnected connectors Go to V T D
and components. Diagnostic
2. M ake sure the ignition is ON. System
3. Connect a scan tool into the diagnostic Link Connec Check
tor.
4. C lear the DTCs from memory.
5. Perform the Reprogramming Procedure - Seed and
Key in this section.

DTC B2947
SECURITY SYSTEM SENSOR POWER CIRCUIT LOW
Circuit Description Conditions for Clearing th e DTC

This circuit supplies power from the Passlock ™ Mod • The Passlock ™ Module continuously monitors the
ule to the Passlock ™ Sensor, circuit 812. signal and moves the D TC from current to history
on the next ignition cycle when the condition caus
Conditions for Setting the DTC ing the fault no longer exists.
• All P ass lo c k ™ M odule history co d e s will be
All of the following conditions must be met:
cleared after 100 ignition cycles (from O F F to RUN)
• Passlock ™ Power is active
with no current codes active during the 100 ignition
• T h e Passlock 12v power circuit is not present for
cycles.
0 .5 second.
• Using a scan tool.
Action Taken When th e DTC Diagnostic Aids

Sets • W hen the diagnostics direct you to take electrical
• Stores D T C B 2947 in the Passlock ™ Module m e as u rem e n ts at the W iring H arn e ss Junction
memory. Blocks , refer to Power Distribution, in Electrical
• If ignition was O F F at the time, vehicle will not Diagnosis, for terminal assignments of the Wiring
start. Harness Junction Blocks .
• If the engine was running at the time, vehicle will • If the D TC is a history DTC, the problem may be
restart but S E C U R IT Y indicator will remain illumi intermittent. Try performing the tests shown while
nated. wiggling wiring and connectors, this can often
Test Description
The numbers below refer to the numbers on the diag
nostic table.
2. This step determines if there is a short to ground
in circuit 812 between the Passlock ™ Module
and the Passlock Sensor.
DTC B2947 - SECURITY SYSTEM SENSOR POWER

CIRCUIT LOW
1 W as the V T D Diagnostic System Check performed? Go to Step 2 Go to VTD
Diagnostic
System
Check
2 1. Ensure the ignition switch is still in the ON position. 10.0 Volts Go to Step Go to Step 3
2. Using the scan tool, read the Passlock ™ power 11
circuit voltage.
Is the voltage reading above the specified value?

3 1. Key OFF. Disconnect the Passlock ™ Sensor con 10.0 Volts Go to Step Go to Step 4
nector. 10
2. Key ON.
3. Using the scan tool, read the Passlock ™ power
circuit voltage.
Is the voltage reading above the specified value?

4 1. K ey O F F . D is c o n n e c t th e P a s s l o c k ™ M od u le Infinite G o to Step 6 Go to Step 5
16-w ay connector.
2. U se a D M M to measure the resistance in circuit 812
between the PASSLOCK ™ Module connector termi
nal A5 and ground.
Is the measured resistance within the specified range?

5 REPAIR short to ground in circuit 812 between the G o to Step
PASSLO CK ™ Module connector terminal A5 and the 12
Passlock ™ sensor connector. Refer to Wiring Repair in
Wiring Systems.
Is repair complete?
6 Check for a poor connection at the Passlock ™ Module Go to Step 7 Go to Step 8
connector terminal A5, circuit 812.
W as a poor connection found?

7 Repair the poor connection at the Passlock ™ Module G o to Step
connector terminal A5. Refer to Wiring Repair in Wiring 12
Systems.

8 Check for a poor connection at the PASSLOCK ™ sen G o to Step 9 Go to Step
sor connector. 11

9 Repair the poor connection at the PASSLOCK ™ sen G o to Step
sor connector. Refer to Wiring Repair in Wiring Sys 12
tems.

10 R EP LA C E the Passlock ™ sensor. G o to Step
12
11 R EP LA C E the Passlock ™ Module. G o to Step
12
12 1. Reconnect all previously disconnected connectors G o to V T D
tor.
4. C lear the DTCs from memory.

r n E V O /P A S SLOCK
r T STEERING
|COLUMN
PASSLOCK
SEN SO R
I.
LOCK CYLINOER
J
DTC B2948 SECURITY SYSTEM SENSOR POWER

CIRCUIT HIGH
\

This circuit supplies power from the Passlock ™ M od • The Passlock ™ Module continuously monitors the
ule to the Passlock ™ Sensor, circuit 812. signal and moves the D T C from current to history
All of the following conditions must be met: • All P asslo ck ™ M o d u le history codes will be
• Ignition is N O T active cleared after 100 ignition cycles (from O F F to RUN)
• Th e Passlock ™ sensor Power 12 volt feedback is with no current codes active during the 100 ignition
present for 0 .5 second. cycles.
Action Taken When the DTC
Diagnostic Aids
• Stores D T C B 2 9 4 8 in the Passlock ™ M odule m easu rem en ts at th e W iring H arn e ss Junction
• If ignition was O F F at the time, vehicle will not Diagnosis, for terminal assignments of the Wiring
start. Harness Junction Blocks .
• If the engine was running at the time, vehicle will • If the D TC is a history D TC, the problem may be
restart but S E C U R IT Y indicator will remain illumi intermittent. Try performing the tests shown while
Test Description
nostic table.
2. This step determines if there is a short to battery
DTC B2948 - SECURITY SYSTEM SENSOR POWER

CIRCUIT HIGH
Step A c tio n Value(s) Yes No
1 W as the V TD Diagnostic System Check performed? Go to Step 2 Go to V TD
Diagnostic
System
Check
2 1. Turn ignition OFF. 0.5 Volt Go to Step 3 Go to Step 4
2. Disconnect the PASSLOCK ™ Sensor connector.
3. Use a D M M to measure the voltage in circuit 812
between the PASSLO CK ™ Sensor connector and
ground.

3 Check for and REPAIR short to battery in circuit 812 Go to Step 7 Go to Step 6
between the PASSLO CK ™ Module connector terminal
A5 and the Passlock ™ sensor connector. Refer to W ir
ing Repair in Wiring Systems.
W as a repair made?
4 1. Disconnect the Passlock ™ Module 16-way connec 0 .5 Volt Go to Step 5 Go to Step 6
tor.
2. Turn ignition ON.
3. Use a D M M to measure the voltage in circuit 812
between the PA SSLO C K ™ Module connector termi
nal A5 and ground.

5 Check for and REPAIR short to battery in circuit 812 Go to Step 7
between the PA SSLO C K ™ Module connector terminal
A5 and the Passlock ™ sensor connector. Refer to W ir
ing Repair in Wiring Systems.
Is repair complete?
6 R EP LA C E the Passlock ™ Module. Go to Step 7

7 1. Turn ignition OFF. Go to V TD
2. Reconnect all previously disconnected connectors Diagnostic
and components. System
3. Turn ignition ON. Check
4. Connect a scan tool into the diagnostic Link Connec
tor.
5. C lear the D TCs from memory.

DTC B2957 - SECURITY SYSTEM SENSOR DATA

CIRCUIT LOW

This circuit supplies the Passlock signal to the • The Passlock ™ Module continuously monitors the
Passlock ™ Module from the Passlock ™ Sensor, cir signal and moves the DTC from current to history
cuit 1836. on the next ignition cycle when the condition caus
Conditions for Setting the DTC • All Passlock ™ Module history codes will be
All of the following conditions must be met: cleared after 100 ignition cycles (from OFF to RUN)
• Ignition is active with no current codes active during the 100 ignition
• The Passlock signal is less than 0.4 volt for cycles.
1.0 second. • Using a scan tool.
Action Taken When the DTC Diagnostic Aids

• When the diagnostics direct you to take electrical
Sets measurements at the Wiring Harness Junction
• Stores DTC B2957 in the Passlock ™ Module Blocks , refer to Power Distribution, in Electrical
memory. Diagnosis, for terminal assignments of the Wiring
• If ignition was OFF at the time, vehicle will not Harness Junction Blocks .
start. • If the DTC is a history DTC, the problem may be
• If the engine was running at the time, vehicle will intermittent. Try performing the tests shown while
restart but SECURITY indicator will remain illumi wiggling wiring and connectors, this can often
nated. cause the malfunction to appear.
Test Description
nostic table.
2. This step determines if there is a short to ground

CIRCUIT LOW
1 Was the VTD Diagnostic System Check performed? Go to Step 2 Go to VTD
Diagnostic
System
Check
2 1. Ensure the scan tool is still connected to the Data 0.8 Volt Go to Step Go to Step 3
Link Connector. 11
2. Using the scan tool read the Passlock ™ sensor
signal voltage.
Is the voltage above the specified value?

3 1. Key OFF. 0.8 Volt Go to Step Go to Step 4
2. Disconnect the Passlock ™ sensor connector. 10
3. Key ON.
4. Using the scan tool read the Passlock ™ sensor
signal voltage.

4 1. Key OFF. Infinite Go to Step 6 Go to Step 5
2. Disconnect the Passlock™ Module 16-way connec
tor.
3. Use a DMM to measure the resistance in circuit
1836 between the PASSLOCK ™ Module connector
terminal B7 and ground.

5 REPAIR short to ground in circuit 1836 between the Go to Step
PASSLOCK ™ Module connector terminal B7 and the 12
Wiring Systems.
Is repair complete?
connector terminal B7, circuit 1836.
Was a poor connection found?

7 Repair the poor connection at the Passlock ™ Module Go to Step
connector terminal B7. Refer to Wiring Repair in Wiring 12
Systems.

8 Check for a poor connection at the PASSLOCK ™ sen Go to Step 9 Go to Step
sor connector. 11

9 Repair the poor connection at the PASSLOCK ™ sen Go to Step
tems.

10 REPLACE the Passlock ™ sensor. Go to Step
12
11 REPLACE the Passlock ™ Module. Go to Step
12
12 1. Reconnect all previously disconnected connectors Go to VTD
2. Make sure the ignition is ON. System
tor.
4. Clear the DTCs from memory.

DTC B2958
SECURITY SYSTEM SENSOR DATA CIRCUIT HIGH

This circuit supplies the Passlock signal to the • The Passlock ™ Module continuously monitors the
Passlock ™ Module from the Passlock ™ Sensor, signal and moves the DTC from current to history
circuit 1836. on the next ignition cycle when the condition caus
Conditions for Setting the DTC • All Passlock ™ Module history codes will be
All of the following conditions must be met: cleared after 100 ignition cycles (from OFF to RUN)
• Ignition is active with no current codes active during the 100 ignition
• The Passlock signal is above 4.3 volts for cycles.
1.0 second. • Using a scan tool.

Sets measurements at the Wiring Harness Junction
• Stores DTC B2958 in the Passlock ™ Module Blocks , refer to Power Distribution, in Electrical
• If ignition was OFF at the time, vehicle will not Harness Junction Blocks .
start. • If the DTC is a history DTC, the problem may be
• If the engine was running at the time, vehicle will intermittent. Try performing the tests shown while
restart but SECURITY indicator will remain illumi wiggling wiring and connectors, this can often
nated. cause the malfunction to appear.
Test Description
nostic table.
4. This step determines if there is an open or short to
battery in circuit 1836 between the Passlock ™
Module and the Passlock Sensor.

CIRCUIT HIGH
Diagnostic
System
Check
2 Using the scan tool, read the VCM DTCs. Go to Step 3 Go to Step 4
Is there an Incorrect Password DTC present?

3 1. If someone tries to fool the system by instantly doing Go to VTD
a Key OFF/Key ON while the engine is running, the Diagnostic
Passlock ™ Module may set this Sensor Data Cir System
cuit High DTC and/or the VCM may set the Incorrect Check
Password DTC.
2. If this was the case during an engine run cycle, one
may be forcing the VCM to look for a password while
the Passlock ™ module does not expect to send
one.
3. Mark down any other VCM DTCs that may be
present and refer those to Engine Controls.
4. Using the scan tool erase VCM DTCs.

4 1. Ensure the ignition key is still ON. 4.5 Volts Go to Step Go to Step 5
2. Using the scan tool read the Passlock ™ sensor 13
signal voltage.
Is the voltage below the specified value?

5 1. Key OFF. Disconnect the Passlock™ Module 4.3 Volts Go to Step 6 Go to Step 7
16-way connector.
2. Disconnect the PASSLOCK ™ Sensor connector.
3. Use a DMM to measure the voltage in circuit 1836
between the PASSLOCK ™ Module connector termi
nal B7 and ground.

6 REPAIR short to battery in circuit 1836 between the Go to Step
PASSLOCK ™ Module connector terminal B7 and the 14
Wiring Systems.
Is repair complete?
7 Use a DMM to measure the resistance in circuit 1836 10.0 Q Go to Step 9 Go to Step 8
between the Passlock ™ Module connector terminal B7
and the PASSLOCK ™ sensor connector.

8 Repair the open circuit in circuit 1836 between the Go to Step
Passlock ™ Module connector terminal B7 and the 14
PASSLOCK ™ sensor connector.

Step A ction Value(s) Yes No
9 Use a DMM to measure the resistance in circuit 1057 10.0 o Go to Step Go to Step
between the Passlock ™ Module connector terminal B5 11 10
and the PASSLOCK ™ sensor connector.

10 Repair the open circuit in circuit 1057 between the Go to Step
Passlock ™ Module connector terminal B5 and the 14
PASSLOCK ™ sensor connector.

11 1. Reconnect the P asslock™ Module and the 4.0 Volts Go to Step Go to Step
Passlock™ sensor. 12 13
3. Disconnect Passlock ™ sensor once again.
4. Use a DMM to measure the voltage between the
Passlock™ sensor connector YEL 1836 wire and
ORN/BLK 1057 wire.

12 REPLACE the Passlock ™ sensor. Go to Step
14
13 REPLACE the Passlock ™ Module. Go to Step
14
14 1. Reconnect all previously disconnected connectors Go to VTD
2. Make sure the ignition is ON. System
tor.
4. Clear the DTCs from memory.

DTC B2960
SECURITY SYSTEM SENSOR DATA INCORRECT BUT
VALID
Circuit Description • The Passlock ™ code does not equal the learned
key code during Engine start or for 1 second at any
This circuit supplies the Passlock ™ signal to the time during an ignition cycle.
Passlock ™ Module from the Passlock ™ Sensor,
circuit 1836. Action Taken When the DTC
Conditions for Setting the DTC Sets
• The Passlock ™ Module enters tamper mode.
• Stores DTC B2960 in the Passlock ™ Module
• Ignition is active memory.
• The Passlock signal is not open. • DTC B2960 will be set at KEY ON and after an
• The Passlock signal is not grounded. attempted start.
• The correct ignition key was used in the cylinder • If ignition was OFF at the time, vehicle will not
(No Tamper). start.
• If the engine was running at the time, vehicle will • If the DTC is a history DTC, the problem may be
restart but SECURITY indicator will remain illumi intermittent. Try performing the tests shown while
Conditions for Clearing the DTC
• The Passlock ™ Module continuously monitors the Test Description
signal and moves the DTC from current to history The numbers below refer to the numbers on the diag
on the next ignition cycle when the condition caus nostic table.
ing the fault no longer exists. 2. This step determines if there is an incorrect Pass-
• All Passlock ™ Module history codes will be lock signal in circuit 1836 reported from the Pass-
cleared after 100 ignition cycles (from OFF to RUN) lock sensor to the Passlock ™ Module.
cycles.
Diagnostic Aids
measurements at the Wiring Harness Junction
Blocks , refer to Power Distribution, in Electrical
Diagnosis, for terminal assignments of the Wiring
Harness Junction Blocks .

INCORRECT BUT VALID
Diagnostic
System
Check
2 1. This DTC may SET if the Passlock ™ sensor was 0.8v - 4.3v Go to Step Go to Step 3
replaced without following the proper procedure. 10
3. Using a DMM to measure the voltage, backprobe
between the Passlock ™ sensor connector YEL
1836 wire and ORN/BLK 1057 wire.
Is the voltage between the specified values?

16-way connector.
Was a poor connector found?

connector. Refer to Wiring Repair in Wiring Systems. 10

5 Check for a poor connection at the PASSLOCK ™ sen Go to Step 6 Go to Step 7
sor connector.

6 Repair the poor connection at The PASSLOCK ™ sen Go to Step
tems.

7 1. Turn Ignition OFF. 4 .0 Volts G o to Step 8 G o to Step 9
2. Disconnect the Passlock ™ sensor.
3. Turn ignition O N .
4. Use a D M M to measure the voltage between the
Passlock™ sensor connector Y E L 1836 wire and
O R N /B LK 1057 wire.

8 R EP LA C E the Passlock ™ sensor. G o to Step
10
9 R EP LA C E the Passlock ™ Module. G o to Step
10
tor.
4. C lear the D TC s from memory.

1 STEERING
I COLUMN
DTC B3031
SECURITY SYSTEM CONTROLLER IN LEARN MODE
C ircuit Description Conditions for Clearing th e DTC

This D TC is set when the Passlock ™ Module is in • The Passlock ™ Module continuously monitors the
Learn Mode. W hen the Passlock ™ Module is in Learn signal and moves the D TC from current to history
Mode and the Ignition Switch is cycled the scan tool will on the next ignition cycle when the condition caus
show the Passlock ™ signal toggle. ing the fault no longer exists.
• All P asslo ck ™ M od u le history cod es will be
Conditions for Setting the DTC cleared after 100 ignition cycles (from O F F to RUN)
All of the following conditions must be met: with no current codes active during the 100 ignition
• Ignition is active. cycles.
• The Passlock ™ code has not been learned. • Using a scan tool.

• W hen the diagnostics direct you to take electrical
Sets m easu rem en ts at the W iring H arness Junction
• Stores D T C B3031 in the Passlock ™ Module Blocks, refer to Power Distribution, in Electrical
Harness Junction Blocks.
• If the D T C is a history D TC , the problem may be 10. This step determines if there is a short to ground
intermittent. Try performing the tests shown while or open within the Passlock Sensor.
wiggling wiring and connectors, this can often 13. T h is step d ete rm in es if th e re is an open in
cause the malfunction to appear. circuit 1057 between the Passlock™ Module and
the Passlock Sensor.
Test Description 15. T h is step d ete rm in es if th e re is an open in
The numbers below refer to the numbers on the diag circuit 1057 between the Passlock ™ Module and
nostic table. the Passlock Sensor.
2. This step determines if the scan tool is reading 19. This step determines if there is the proper voltage
that the Passlock ™ Module is sending the proper between the Passlock signal terminal and the sen
voltage. sor ground terminal at the Passlock Sensor.
5. This step determines if the Passlock ™ Module is 23. This step determines if there is a short to ground
actually sending the proper voltage. in circuit 1836 between the Passlock™ Module
6. This step determines if there is a short to ground and the Passlock Sensor.
between the Passlock™ Module and the Pass- 25. This step determines if there is an open circuit in
lock Sensor. circuit 1836 between the Passlock ™ Module and
8. T h is step d e te rm in e s if th e re is an open in the Passlock Sensor.
circuit 812 between the Passlock ™ Module and
the Passlock Sensor.
DTC B3031 - SECURITY SYSTEM CONTROLLER IN

LEARN MODE
1 W as the V T D Diagnostic System Check performed? Go to Step 2 Go to V TD
Diagnostic
System
Check
2 1. Using a D M M to measure the voltage, backprobe 0 .8v - 4.3v Go to Step Go to Step 3
between Y E L 1836 wire and O R N /B LK 1057 wire at 28
the Passlock ™ sensor connector.
2. Turn the Ignition Switch to the C R AN K position.
Is the voltage reading within the specified range?

3 Check for a poor connection at the Passlock Sensor G o to Step 4 Go to Step 5
connector.

4 Repair the poor connection at the Passlock Sensor. Go to Step
28
5 1. Turn the Igntion Switch to the O N position. 10.0v Go to Step Go to Step 6
2. Use a D M M to backprobe and measure the voltage 12
in R E D /W H T 812 wire between the Passlock Sensor
connector and ground.

6 1. K EY OFF. Disconnect the Passlock Sensor connec Infinite Go to Step 8 Go to Step 7
tor.
2. Disconnect the Passlock ™ Module connector.
3. Use a D M M to measure the resistance in R E D /W H T
812 wire between the Passlock Sensor connector
and ground.

7 Repair the short to ground in circuit 812 between the Go to Step
Passlock Sensor connector and the Passlock ™ Module 28
connector trerminal A5.

8 Use a D M M to measure the resistance in R E D /W H T 10.0 Q Go to Step Go to Step 9
812 wire between the Passlock Sensor connector and 10
the Passlock ™ Module connector terminal A5.

9 Repair the open in R E D /W H T 812 wire between the Go to Step
connector terminal A5.

10 1. KEY OFF. Reconnect the Passlock ™ Module con 10.0v G o to Step Go to Step
nector. 11 27
2. Turn the Ignition Switch to the O N position.
3. Using a D M M m easure the voltage between the
R E D /W H T 812 wire of the Passlock™ sensor con
nector and ground.

11 K EY OFF. R EP LA C E the Passlock ™ sensor. G o to Step
28
12 1. M ake sure the Ignition Switch is still in the O N prosi- 10.0v Go to Step Go to Step
tion. 19 13
2. Use a D M M to backprobe and measure the voltage
between the R E D /W H T 8 12 wire and the O R N /B LK
1057 wire of the Passlock Sensor connector.

13 1. Turn Ignition Switch OFF. 10.0v Go to Step Go to Step
2. Disconnect the Passlock ™ sensor. 14 15
3. Turn Ignition Switch O N .
4. Use a D M M to m easure the voltage between the
R E D /W H T 812 wire and the O R N /B LK 1057 wire of
the Passlock Sensor connector.

14 K EY OFF. R EPLA C E the Passlock ™ sensor. Go to Step
28
15 1. Turn Ignition OFF. 10.0 Q G o to Step Go to Step
2. Disconnect the Passlock ™ Module. 17 16
3. U se a D M M to m e as u re the resistance of the
O R N /B LK 1057 wire between the Passlock™ Mod
ule connector terminal B5 and the Passlock Sensor
connector.

16 Repair the open in circuit 1057 between the Passlock G o to Step
Sensor connector and the Passlock ™ Module connec 28
tor.

17 Check for a poor connection at the Passlock ™ Module G o to Step Go to Step
connector terminal B5. 18 27

connector terminal B5. Refer to Wiring Repair in Wiring 28
Systems.

19 1. K EY OFF. 4 .0v - 6.0v Go to Step Go to Step
2. Disconnect the Passlock ™ sensor connector. 20 21
3. K EY ON.
4. Use a D M M to measure the voltage between the
Y E L 1836 wire and the O R N /B LK 1057 wire at the
Passlock Sensor connector.
Is the measured voltage within the specified value?

20 KEY OFF. R E P LA C E the Passlock ™ sensor. Go to Step
28
21 Check for a poor connection at the Passlock ™ Module Go to Step G o to Step
connector terminal B7. 22 23

terminal B7. Refer to Wiring Repair in Wiring Systems. 28

23 1. Turn Ignition OFF. 10.0 Q Go to Step Go to Step
2. Disconnect the Passlock ™ Module. 24 25
3. Use a D M M to measure the resistance of the YEL
1836 wire between the Passlock ™ Module connec
tor terminal B7 and ground.
Is the resistance below the specified value?

24 Repair the short to ground in circuit 1836 between the Go to Step
connector trerminal B7.

25 Use a D M M to m easure the resistance of the Y E L 1836 10.0 Q Go to Step Go to Step
wire between the Passlock ™ Module connector termi 27 26
nal B7 and the Passlock ™ sensor connector.
Is the resistance below the specified value?

26 Repair the open in circuit 1836 between the Passlock Go to Step
Sensor connector and the Passlock ™ Module connec 28
tor trerminal B7.

27 KEY OFF. R E P LA C E the Passlock ™ Module. Go to Step
28
28 1. Reconnect all previously disconnected connectors Go to V TD
tor.

DTC B3033
SECURITY SYSTEM INDICATES TAMPER
C ircuit Description • If ignition was O F F at the time, vehicle will not

start.
In this mode the Passlock ™ Module and the Vehicle • If the engine was running at the time, vehicle will
Control Module (V C M ) will not allow the Engine to start. restart but S E C U R IT Y indicator will remain illumi
nated.
Conditions for S etting th e DTC
All of the following conditions must be met: Conditions fo r Clearing th e DTC
• Ignition is active • The Passlock ™ Module continuously monitors the
• T h e Passlock ™ signal reported to the Passlock ™ signal and moves the D TC from current to history
M odule is not within range (0.8-4.3v). on the next ignition cycle when the condition caus
• T h ree consecutive bad key reads (approximately ing the fault no longer exists.
1 second). • All P ass lo c k ™ M o d u le history c od es will be
cleared after 100 ignition cycles (from O F F to R U N )
A ction Taken When th e DTC with no current codes active during the 100 ignition
Sets cycles.
• Th e Passlock ™ Module enters tam per mode.
• Stores D T C B 30 3 3 in the Passlock ™ M odule
memory.
Diagnostic Aids
• Check for a bad or broken Passlock Sensor in the
Ignition Switch.
• W hen the diagnostics direct you to take electrical
m easu rem en ts at the W iring H arn ess Junction
Blocks , refer to Power Distribution, in Electrical
Diagnosis, for terminal assignments of the Wiring
• If the D TC is a history D TC, the problem may be
intermittent. Try performing the tests shown while
DTC B3033 - SECURITY SYSTEM INDICATES TAMPER

1 W as the V T D Diagnostic System Check performed? Go to Step 2 Go to V T D
Diagnostic
System
Check
2 Perform the Passlock ™ System Auto Learn Procedure Go to Step 3
in this section.

3 With scan tool read D TC(s). Refer to Go to V T D
Has any D TC(s) reset? appropriate Diagnostic
D TC table. System
Check
DATA LINK
CONNECTOR (DLC)
2
.5 PPL I 1807
I'
1
S280 • i
.35 PPL I 1807

.5 PPL 1807
84
r — — n evo / passlock
I DATA | MODULE B 8 V l/ C100
JOASSJ^ a
Y~
s is o a m
.5 PPL 1807 .5 PPL 1807
.5 PPL 1807
C8 C3 (DIESEL)
11 C4 (GAS) G A£.1 E« A £1
- T VEHICLE HsERLaT ” n ELECTRONS r s£RykT’
^SERIAL
I DATA | CONTROL | DATA | BRAKE CONTROL | DATA | TRANSFER
l (CLASS_2)j MODULE (VCM) (GAS) JCJ^SSJ^j MODULE(EBCU) JCLASS^Jj CASE (ATC)
POWERTRAIN A MODULE
CONTROL ^ A
MODULE (PCM)(DIESEL)
>
DTC C0559
EEPROM CHECKSUM ERROR
C ircuit Description Conditions for Clearing th e DTC

In this m ode the Passlock ™ Module and the Vehicle • The Passlock ™ Module continuously monitors the
Control Module (V C M ) will not allow the Engine to start. signal and moves the D TC from current to history
• All P ass lo c k ™ M o d u le history cod es will be
cleared after 100 ignition cycles (from O F F to RUN)
• Ignition is active
• T h e Passlock ™ calculated memory checksum is
cycles.
not equal to the memory checksum calibration.
• Replace the Passlock ™ Module.
A ction Taken When th e DTC Diagnostic Aids

Sets T h e E E P R O M is not removable from the Passlock ™
• Stores D T C C 0 5 5 9 in the Passlock ™ M odule Module. If service is required, the module must be
memory. replaced. Refer to Passlock ™ Module Replacerrjgnt.
• If ignition was O F F at the time, vehicle will not
start.
• If the engine was running at the time, vehicle will
restart but S E C U R IT Y indicator will remain illumi
nated.
Test Description
T h e numbers below refer to the step numbers on the
E E P R O M Checksum Error Diagnostic Table.
1. M akes sure the Diagnostic System Check is com
pleted.
2. Indicates that Passlock ™ Module replacement is
required.
DTC C0559 - EEPROM CHECKSUM ERROR

Step Action V alu e (s ) Yes No
1 W as the V T D Diagnostic System Check performed? Go to Step 2 G o to V T D
Diagnostic
System
Check
2 KEY OFF. R eplace the Passlock ™ Module. Go to Step 3

tor.

DATA LINK
CONNECTOR(DIC)
.5 PPL 1807
T — — T EVO/PASSLOCK
| DATA | MODULE B 8 \ | / C l 00
A
l (O A S S 2)j
Y_
.5 PPL 1807 .5 PPL 1807
.5 PPL 1807
C8 C3 (DIESEL)
11 /-s C 4 (GAS) GA L' E9 Cl
r s h:
AUTOMATIC
[ S T IS f iE rSERML” *l ELECTRQNtc SERIAL
| DATA I _________
CONTROL ___________| DATA | BRAKE CONTROL | DATA | TRANSFER
l (CLASS_2)j MODULE (VCM) (GAS) 2i j MODULE (EBCM) | i Ci^ S£_2) j CASE (ATC)
POWERTRAIN A MODULE
CONTROL
MODULE (PCM) (DCSEL)
DTC U1016
LOSS OF CLASS 2 COMMUNICATION W ITH VCM
C ircuit Description Action Taken When th e DTC

This circuit supplies the Passlock data to the Vehicle Sets
C o n tro l M o d u le fro m th e P a s s lo c k ™ M o d u le ,
• Stores D T C U 1 0 1 6 in the P a ss lo c k™ M odule
circuit 1807.
memory.
• If ignition was O F F at the time, vehicle will not
Conditions for Setting th e DTC start.
All of the following conditions must be met: • If the engine was running at the time, Vehicle will
• Ignition is active restart but S E C U R IT Y indicator will remain illumi
• Communication between the Passlock ™ Module nated.
and the Vehicle Control Module was present for at
least 1 second, then lost for more than 5 seconds Conditions for Clearing th e DTC
(ususally due to intermittent connection).
• The Passlock ™ Module continuously monitors the
• Th e Vehicle Control Module has not received a val
signal and moves the D TC from current to history
id state of health m essage from the Passlock ™
Module.
• All P asslo ck ™ M o d u le history codes will be • If the D TC is a history DTC, the problem may be
cleared after 100 ignition cycles (from O F F to RUN) intermittent. Try performing the tests shown while
with no current codes active during the 100 ignition wiggling wiring and connectors, this can often
cycles. cause the malfunction to appear.
Test Description
Diagnostic Aids Th e numbers below refer to the numbers on the diag
• W hen the diagnostics direct you to take electrical nostic table.
m easu rem en ts at the W iring H arn ess Junction 2. T h is step d e te rm in e s if th e re is an o pen in
Blocks , refer to Power Distribution, in Electrical circuit 1807 between the Passlock™ Module and
Diagnosis, for terminal assignments of the Wiring the Vehicle Control Module (VC M ).
DTC U1016 - LOSS OF CLASS 2 COMMUNICATION

WITH VCM
* NEVER REPLACE ANY COM PONENT BASED ON TH IS OR ANY OTHER HISTORY DTC ONLY.
Step Action V a lu e Yes No

1 W as the V T D Diagnostic System Check performed? Go to Step 2 G o to V T D
Diagnostic
System
Check
2 1. Turn the ignition OFF. 10.0 Q Go to Step 4 Go to Step 3
2. D is c o n n e c t th e P a s s lo c k ™ M o d u le 1 6 - w a y
Connector.
3. U s e a D M M to m e a s u r e t h e r e s i s t a n c e in
circuit 1807 between the Passlock™ Module con
nector terminal B4 and the Data Link connector ter
minal 2.

3 REPAIR open in PP L 1807 wire between the Go to Step 5
Passlock ™ Module terminal B4 and the Data Link Con
nector terminal 2.

4 R EP LA C E the Passlock ™ Module. Go to Step 5

5 1. Turn Ignition OFF. Go to V TD
2. Reconnect any previously disconnected components. Diagnostic
3. R EP LA C E the Passlock ™ Module. System
4. Perform the Seed and Key Procedure. Check

DATA LINK
CONNECTOR (DLC)
I
2
.5 PPL 1 1807
S280 • i
.35 PPL I 1807

.5 PPL 1807
84
r.— 1 EVO/PASSLOCK
DATA I MOPUIE 88 \ 1 / C100
l «XASS 2)j
Y“
a
Ih A S l5 0 * H H i
.5 PPL 1807 .5 PPL 1807
.5 PPL 1807
C3 (OIESEL)
/- n C4(GAS) G / " \ £J E9 /*N Cl
rSERi*r” n ELECTR0Ntc " T AUTOMATIC
'SERIAL
| DATA |________
CONTROL. . . . | OATA | BRAKE CONTROL |5 aTA~ | TRANSFER
l (CLASSJ)j MODULE(VCM)(GAS) j_(C^SS_2)j MODULE(EBCM) CASE(ATC)
POWERTRAIN A MODULE
CONTROL
MODULE (PCM) (OIESEL)
A
A
DTC U1255
CLASS 2 COMMUNICATION MALFUNCTION
C ircuit Description • If the engine was running at the time, Vehicle will
restart but S E C U R IT Y indicator will remain illumi
This circuit supplies the Passlock data to the Vehicle
nated.
Control Module from the Passlock ™ Module, as well
as communicating all of the Class 2 messages among
all modules and the tool, circuit 1807.
Conditions for Clearing th e DTC
• The Passlock ™ Module continuously monitors the
Conditions for Setting th e DTC signal and moves the D TC from current to history
• Ignition is active
• All P asslo ck ™ M od u le history cod es will be
• Communication with the Data Link Connector and
cleared after 100 ignition cycles (from O FF to RUN)
other modules is lost or at least has been lost at
one time due to intermittent connection (this is usu
cycles.
ally a history DTC).

• Stores D T C U 1 2 5 5 in the P asslock™ M odule m easu rem en ts at the W iring H arness Junction
• If ignition was O FF at the time, vehicle will not Diagnosis, for terminal assignments of the Wiring
start. Harness Junction Blocks.
• If the DTC is a history DTC, the problem may be
intermittent. Try performing the tests shown while
Test D escription
nostic table.
2. This step determines if there is an open in
circuit 1807 between the Passlock ™ Module and
the other components.
DTC U1255 - CLASS 2 COMMUNICATION

MALFUNCTION
* NEVER REPLACE ANY COMPONENT BASED ON THIS OR ANY OTHER HISTORY DTC ONLY.

Diagnostic
System
Check
2 1. Cycle the Ignition Switch from the OFF to the ON Go to Step 4 Go to Step 3
position, engine OFF.
2. Connect a scan tool into the Diagnostic Link Con
nector (DLC).
3. Attempt to establish communication with the Vehicle
Control Module (VCM).
Does the scan tool communicate with the Vehicle Con

trol Module (VCM)?
3 Refer to Data Link Connector (DLC) in Electrical Diag Go to Step 4
nosis.
Can communication be established?

4 1. Turn the ignition OFF. 10.0 Q Go to Step 6 Go to Step 5
2. Disconnect the Passlock ™ Module 16-way Connec
tor.
3. Use a DMM to measure the resistance in circuit
1807 between the Passlock™ Module connector
terminal B4 and the Data Link connector terminal 2.

5 LOCATE and REPAIR open in PPL 1807 wire between Go to Step 7
the Passlock ™ Module terminal B4 and the Data Link
Connector terminal 2.

6 REPLACE the Passlock ™ Module. Go to Step 7

7 1. Turn Ignition OFF. Go to VTD
2. Reconnect any previously disconnected components. Diagnostic
3. REPLACE the Passlock ™ Module. System
4. Perform the Seed and Key Procedure. Check

ON-VEHICLE SERVICE
CHANGING VTD COMPONENTS 3 . 1/P auxiliary storage compartment (if equipped).
Refer to Instrument Panel and Gauges.
The PASSLOCK ™ System is designed to prevent 4. Remote CD Player (if equipped).
theft even if various theft deterrent parts are changed. 5. Ashtray. Refer to Ashtray Replacement in Instru
Parts that can no longer be changed without the possi ment Panel and Gauges.
bility of going into a tamper mode are: 6. Electrical connector.
• PASSLOCK ™ Sensor • Push on clip s behind a u x ilia ry storage
• Passlock ™ Module compartment/remote CD player and pull down
• Vehicle Control Module (VCM) on module to release.
If any of these parts are replaced, the vehicle may
start and stall for 10 (ten) minutes (Long Tamper Mode).
If this occurs, the system must go through a Long
E3 Install o r C onnect (Figure (5)
Tamper Mode cycle. During this time, the SECURITY 1. Electrical connector.
indicator will be flashing for the full ten minutes and • Slide in rear tabs and push up to engage mod
DTC B3031 will be set. The Passlock ™ Module and ule.
the Vehicle Control Module (VCM) require the full ten 2. Ashtray.
minutes to complete a learn cycle. The Ignition Switch 3 . 1/P auxiliary storage compartment (if equipped).
must remain in the RUN position until the SECURITY 4. Remote CD player (if equipped)
indicator stops flashing or the cycle will have to be 5. Knee bolster.
repeated. If any of the above parts is replaced, it is 6. Negative battery cable.
recommended to perform the Seed and Key Procedure
or the Auto Learn Procedure in this section.
EVO/PASSLOCK MODULE

2. Knee bolster. Refer to Knee Bolster Replacement
in Interior Trim.
Figure 5— EVO /Passlock M odule

ENGINE COOLANT HEATER 9E-1
SECTION 9E
ENGINE COOLANT HEATER

GENERAL DESCRIPTION
The optional engine coolant heater (RPO K05) pre ment warms the coolant as long as the heater cord is
heats engine coolant to aid cold weather starting. The plugged into an AC power source.
engine coolant heater operates from a 110-volt AC pow The unit has a detachable electrical cord. If the heater
er source and uses a heating element that is installed in fails to operate, check the cord, connections, and power
the water jacket of the engine block. The heating ele supply before replacing the heating element.
ON-VEHICLE SERVICE
ENGINE COOLANT HEATER Clean
0 Rem ove or D isconnect (Figures 1 through 7) • Core plug hole, removing any burrs, compound,
paint, or rough spots.
1. Engine coolant. Refer to Engine Cooling.
2. Coolant jacket plug. 0 Install or Connect (Figures 1 through 7)
• If not originally equipped with an engine coolant
heater, remove the coolant jacket plug. Careful 1. Apply a coating of lubricant to the O-ring seal and
ly tap it near its outer edge, causing it to rotate the cleaned surface of plug opening in the block.
out of the hole. Do not score the machined sur Use a water spray resistant, high-temperature
face of the hole. Grasp with pliers and pull to grease GM P/N 9985164 or equivalent.
remove. 2. The coolant heater and push tight to the block.
3. Cord from engine coolant heater.
4. Loosen bolt.
5. Engine coolant heater.
(1) 6.5L Engines

(2) 4.3L Engines
(3) 5.0L, 5.7L, and 7.4L Engines
(1) Line Parallel to Crankshaft Centerline (4) Engine Coolant Heater Cord Mounting Bolt
(2) 4.3L and 6.5L Engines (5) Engine Coolant Heater Cord Mounting Bolt
(3) 5.7L and 7.4L Engines (6) Engine Coolant Heater Cord
Figure 1— Engine C oolant H eater Elem ent Figure 2— Engine C oolant H eater Cord Routing
Positioning (R ear-W heel Drive M odels)
9E-2 ENGINE COOLANT HEATER
Im portant
• Install the heater element in the correct direc

tion to avoid element contact to the inside walls
of the engine block as shown in Figure 1.
3. Tighten screw until both locking wings draw tight
against inner wall of engine block.
Tighten
• Mounting screw to 2 N-m (18 lb in).
(1) 6.5L Engines

(2) 4.3L Engines
(3) 5.0L and 5.7L Engines
(4) Engine Coolant Heater Cord Clip Mounting Bolt
(5) Engine Coolant Heater Cord Clip
(6) Engine Coolant Heater Cord
(7) Engine Coolant Heater Cord Mounting Bolt
Figure 3— Engine C oolant H eater Cord Routing
(S electable and A utom atic Four-W heel Drive
M odels)

M odels w ith 7.4L Engine)
(1) 6.5L Engines

(2) 4.3L Engines
(3) 5.7L Engines
(R ear-W heel D rive - 1 Ton M odels)
Figure 6— Engine C oolant H eater Cord (Selectable
and A utom atic Four-W heel D rive M odels w ith 7.4L
Engines)
ENGINE COOLANT HEATER 9E-3
4. Heater cord to the coolant heater and route heater
cord (Figures 2 through 7).
j^| Im portant
• The heater cord must not touch the engine, hot

pipes, manifold, or any moving parts.
5. Engine coolant. Refer to Engine Cooling.

(3) Engine Coolant Heater Cord Washer
Figure 7— Engine C oolant H eater Cord Mounting
M odels w ith 7.4L Engines)
SPECIFICATIONS
Engine Coolant Heater Mounting Screw 2 — 18
9E-4 ENGINE COOLANT HEATER
BLANK
LUGGAGE CARRIER 9F-1
SECTION 9F
LUGGAGE CARRIER
GENERAL DESCRIPTION
The luggage carrier is available as a dealer-installed The following procedures are for a previously installed
option. Skid strips and support mounting anchor nuts luggage carrier,
are installed at the factory. During predelivery opera
tions, the dealer will complete the assembly installation.
ON-VEHICLE SERVICE
LUGGAGE CARRIER 3. Cross rails onto the sliders.
4. Screws to cross rails.
REPLACEMENT
Tighten
Rem ove o r D isconnect (Figures 1 through 4)
• Cross rail screws to 2 N-m (18 lb in).
1. Rubber side rail cap from the center rail support
5. Side rail supports to the side rails.
(Figure 4).
2. Screws from the center supports (Figure 4). 6. Screws to the side rail supports.
3. Screws from the end supports (Figure 4).
Q Tighten
4. Luggage carrier from the roof (Figure 2).
5. Center rail supports (Figure 1).
6. Side and center rail support gaskets (Figure 2). • Side rail support screws to 2 N-m (18 lb in).
D isassem ble (Figure 1) Install o r C onnect (Figures 1 through 3)
1. Remove screws from the side rail supports. 1. Side and center rail support gaskets.
2. Side rail supports from the side rails. 2. Center rail supports.
3. Remove screws from the cross rails. 3. Luggage carrier onto the roof.
4. Cross rails from the sliders. 4. End support to the vehicle screws.
5. Screws from the sliders and the lock plates.
6. Sliders from the slots in the side rails. Tighten
A ssem ble
* • End support screws to 3 N-m (27 lb in).
5. Screws into the center supports.
1. Sliders into the slots in the side rails.
2. Screws into the sliders and the lock plates. Tighten
S Tighten
• Center support screws to 3 N-m (27 lb in).
• Slider to the side rail screws to 3 N-m (27 lb in). 6. Rubber side rail cap to the center rail support.
9F-2 LUGGAGE CARRIER
Legend
(1) Side Rail Assembly (5) Slider Plate
(2) Rail Support (6) Screw
(3) Screw (7) Side Rail Slider
(4) Cross Rail (8) Screw
Figure 1— Luggage C arrier Com ponents (Suburban Show n, 2 and 4 - Door U tility S im ilar)
LUGGAGE CARRIER 9F-3
Figure 3— Luggage C arrier (4 - Door U tility)

9F-4 LUGGAGE CARRIER
Figure 4— Luggage C arrier (S uburban)
SPECIFICATIONS
End Support Screw 3 — 27
Center Support Screw 3 — 27
Cross Rail-to-Side Rail Slider Screw 2 — 18
Side Rail Support-to-Side Rail Screw 2 — 18
Sider-to-Side Rail Screw 3 — 27
RUNNING BOARDS 9G-1
SECTION 9G
RUNNING BOARDS
GENERAL DESCRIPTION
The Running Boards are a dealer installed option that The following procedures are for the complete
are mounted on factory installed brackets located under replacement of a previously installed running board,
the truck.
ON-VEHICLE SERVICE
RUNNING BOARD D isassem ble (Figure 2)
REPLACEMENT 1. Remove nuts securing running board exten

sions and mat to running board frame.
Rem ove or D isconnect (Figure 1) 2. Remove extensions and mat from running board
frame.
1. Bolts attaching running board end caps to body.
2. Nuts securing running board to T-bolts and Assem ble (Figure 2)
brackets. *
3. Running board from truck.
1. Install mat and extensions to running board
frame.
Figure 1— Running Board (Left side show n, R ight side sim ilar)
9G-2 RUNNING BOARDS
2. Install nuts securing mat and extensions to run 2. Nuts securing running boards.
ning board frame.
a Tighten
Tighten
• Nuts to 23 N-m (17 lb ft)
• Nuts to 1 N.m (9 lb in)
3. Bolts securing end caps to truck.
++ Install or Connect (Figure 1)
Tighten
1. Running board assembly to truck.
. Bolts to 17 N.m (13 lb ft)
SPECIFICATIONS
End Cap Bolts 17 13 —
Mat to Frame Nuts 1 — 9

Running Board Nuts 23 17 —
Restraints Seat Belts 9J-1
Seat Belts
Specifications
Fastener Tightening Specifications

Application N-m Lb Ft Lb In
Anchor Plate Bolts 55 41 —
Child Restraint Anchor Nut 30 22 —
Front Seat Belt Anchor Plate Bolts 55 41 —
Front Seat Belt Buckle Assembly Bolts (Extended Cab 55 41 —
Front Seat Belt Buckle Assembly Bolts (Regular Cab) 42 31 —
Front Seat Belt Retractor Bolts 55 41 —

Intermediate Seat Belt Buckle Assembly Nuts 42 31 —
Intermediate Seat Belt Retractor Bolts 55 41 —

Intermediate Seat Belt Anchor Plate Bolts 55 41 —
Rear Seat Belt Buckle Assembly Nuts 42 31 —
Rear Seat Belt Retractor Bolts 55 41 —
9 J -2 Seat Belts Restraints
Repair Instructions 2. Accelerate the vehicle slowly to 16 km/h

(10 mph) and then apply the brakes firmly.
Seat Belt Checks (General Checks) 3. Verify that the seat belt locks when
1. From the driver’s seat, turn the ignition switch braking firmly.
ON. Verify proper operation of the seat belt
4. If the belt does not lock, proceed with
reminder lamp with the seat belt buckled and
steps 5 through 8.
unbuckled, refer to Seat Belt System Operation
(Description) - Front Seat System. 5. Remove seat belt retractor assembly.
2. Inspect the shoulder belt guide. Check that the 6. Tilt the seat belt retractor slowly.
guide swivels freely, the seat belt webbing is
7. Check that the seat belt webbing can be
seated flat in the guide slot, and that the
webbing does not bind. pulled from the retractor at an inclination of
15 degrees or less and cannot be pulled from
3. Check that the seat belt buckle faces inboard the retractor at an inclination of 45 degrees
and is accessible.
or more.
4. Check that the seat belt retractor units are
securely attached. 8. If the seat belt retractor does not operate as
described, replace the retractor assembly.
5. Check the seat belt anchor bolts to verify that
they are secure. Seat Belt Service Precautions
6. Fully extend the seat belt webbing and check
• Clean the seat belt webbing with a mild soap
that there are no twists or tears in the webbing.
and water solution and a soft brush or cloth.
7. Allow the seat belt webbing to retract and Do not bleach or dye the seat belt webbing.
check that the webbing returns freely and
completely back into the retractor. • Keep sharp edges and damaging objects away
from the seat belts. Do not bend or damage
8. Snap the seat belt latch plate into the buckle.
any part of the seat belt buckle or latch plate.
9. Tug sharply on the seat belt latch plate and Replace any seat belts that are cut or
buckle. Check that it remains locked. damaged.
10. Push the button on the buckle. The seat belt • Use only the correct seat belt anchor fasteners.
latch plate must release from the buckle easily
Tighten the anchor fasteners to the correct
and the button must return to its original
torque value after you refer to Fastener
position.
Tightening Specifications in this section. When
11. Repeat steps 2 through 10 from the front installing a seat belt anchor bolt, start the bolt
passenger seat. by hand to ensure that you do not damage
12. Check that the center belts are accessible and the bolt.
that there are no twists or tears in the webbing.
• When replacing seat belts, use only service
13. Snap the seat belt latch plate into the buckle. replacement parts.
14. Tug sharply on the seat belt latch plate and • Verify the correct replacement part number.
buckle. Check that it remains locked. Make sure the part number is correct for that
15. Push the button on the buckle. The seat belt vehicle at that seating position. Do no substitute
latch plate must release from the buckle easily a seat belt from a different seating position or a
and the button must return to its original different vehicle.
position.
• Replace any seat belts which have a visible
16. Repeat steps 2 through 10 from the rear seats. label that says to replace the seat belt.
To remove the seats or the seat cushions, refer
to Seats and Carpet. • Some seat belts have an Energy Management
Loop. This is an overlap of the seat belt
17. Repeat steps 12 through 15 for the rear seat
webbing that is stitched together. IF any of the
center belts. To remove the seats or the seat
cushions, refer to Seats and Carpet. stitching is separated, replace the seat belt.
• If the door is to be left open for an extended
Emergency Locking Retractor Checks period of time, remove the CTSY fuse.
Caution: Perform this test in an area clear of Removing the fuse prevents battery drain by
other vehicles and/or obstructions. Do not the courtesy lamps and the block-out solenoid.
conduct this test on the open road. A large,
empty parking lot is suitable. Failure to observe
this precaution may result in damage to the
vehicle and possible personal injury.
1. Fasten the seat belts. An assistant is needed
when the retractor under test is not part of the
driver’s seat belt.
Front Seat Belt Replacement

(Regular Cab With Bucket Seat)
R e m o v a l P ro c e d u re
Caution: Refer to Belt Replacement Caution in
Notice: Refer to Servicing and Replacing Seat Belt
Notice in Cautions and Notices.
1. Remove the cover from the door pillar anchor
plate. Pry up the bottom.
2. Remove the bolt from the door pillar weld nut.
3. Remove the bolt retaining the retractor to the

floor panel.
4. Remove the retractor from the vehicle.
5. Remove the cover from the buckle assembly
which conceals the nut.
15 7 0 9 6
9J-4 Seat Belts Restraints
6. Remove the nut from the buckle assembly to
floor weld stud.
7. Remove the seat belt warning wire from the
buckle assembly on the driver’s side only.
8. Remove the buckle assembly from the vehicle.
In s ta lla tio n P ro c e d u re
1. Install the buckle assembly to the floor panel.
2. Install the seat belt warning wire to the buckle
assembly on the driver’s side only.
156627
Restraints Seat Beits 9J-5
3. Install the nut to the buckle assembly and onto
the floor panel weld stud.
T ig h te n
Tighten the nut to 42 N-m (31 lb ft).
and Notices.
4. Install the cover assembly over the nut.
5. Install the retractor and belt to the floor.

6. Install the bolt through the retractor into
the floor panel weld nut.
T ig h te n
Tighten the bolt to 55 N-m (41 lb ft).
7. Install the bolt through the anchor plate and

washer into the door pillar weld nut.
T ig h te n
8. Install the cover over the door pillar
anchor plate.
15 66 17

(Regular Cab With Bench Seat)
Caution: Refer to Belt Replacement Caution In
3. Remove the bolt retaining the retractor to

the floor panel.
15 70 96
floor weld stud.
Installation Procedure
15 66 27
Tighten
and Notices.

T ighten

T ighten
anchor plate.
15 66 17

(Suburban And Crew Cab)
R em o val P ro ced u re

the floor panel.
157116
floor weld stud.
156631
3. Install the nut to the buckle assembly and
onto the floor panel weld stud.
Tighten
Tighten the nut to 42 N.m (31 lb ft).
and Notices.

Tighten
Tighten the bolt to 55 N.m (41 lb ft).
157116
7. Install the bolt through the anchor plate
and washer into the door pillar weld nut.
Tighten
anchor plate.

(Utility Model)
R em oval P ro ced u re
156633
the floor panel.

6. Remove the nut from the buckle assembly
to floor weld stud.
3. Install the nut to the buckle assembly and
onto the floor panel weld stud.
Tighten
and Notices.
156634
Tighten

Tighten
anchor plate.
156633

(Extended Cab with Bucket Seat)


floor panel.
15 71 03
floor weld stud.
178563
Tighten
and Notices.

6. Install the bolt through the retractor into the
floor panel weld nut.
Tighten
>\
157103

Tighten
anchor plate.
15 66 24
(Extended Cab with Bench Seat)
Caution: Refer to B elt Replacement Caution In

floor panel.
157103
floor weld stud.
188238
Tighten
and Notices.

Tighten

Tighten
8. Install the cover over the door pillar anchor
plate.
156624
(Extended Cab with 3rd Door)
1. Remove the retractor cover from the rear seat
access panel.
2. Remove the bolt from the retractor in the

rear seat access panel.
186884
floor weld stud.
178563
Tighten
and Notices.
5. Install the retractor and belt to the rear seat

access panel.
rear seat access panel.
Tighten

washer into the rear seat access panel.
Tighten
186882
Front Seat Belt Height Adjuster

Replacement
1. Remove the bolt retaining the shoulder/seat belt
guide to the guide adjuster.
2. Remove the shoulder/seat belt guide from the
guide adjuster.
3. Remove the front door upper pillar garnish
molding. Refer to Front Door Upper Pillar
Garnish Molding Replacement in Interior Trim.
4. Remove the shoulder/seat belt guide adjuster

retaining bolts from the pillar.
5. Remove the shoulder/seat belt guide adjuster
from the vehicle.
186879
1. Install the shoulder/seat belt guide adjuster
to the vehicle.
2. Install the shoulder/seat belt guide adjuster
retaining bolts to the pillar.
Tighten
Tighten the shoulder/seat belt guide adjuster
retaining bolts to 52 N-m (38 lb ft).
and Notices.
3. Install the shoulder/seat belt guide to the

guide adjuster.
4. Install the shoulder/seat belt guide retaining
bolt to the guide adjuster.
Tighten
Tighten the shoulder/seat belt guide retaining
bolt to 52 N.m (38 lb ft).
5. Install the front door upper pillar garnish
molding. Refer to Front Door Upper Pillar
Garnish Molding Replacement in Interior Trim.
18 68 79
Intermediate Seat Belt Replacement

Removal Procedure

the floor panel.
157103
6. Remove the nut from the buckle assembly
to floor weld stud.
156629
156629
Tighten
and Notices.

Tighten
7. Install the bolt through the anchor plate

and washer into the door pillar weld nut.
Tighten
anchor plate.
156624
Rear Seat Belt Replacement

(Suburban Removable Rear Seat)
Rem oval Procedure
1. Remove the rear seat. Refer to Rear Seat
Replacement.
2. Remove the buckle from the rear seat
support assembly.
3. Remove the quarter trim panel. Refer to
Quarter Panel Trim Replacement in
Interior Trim.
4. Remove the bolt holding the retractor to
the body.
5. Remove the seat belt and retractor.
6. Remove the nuts holding the buckle
assembly to the studs.
7. Remove the buckle assembly.
1. Install the buckle assembly to the floor
panel stud.
2. Install the nuts to the buckle assembly.
Tighten
Tighten the nuts to 42 N.m (31 lb ft).
Notice: Refer to Fastener Notice in
3. Install the bolt through the seat belt retractor
to the weld nut.
Tighten
4. Install the quarter trim panel. Refer to Quarter
Panel Trim Replacement in Interior Trim.
5. Install the bolt to the upper anchor plate.
Tighten
6. Install the rear seat. Refer to Rear Seat
Replacement.

(2 Door Utility)
Rem oval Procedure
Replacement.
support assembly.
Interior Trim.
4. Remove the bolt holding the retractor to the

body.
186865
6. Remove the nuts holding the buckle assembly
to the studs.
1. Install the buckle assembly to the floor panel
stud.
Tighten
Tighten the nuts to 42 N-m (31 lb ft).
and Notices.

to the weld nut.
Tighten
Tighten
Replacement.
18 68 65
Rear Seat Belt Replacement (Crew Cab)
Removal Procedure
Replacement.
2. Remove the buckle from the rear seat support
assembly.
Interior Trim.
the body.
156670
186874
panel stud.
Tighten
and Notices.

to the weld nut.
Tighten
Tighten
Replacement.
1 S66 67
(Extended Cab)
Notice: Refer to Servicing and Repiacing Seat Belt
Replacement.
2. Remove the buckle from the rear seat support
assembly.
Interior Trim.
the body.
15 66 70
panel stud.
Tighten
and Notices.

to the weld nut.
Tighten
Tighten
Replacement.
156661
(Extended Cab with 3rd Door)
Rem oval Procedure
Replacement.
support assembly.
Interior Trim.
the body.
156670
panel stud.
Tighten
Tighten the nuts to 42 N-m (31 lb ft).
and Notices.

to the weld nut.
Tighten
Tighten
Replacement.
156661

(4 Door Utility)
Rem oval Procedure
Caution: Refer to B elt Replacement Caution in
Replacement in Seats.
Interior Trim.
3. Remove the bolt holding the retractor

to the body.
186862
5. Remove the nuts holding the buckle assembly
to the studs.
panel stud.
Tighten
and Notices.

to the weld nut.
Tighten
186862
Tighten
Replacement.
Child Seat Tether Outer Hardware Kit

Tools Required
J 38778 Trim Pad Clip Remover
1. Remove the seat. Refer to Seat Replacement.
2. Pry the trim panel off the sheet metal below the
rear window with the J 38778.
3. Pry the carpet off the rear panel with the
J 38778.
4. Locate the position where the hole will be
drilled from inside the cab. Locate the hole
either 109 mm (4.3 in) or 545 mm (21.4 in)
outboard from the center line of the back panel
and 42 mm (1.65 in) below the horizontal sheet
metal panel.
5. Drill a 9 mm (3/s in) hole through the sheet
metal from inside the cab. Use a drill stop to
prevent damage to the pickup box.
6. Place the washer on the bolts.
7. Apply a bead of sealer around the hole in the
washer.
8. Using a clamping tool, feed the bolts through
the hole from the outside of the cab.
9. Thread the nut on the bolts. Hold the bolt head
with an extended length wrench.
Tighten
and Notices.
10. In the extended cab, if the length of the
bolts interferes with the rear seat in the
folded position, saw off the end of the bolts.
Leave at least two threads visible from the
end of the nut.
11. If the child seat anchorage is removed, properly
reseal the 9 mm (3/8 in) diameter hole.
156687
Child Restraint Tether Anchor

Extended Cabs with a Second Seat (AM7)
• Position the child seat in the front seat center
or the front seat right. Use the 2nd seat center
occupant lap belt latch plate if the seat is
unoccupied.
Position the child seat in the 2nd seat left,

center, or right. Use pick-up anchorage. Locate
the anchor between the scallops from the right
or left side of the back panel.
If all seats are occupied, then place the child
seat in a rear seat position that will allow the
use of the cargo tie downs.
156703
Utility Model
1. Position the child seat in the front seat center
or the front seat right. (2 Door)
2. Position the child seat in the front seat center.
(4 Door with 2nd folding seat (AM7)
3. Use the 2nd seat center occupant lap belt latch
plate if the seat is unoccupied.
4. If all seats are occupied, then place the child
Suburban with 2nd Folding Seat (AT5),

Utility-4 Door with 2nd Folding Seat (AM7)
1. Position the child seat in the front seat right.
Use GM P/N 15971501 in order to latch the
tether to the buckle on the 2nd 40% seat if the
seat is unoccupied.
156682

Use 2nd seat center occupant lap belt latch
plate if seat is unoccupied.
156645
3. Position the child seat in the 2nd seat center.
Use GM P/N 15989781 to the rear most set of
cargo tie downs. Hook the top tether to the
plate at the center of the tether.
4. Position the child seat in the 2nd seat left.

Use the left rear cargo tie down.
5. Position the child seat in the 2nd seat right.

Use the right rear cargo tie down.
156699
Suburban with 2nd Folding Seat (AT5),
Crew Cab
or the front seat right. (Crew cab)
(Suburban)
3. Use the 2nd seat center occupant lap belt latch
plate if the seat is unoccupied.
Extended Cab without 2nd Seat (AM7)

1. If you position the child seat in the front seat
center, use the stud in the floor closer to the
center of the vehicle.
2. If you position the child seat in the front seat
right, use the stud in the floor closer to the
side of the vehicle.
Suburban with 3rd Seat (AS3)

1. If you put the child seat in the 2nd seat center
folding position or in the 2nd seat left folding
position, use the 3rd seat center occupant lap
belt latch plate if the seat is unoccupied.
2. If you put the child seat in the 2nd seat right
folding position, use GM P/N 15971501 in order
to latch the tether to the 3rd seat buckle
directly behind this child seat position if the
seat is unoccupied.
15 66 40
3. If you put the child seat in the 3rd seat center,
use GM P/N 15989781 to the rearmost set of
the cargo tie downs. Hook the top tether to the
plate at the center of the tether.
4. If you put the child seat in the 3rd seat left,

use the left rear cargo tie down. If you put the
child seat in the 3rd seat right, use the right
rear cargo tie down.
Suburban without 2nd Folding Seat (AT5)

or the front seat right.
2. Use the seat anchor.
156697
Suburban with and without 3rd Folding Seat
(AS3), Utility-2 Door and 4 Door
1. If you put the child seat in the 2nd seat left
folding position, use the left front cargo tie
down. (Suburban without 3rd folding seat)
2. If you put the child seat in the 2nd seat right
folding position, use the right front cargo tie
down. (Suburban without 3rd folding seat)
3. If you put the child seat in the 3rd seat left
(Suburban with 3rd seat) or in the 2nd seat left
(Utility), use the left rear cargo tie down.
4. If you put the child seat in the 3rd seat right
(Suburban with 3rd seat) or in the 2nd seat
right (Utility), use the right rear cargo tie down.
Suburban without 3rd Folding Seat (AS3),

Utility-2 Door and 4 Door
1. If you put the child seat in the 2nd seat center
folding position (Suburban) or in the 2nd center
seat (Utility), attach GM P/N 15989781 to the
rearmost set of cargo tie downs.
2. Hook the top tether to the plate at the center of
the tether.
Suburban with 3rd Seat (AS3), Crew Cab,

Extended Cab, Regular Pickup
1. If you put the child seat in the 3rd seat center
position (Suburban), attach GM P/N 15989781
to the rearmost set of cargo tie downs. Hook
the top tether to the plate at the center of
the tether.
2. If you put the child seat in the front seat center
or front seat right (Regular pickup) or the 2nd
seat right (Crew cab or Extended cab), use the
pickup anchorage. Locate the anchor between
scallops from the right side of the back panel.
3. If you put the child seat in the front seat left
(Crew cab or Extended cab), use the pickup
anchorage. Locate the anchor between scallops
from the left side of the back panel.
4. If you put the child seat in the 2nd center
position, use the pickup anchorage. Locate the
anchor between scallops from the right or left
side of the back panel.
Description and Operation Seat Belt System Operation

(Police Package)
Seat Belt System Operation (Description)
Seat belts are the primary means of occupant Police Package Pursuit Performance
restraint. Seat belts help to keep the occupant inside Safety Belt
the passenger compartment and also help to ride A driver side safety belt with a locking lap retractor
down the crash forces more gradually during the is available as a dealer option. The purpose of this
following events: safety belt is to hold the officer more securely in the
• Frontal impact type crashes. seat during maneuvers associated with high speed
pursuits. To activate the system, buckle the belt as
• Rear impact type crashes.
normal and then pull out all of the lap belt webbing.
• Side impact type crashes. This activates a mechanism that puts the lap
• Roll over type crashes. retractor into an automatic locking mode. Once in
All seat belts have emergency locks in the retractors. this mode the belt can be tightened by pulling the
During normal operation, the retractors remain belt toward the retractor to return any slack. To
unlocked to allow free movement of the occupant’s deactivate the mechanism unbuckle the safety
upper body under normal driving conditions. The belt and let all of the lap belt webbing return to
seat belt webbing is locked into position by a the retractor.
pendulum that causes a locking bar to engage a cog The mechanism in this optional belt is similar to that
on the spool of the retractor mechanism under the already installed on the passenger side lap belt and
following conditions: in both outboard rear seat safety belts. The feature
• Rapid extraction of the seat belt webbing from was added to these other locations to allow a child
the retractor. restraint to be properly secured in the vehicle. See
the Owner’s Manual for further information.
• The speed of the vehicle changes abruptly.
• The direction of the vehicle changes abruptly.
• The vehicle is on a steep upgrade or a
downgrade.
In conjunction with the seat belts, this vehicle is
equipped with a Supplemental Inflatable Restraint
(SIR) System. Refer to Supplemental Inflatable
Restraint for more information about the (SIR) air
bag system.
Restraints SIR 9J-47
SIR
Specifications
F a s te n e r T ig h te n in g S p e c ific a tio n s
Specification
Application Metric English
Inflatable Restraint Front End Discriminating Sensor Fastener 8 Nm 71 lb in
Inflatable Restraint Sensing and Diagnostic Module Fasteners 12 N m 106 lb in
S c a n T o o l D a ta L is t Use the SIR Scan Tool Data List only after the
The scan tool used provides the following following is determined:
capabilities: • Diagnostic System Check is completed.
• Read the data list. • No Diagnostic Trouble Codes (DTCs) are set.
• Read current and history trouble codes. • SIR Diagnostics indicates system is functioning
• Clear the diagnostic trouble codes after a repair properly.
is completed. Scan tool values from a properly operating system
Make sure the scan tool contains an updated may be used for comparison with the SIR system
cartridge before attempting to communicate with the you are diagnosing. The SIR Scan Tool Data List
SIR system. To use the scan tool, connect it to the represents typical values seen on a properly
Data Link Connector (DLC) and turn the ignition operating system.
switch to the RUN position. The scan tool reads Im portant: Make sure the scan tool that you are
serial data sent from the inflatable restraint Sensing using is functioning properly. Use of a malfunctioning
and Diagnostic Module (SDM) Serial Data output scan tool can result in misdiagnosis and
terminal 5 to the DLC terminal 9. unnecessary parts replacement.
The SIR Scan Tool Data List contains all restraint Only the parameters listed below are referenced in
related parameters that are available on the scan this service manual for use in diagnosis. If all values
tool. The list is arranged in the order as they appear are within the typical range described below, refer to
on the scan tool. Intermittents and Poor Connections for diagnosis.
Scan Tool Parameter Units Displayed Typical Data Value

Ignition ON, Engine OFF, Inflatable Restraint IP Module Switch ON (if equipped), and Driver Seat Belt Buckled
Ignition Volts 12 V
Lamp Driver Intemal/Extemal Internal
Driver Resistance Ohms 2.6 0
Passenger Resistance Ohms 2.2 0
Driver Senselo Volts 4.1 V
Passenger Senselo Volts 4.1 V
Driver VDIF Millivolts 4-8 mV
Passenger VDIF Millivolts 4-8 mV
Warning Lamp Control On/Off Off
Lamp Driver Feedback Active/lnactive Inactive
Warning Lamp ON Hours 0 - 182 Hrs
Warning Lamp Cycles Cycles 0 - 1 2 5 Cycles
Driver Seat Belt Buckled/Unbuckled Buckled
Pass Air Bag Enable High/Low High
Pass Air Bag Disable High/Low Low
Suppression Lamp Driver On/Off Off
9J-48 SIR Restraints
S c a n T o o l D a ta D e fin itio n s D river V D IF: The scan tool displays 0-400 millivolts.
The SDM measures the voltage difference between
The SIR Scan Tool Data Definitions contain a brief
driver high and driver low and displays this voltage
description of all SIR related parameters available on
difference as Driver VDIF.
the scan tool. The list is in the order it appears on
the scan tool. P assen g er V D IF: The scan tool displays
0-400 Millivolts. The SDM measures the voltage
Ig n itio n : The scan tool displays 0-25.5 Volts. The
difference between passenger high and driver low
Ignition represents the system voltage measured by
and displays this voltage difference as Passenger
the SDM at its ignition feed.
VDIF.
Lam p D river: The scan tool displays Internal or
W arning Lam p C ontrol: The scan tool displays ON
External. The warning lamp control method for a
or OFF. The warning lamp state commanded by the
hard wired lamp is Internal. The warning lamp
SDM.
control method for a serial date controlled lamp is
External. Lam p D river Feedback: The scan tool displays
Active or Inactive. The warning lamp state detected
D river R esistan ce: The scan tool displays
by the SDM.
0-6.3 Ohms. The SDM performs the resistance
measurement test once each ignition cycle and W arning Lam p ON: The scan tool displays
verifies the Ignition 1 and the 23 VLR voltages are 0-182 Hours. The SDM measures the continous
within the normal ranges. Then the SDM sources a warning lamp on time.
constant current to the driver deployment loop. The W arning Lam p C ycles: The scan tool displays
SDM then measures the voltage drop across the 0-125 Cycles. The ignition cycles of the current
deployment loop and converts the measured voltage warning lamp state.
value to a driver deployment loop resistance value. D riv er S eatb elt: The scan tool displays Buckled or
P assen g er R esistan ce: The scan tool displays Unbuckled. The signal from the drivers seatbelt
0-6.3 Ohms. The SDM performs the resistance switch that the seatbelt is fastened.
measurement test once each ignition cycle and Pass A ir Bag E nable: The scan tool displays High
verifies the Ignition 1 and 23 VLR voltages are within or Low. The state of the Passenger Air Bag IP
the normal ranges. Then the SDM sources a Module switch ON output.
constant current to the passenger deployment loop.
P ass A ir B ag D isable: The scan tool displays High
The SDM then measures the voltage drop across the
deployment loop and converts the measured voltage or Low. The state of the Passenger Air Bag IP
value to a passenger deployment loop resistance Module Switch OFF output.
value. S u p p ressio n Lam p D river: The scan tool displays
D riv er S en selo : The scan tool displays 0-20 Volts.
ON or OFF. The state of the Passenger Air Bag IP
The SDM measures the voltage of the driver low Module Switch OFF output driver.
terminal voltage and displays it as Driver Senselo.
P assen g er S en selo : The scan tool displays
0-20 Volts. The SDM measures the voltage of the
passenger low terminal voltage and displays it as
Passenger Senselo.
G M S P O G ro u p N u m b ers
Application GM SPO Group Num ber
Air Bag Warning Lamp 9.744
Inflatable Restraint Front End Discriminating Sensor 16.712
Inflatable Restraint IP Module 16.712
Inflatable Restraint IP Module Switch 16.712
Inflatable Restraint Sensing and Diagnostic Module 16.712
Inflatable Restraint Steering Wheel Module 16.712
Inflatable Restraint Steering Wheel Module Coil 16.712
Schematic and Routing Diagrams
S IR S ch em atic R eferen ces

Service Category Type Number
Reference on Schematic - Service Category
Fuse Block Details - Cell 11 8 - Wiring Systems
Ground Distribution - Cell 14 8 - Wiring Systems
Instrument Cluster - Cell 81 8 - Instrumentation
A
Power Distribution - Cell 10 8 - Wiring Systems
S IR S ch em atic Ico n s
Icon Icon Definition
C a u t io n : R e f e r to S e r v i c i n g T h e S I R S y s t e m C a u t io n .
19386
N o t ic e : Refer to E S D N o tic e .
19384
9 J -5 0
S IR S ch em atics (P o w er, G N D an d D LC )
Hot With Headlamp

Switch In PARK O r HEADLIGHT | Hot In Run, Teat, O f S ta rt!
S IR
-► Power • + Power "MP
Distribution T ILLUM Distribt GAUGES ! Fuse
Ceil 10 p Fuse 14 Cell 10 Fuse 4
\ 10 A 10 A ! Block
0.8 YEL) 1139

0.35 GRY
S217I
Fuse Block*
Details
Instrument Panel 0.8 PNK 39 h u e Block
l
0
Dimming Cell 117
0.35 GRY Cell 11 S213+- - Details
------- ? ------- C a l 11
0.8 PPL/WHT 0.35 PNK 39
>S216
cr 1382
Inflatable
0.8 22
A
PPL/ 1382
^ ^ Illu m in a tio n Restraint Instrument
WHT
IP Module
Switch
(PickUp
N,
r ■ ''Headlam p IP
Instrument
Cluster
Cell 81
Cluster
Ground
Power Only) 1And Panel AIRBAG
On
PSIR
Indicator Lamp
(Dimmer
J Switch 9 YDataLink i Y
(D
Indteator
i
Distribution
Call 14
Off
Connector1- -------- * ----------------------J
Indicator 0.8 BLK/WHT 1751
© Lamp
j ; __________ 0.8 BRN 358
0.5 TAN 800 0.8
BLK/ 1751
WHT
0.8 0.5 BLK 150
0.8 LTGRN 371 0.8
YEL 1139 PNK 353 S218<
B2 l Shorting
B1 y C 2 3 2 AyC231 G iC 2 3 1 Shorting Bars
Bar
2 BLK 150 1 Close ToShort
Ground 4C 232 Connectors When
S2041 >- - Distribution
A2‘ Connectors Are
0.8 0.8 C el 14 Separated
YEL 1139 PNK 353 0.5 TAN 800 0.8
3 BLK 150
1 BLK BLK/ 1751
0.8
WHT
it^oo
BLK/WHT 371 150 0.8 BRN 358
6
J 0 ._ _ 11 12 5A s
Ignition Passenger Passenger UART Line 1 1nflatable
Airbag Airbag Serial Data Restraint
Enable Disable / ! Sensing And
j Diagnostic
j Module
R e s tra in ts
Case Ground *
162672
R e s tra in ts S IR 9J-5 1
16 2 6 7 9
Component Locator
S IR C o m p o n en ts
C o n n e cto r End G ro u p
N am e Location L o cato r View View No.
Data Link Under LH side of IP 8A-201-71

8A-202 —
Connector (DLC) Fig 72
Inflatable Restraint Front Front of vehicle
8A-201-4
End Discriminating 8A-202 —
Fig 5
Sensor
Inflatable Restraint RH side of IP 8A-201-79
8A-202 —
IP Module Fig 80
Inflatable Restraint Under LH front seat
8A-201-69
Sensing and Diagnostic 8A-202 —
Fig 70
Module
Inflatable Restraint RH side of IP, behind dash panel 8A-201-79
8A-202 —
Diagnostic Resistor Fig 80
Inflatable Restraint In steering wheel 8A-201 -58
8A-202 —
Steering Wheel Module Fig 59
Inflatable Restraint In steering column
8A-201-58
Steering Wheel 8A-202 —
Fig 59
Module Coil
Top LH side of IP 8A-201-5
Instrument Cluster 8A-202 —
Fig 52
LH kick panel 8A-201 -66
IP Fuse Block 8A-202 —
Fig 67
Part of LH seat belt buckle assembly 8A-201-69
Seat Belt Switch 8A-202 —
Fig 70
LH engine compartment, next to underhood 8A-201-8
C114 8A-202 —
fuse-relay center Fig 9
Inflatable restraint harness, RH side, under 8A-201-79
C216 8A-202 —
instrument panel Fig 80
Inflatable restraint harness, near lower steering 8A-201-61
C218 8A-202 —
column Fig 62
IP harness behind LH kick panel near IP fuse block 8A-201 -66
G201 — —
Fig 67
IP harness behind LH kick panel near IP fuse block 8A-201-66
G202 — —
Fig 67
LH rear of engine compartment at bulkhead 8A-201-45
P100 — —
Fig 46
IP harness, approx 4 cm from park brake warning
S201 — — —
switch breakout toward DLC breakout
IP harness, approx 7 cm into inflatable restraint
S208 — — —
sensing and diagnostic module breakout
IP harness, approx 39 cm into inflatable restraint
S209 — — —
sensing and diagnostic module breakout
IP harness, approx 8 cm from C200 breakout
S216 — — —
toward instrument cluster breakout
S IR C o m p o n e n t V ie w s
187122
Legend
(1) Radiator Support Bracket (7) Floor Pan
(2) Forward Lamp Harness (8) Steering Wheel
(3) Inflatable Restraint Front End (9) Inflatable Restraint Steering Wheel Module
Discriminating Sensor
(10) Instrument Panel
(4) Instrument Panel
(11) Inflatable Restraint IP Module Switch
(5) Inflatable Restraint IP Module
(6) Inflatable Restraint Sensing and
Diagnostic Module
S IR C o n n e c to r E n d V ie w s In fla ta b le R e s tra in t IP M o d u le E n ab le S w itch
(S w itc h a n d S e n s o r V ie w s )
In fla ta b le R estrain t F ro n t E nd D iscrim in atin g

S e n s o r C o n n ecto r
Connector Part • 12191470

Information • CONN 6F M/P 150 (YELLOW )
68712
Circuit
Pin W ire Color No. Function
Connector Part • 12160310
Information • ASM 2F M/P 280 (YELLOW) SIR Defeat Switch
A TAN/BLK 371
Signal - Passenger
Circuit
Pin Wire Color No. Function Fuse Output - Ignition 1 -
B YEL 1139
Type III Fuse - SIR
SIR Inflatable Output
A GRY 349 C PPL/WHT 1382 LED Dimming Signal
Driver
B BLK/WHT 1751 SIR Ground D GRY 8 IP Lamp Feed
SIR Defeat Indicator Lamp
E PNK 353
Output - Passenger
F BLK 150 Ground
S IR C o n n e c to r E n d V ie w s
(S D M C o n n e c to r V ie w )
In fla ta b le R e s tra in t S en sin g an d D iag n o stic M o d u le (S D M )
J
m ■
r
1 2 3 4 5 6 7 8 9 10 11 12
203005
• 12160341
Connector Part Information
• 12-Way F Micro-Pack 100 Series (Yellow)
Component
Circuit Connector DTC(s) Possible Symptoms From
Pin Wire Color No. Function Cavity Affected a Faulty Circuit
B1015,
B1016, Air Bag Warning Lamp
1 WHT/BLK 1403 Passenger Side High 1 B1017, Flashes Seven Times Then
B1018, Stays ON Steady
B1019
B1021,
2 WHT 347 Driver Side High 2 B1024, Flashes Seven Times Then
B1026
B1021,
3 DK GRN 348 Driver Side Low 3 B1024, Flashes Seven Times Then
B1026
B1015,
DR
4 1404 Passenger Side Low 4 B1017, Flashes Seven Times Then
GRN/WHT
B1019
Scan Tool Does Not
5 TAN 800 Serial Data (UART) 5 —
Communicate with SDM
Air Bag Warning Lamp
6 BLK/WHT 1751 Ground 6 —
Comes On Steady
Comes On Steady, Air Bag
7 BRN 358 Inflatable Restraint Indicator 7 —
Warning Lamp Does Not
Come On
In fla ta b le R estrain t S en sin g an d D iag n o stic M o d u le (S D M ) (c o n t’d)
J
■ ■
1 2 3 4 5 6 7 8 9 10 11 12
203005
• 12160341
Connector Part Information
• 12-Way F Micro-Pack 100 Series (Yellow)
Component
Circuit Connector DTC(s) Possible Symptoms From a
Pin W ire Color No. Function Cavity Affected Faulty Circuit
Fasten Seat Belt Indicator
8 BLK/WHT 238 Seat Belt Switch Signal 8 — Always On, Fasten Seat Belt
Indicator Does Not Come On
Inflatable Restraint Forward B1035,
9 YEL 1834 9 Flashes Seven Times Then
Sensor Signal B1036
Stays ON Steady
10 YEL 1139 Ignition 1 10 —
Comes On Steady
Inflatable Restraint Defeat Inflatable Restraint Defeat Is

11 TAN/BLK 371 11
Switch Signal-Passenger B1054 Inoperative
Inflatable Restraint Defeat Inflatable Restraint Defeat

12 PNK 353 Indicator Lamp 12 B1054 Indicator
Output-Passenger Does Not Come On
Diagnostic Information and S IR G e n e ra l D ia g n o s is

Procedures D iagnostic Trouble Codes
In te rm itte n ts a n d P o o r C o n n e c tio n s Caution: In order to avoid deploying the a ir bag
Most intermittents are caused by faulty electrical when troubleshooting the SIR system, use only
connections or wiring. Some items to check are: the equipment specified in this manual and the
instructions given in this manual. Failure to use
• Poor mating of connector halves, or terminals the specified equipment as instructed could
not fully seated in the connector body cause a ir bag deployment, personal injury to you
(backed out). or someone else, or unnecessary SIR system
• Dirt or corrosion on the terminals. The terminals repairs.
must be clean and free of any foreign material
which could impede proper terminal contact. The SIR Diagnostic System Check must always be
the starting point of any SIR system diagnosis. The
• Damaged connector body, exposing the SIR Diagnostic System Check checks for proper AIR
terminals to moisture and dirt, as well as not BAG warning lamp operation and checks for SIR
maintaining proper terminal orientation with Diagnostic Trouble Codes (DTC) using the scan tool.
the component or mating connector. The following describes the difference between
• Improperly formed or damaged terminals. All current and history DTCs:
connector terminals in problem circuits should • Current DTCs - Malfunctions that are presently
be checked carefully to ensure good contact being detected. Random Access Memory (RAM)
tension. Use a corresponding mating terminal to stores the current DTCs. Turning the ignition
check for proper tension. Refer to Checking switch to the OFF position erases current
Terminal Contact in Electrical Diagnosis for the DTCs. The presence of a current DTC will
specific procedure. cause the inflatable restraint Sensing and
• J 35616-A Connector Test Adapter Kit must be Diagnostic Module (SDM) to turn ON the AIR
used whenever a diagnostic procedure requests BAG warning lamp.
checking or probing a terminal. Using the • History DTCs - All malfunctions detected since
adapter will ensure that no damage to the last clearing of history memory. Electrically
terminal will occur, as well as giving an idea of Erasable Programmable Read Only Memory
whether contact tension is sufficient. If contact (EEPROM) stores the history DTCs. A scan tool
tension seems incorrect, refer to Checking clear codes command will erase history DTCs.
Terminal Contact in Electrical Diagnosis for the
Some DTCs are latched and can not be cleared.
specific procedure.
Latched DTCs will require replacement of the SDM
• Poor terminal to wire connection. Some after proper diagnostics.
conditions which fall under this description are
poor crimps, poor solder joints, crimping over wire Use of Special Tools
insulation rather than the wire itself, corrosion in You should be familiar with the tools in this service
the wire to terminal contact area, etc. category listed under the heading Special Tools. You
• Wire insulation which is rubbed through, should know how to measure voltage and resistance.
causing an intermittent short as the bare area Diagnosis requires proper use of the following tools:
touches other wiring or parts of the vehicle. • The Scan Tool
• Wiring broken inside the insulation. This • The J 38715-A SIR Driver/Passenger Load Tool
condition could cause a continuity check to
show a good circuit, but if only one or two • The J 35616-A Connector Test Adapter Kit
strands of a multi-strand type wire are intact, • The J 39200 Digital Multimeter
resistance could be far too high. • The J 38715-96 SIR Shorting Bar Tool
To avoid any of the above problems when making
wiring or terminal repairs, always follow the
instructions for wiring and terminal repair detailed in
Wiring Repair in this section.
S IR D ia g n o s tic S y s te m C h e c k C ircuit Description

Caution: In order to avoid deploying the a ir bag The ignition switch supplies Ignition 1 voltage to the
when troubleshooting the SIR system, use only the inflatable restraint Sensing and Diagnostic Module
equipment specified in this manual and the (SDM) at terminal 10 using the AIR BAG Fuse.
instructions given in this manual. Failure to use When the ignition switch is first turned to the RUN
the specified equipment as instructed could cause position, the SDM responds by flashing the AIR BAG
air bag deployment, personal injury to you or warning lamp seven times, then turning it OFF, while
someone else, or unnecessary SIR system repairs. performing tests on the SIR system.
Caution: If any water enters the vehicle’s in te rio r D iagnostic Aids
up to the level o f the carpet o r higher and soaks You must diagnose the diagnostic trouble codes in
the carpet, the Sensing and Diagnostic Module the order specified by the SIR Diagnostic System
(SDM) and the SDM harness connector may need Check. Failure to do so may result in the following:
to be replaced. The SDM could be activated when
• Extended Diagnostic Time
powered, which could cause deployment o f the
a ir bag(s) and result in personal injury. Before • Incorrect Diagnosis
attem pting these procedures, the SIR system • Incorrect Parts Replacement
m ust be disabled. Refer to Disabling SIR System
in this section. With the ignition OFF, inspect the Test Description
SDM m ounting area, including the carpet. If any Refer to step numbers on the diagnostic table.
sig nifica nt soaking o r evidence o f significant 2. The inflatable restraint IP module switch must
soaking is detected, you MUST: be in the ON position to perform the system
• Remove a ll water diagnostic check.
• Repair the water damage 3. The AIR BAG warning lamp should flash seven
• Replace the SDM harness connector times after the ignition switch is first turned to
the RUN position.
• Replace the SDM
Failure to follow these procedures could result in 4. The AIR BAG warning lamp indicates improper
possible a ir bag deployment, personal injury, o r operation. This test differentiates a warning
otherwise unneeded SIR system repairs. lamp stays ON condition from a warning lamp
does not come ON condition.
These diagnostic procedures will help you to find and
5. The AIR BAG warning lamp should turn OFF
repair SIR system malfunctions. This service category
after flashing seven times.
also contains information for repairing SIR system
malfunctions. For best results, use the diagnostic 6. This test checks for the proper operation of the
tables, and follow the sequence listed below: Serial Data line.
1. Perform the SIR Diagnostic System Check. All 8. This test will identify the stored diagnostic
SIR diagnostics must begin with the SIR trouble codes and whether they are current or
Diagnostic System Check. The SIR Diagnostic history.
System Check determines the following: 10. This test checks for the proper operation of the
• Proper AIR BAG warning lamp operation Serial Data line.
• Ability of the SDM to communicate through 11. This test refers to the appropriate DTC
the Data Link Connector (DLC) Table Diagnostic Aids for diagnosis of the
history DTCs.
• Existence of SIR Diagnostic Trouble
Codes (DTC)
2. Refer to the diagnostic table as directed by the
SIR Diagnostic System Check. The diagnostic
tables will help enable you to diagnose any SIR
system malfunction. Bypassing these
procedures may result in the following:
• Extended Diagnostic Time
• Incorrect Diagnosis
• Incorrect Parts Replacement
3. Repeat the SIR Diagnostic System Check after
you perform any repair or diagnostic
procedures. This will verify that you correctly
performed the repair. This will also ensure that
no other malfunctions exist.
SIR Diagnostic System Check
Does this vehicle have a inflatable restraint IP module —
1 switch? Go to Step 2 Go to Step 3
1. Turn the ignition switch to the ON position.
2. Turn the inflatable restraint IP module switch to the
OFF position and then back to the ON position. — —
Is the inflatable restraint IP module switch in the
2 ON position? Go to Step 3
Note the AIR BAG warning lamp while turning the ignition
3 switch to the RUN position. —
Does the AIR BAG warning lamp flash seven times? Go to Step 5 G o to Step 4
Does the AIR BAG warning lamp come ON steady? Go to A IR BAG Go to A IR BAG
4 — Warning Lamp
Comes On
Warning Lamp
Does Not
Steady Com e On
Note the AIR BAG warning lamp after it flashed seven

5 times. —
Does the AIR BAG warning lamp go OFF? Go to Step 9 Go to Step 6
1. Turn the ignition switch to the OFF position.
2. Connect a scan tool to the Data Link Connector.
3. Turn the ignition switch to the RUN position. —
4. Request the SIR Diagnostic Trouble Code (DTC)
6
display.
Is a current DTC displayed? Go to Step 8 Go to Step 7
Does the scan tool indicate no data received? Go to Data Link

7 — Connector in Go to SDM
Wiring Systems Integrity Check

2. Record the displayed DTCs on the repair order,
specifying as current or history.
• When DTC B1051 is set, refer to D T C B1051
Deployment Commanded.
• When DTC B1018 is set, refer to D T C B 1018
Passenger Deployment Loop Short to GND.
8
• When DTC B1024 is set, refer to D T C B 1024 — —
Driver Deploym ent Loop Short to Ground.
3. Diagnose the remaining DTCs from lowest to
highest.
4. When only history DTCs exist, refer to Diagnostic
Aids for that specific DTC. A history DTC indicates
the malfunction has been repaired or is intermittent.
Has current DTC diagnosis been performed and the
current DTCs cleared? Go to Step 3
SIR Diagnostic System Check (cont’d)
2. Connect a scan tool to the Data Link Connector.
3. Turn the ignition switch to the RUN position.
9 —
4. Request the SIR Diagnostic Trouble Code (DTC)
display.
Is a history DTC displayed? G o to S t e p 11 G o to S t e p 1 0
Does the scan tool indicate no data received? Go to Data Link

10 — Connector in
Wiring Repairs System OK
2. Record the displayed DTCs on the repair order
specifying as history.
3. When DTC B1071 is set, refer to D T C B 1 0 7 1
11 In t e r n a l S D M F a ilu re . — —
4. For all other DTCs, Refer to Diagnostic Aids for that
specific DTC. A history DTC indicates the
malfunction has been repaired or is intermittent.
Has the diagnosis been performed and the DTCs cleared? G o to S t e p 3
S D M In te g rity C h e c k T est D escrip tio n
The numbers below refer to the step numbers on the
C irc u it D escrip tio n diagnostic table:
When the inflatable restraint Sensing and Diagnostic 2. This test confirms a circuit malfunction. If no
Module (SDM) recognizes IGNITION 1 voltage, current malfunction is occurring (history DTC
applied to terminal 10, is greater than 8.2 volts, the set), refer to the diagnostic aids for the
SDM flashes the AIR BAG warning lamp seven appropriate DTC table as indicated through the
times to verify operation. At this time the SDM scan tool. Do not replace the inflatable restraint
performs POWER-ON tests followed by the Sensing and Diagnostic Module (SDM) for a
RESISTANCE MEASUREMENT test and the history DTC other than DTC B1071.
CONTINUOUS MONITORING tests. Upon detection 3. This test checks for a malfunction introduced
of a malfunction, the SDM sets a current Diagnostic into the SIR system during the diagnostic
Trouble Code (DTC) and illuminates the AIR BAG process. It is unlikely that a malfunctioning
warning lamp. The SDM will clear current DTCs and SDM would cause a new malfunction to occur
preserve them in a history file when: during this process.
• The malfunction is no longer detected. 4. When you have found all circuitry outside the
SDM to operate properly, as indicated by the
• The ignition switch is cycled. appropriate diagnostic table, replace the SDM.
This does not include DTCs B1018, B1024, B1051, This table assumes that the SIR Diagnostic System
B1053, and B1071. DTCs B1018, B1024, B1051, Check and either a symptom table or a Diagnostic
B1053 are latched codes. You cannot clear a latched Trouble Code table diagnosis has been performed.
code. DTC B1071 may not clear after you issue a When all circuitry outside the SDM has been found
clear codes command. to operate properly, as indicated by the appropriate
diagnostic table, and the symptom or DTC remains
Im portant: Repair the malfunction that set the current, the following diagnostic procedures must be
DTC before you replace the SDM. performed to verify the need for SDM replacement.
SD M In te g rity C h eck
Were you sent here from a symptom table or a Diagnostic Go to S IR
1 Trouble Code (DTC) table? — Diagnostic
Go to Step 2 System Check

2. Reconnect all the SIR components, make sure all
the components are properly mounted.
3. Make sure the ignition switch has been turned to the
2 OFF position for at least 30 seconds. —
4. Note the AIR BAG warning lamp while turning the
ignition switch to the RUN position.
Does the AIR BAG warning lamp flash seven times
then go OFF? Go to Step 7 Go to Step 3
Using the scan tool, request the SIR DTC display. Go to the
3 Is the same symptom or DTC occurring as when the — appropriate
SIR Diagnostic System Check was first performed? Go to Step 4 DTC table
1. Clear the SIR DTCs.

2. Turn the ignition switch to the OFF position for at
least 30 seconds.
4 3. Note the AIR BAG warning lamp while turning the —
Does the AIR BAG warning lamp flash seven times
then go OFF? System OK Go to Step 5
SDM Integrity C heck (cont’d)
2. Replace the SDM. Refer to In fl R s t S e n s i n g a n d
5 — —
D ia g n o s t ic M o d u le R e p la c e m e n t .
Has the SDM been replaced? G o to S t e p 6
Reconnect all the SIR system components, make sure all

the components are properly mounted. Go to S I R
6 — —
Have all the SIR components been reconnected and D ia g n o s t ic
properly mounted? S y ste m C h eck
Clear the SIR DTCs. Go to S I R

7 Have the SIR DTCs been cleared? — D ia g n o s t ic —
S y ste m C h e ck
A IR B A G W a rn in g L a m p C o m e s O n S te a d y
Hot In Run, Hot With Headlamp L

Test Or Start Switch In Park Or Headlight | Hot In Run, Test. Or Start |
°c
r - r “ -
He r
?
ILLUM GAUGES
I Block
H
Distribution
Fuse 14 Fuse 4 Cell 10
10 A 10 A
J7 t
0.35 GRY
0.8 YEL 1139
0.35
Details
instrument ran ei
Dimming CeN 117
0.8 PNK 39
S213< •----------- ►
fu se Block
Details
A.
r
S217 Cell 11 4 0.35 PNK 39
Cell 11
GRY 8 0.8 PPL/WHT 221
♦ S216
DJI c 1382 1Instrument
Inflatable 0.8 -► Instalm ent
' X 5
PPL/ 1382 Cluster
Cluster Ground
Restraint
CD
IP Module WHT Cell 81 Distribution
AIR BAG Cell 14
______ Y ___________________________
1 Solid State 1 Switch
(Pickup
®
Indicator
0.8 only) N &. . 'I _______ 0.8 BLK/WHT 1751
YEL 1139 0.8 A F "• Headlamp
I0.5BLK 150 0.8
LTGRN 371 1And Panel
S218< h - BLK/ 1751 # G201
I Dimmer WHT
B1 B2 C232 o.8 2 BLK 150 0.8
J Switch Shorting Bars
PNK 353 BRN 358 Close To Short
0.8 S 2 0 4 *- -
Ground
Distribution A1
Shorting
Bar A2 Connectors When
BLK/WHT 371 ____ \A C232 Connectors Are
0.8 A$C231 o !8 " Separated_______
YEL 1139 3 BLK 150 1 BLK T 0.8 BRN 358 BLK/WHT 1751
0.8 PNK 353
11JL 150 Shorting Bar 6
A
10JL 12 JL G200 7 is S
ignition1 Passenger Passenger Air Bag > 11nflatable
Airbag Airbag Indicator £ Ground 'Restraint
Enable Disable Control T I Sensing And
----------■»Diagnostic
7 Case Ground Module
207858
C ircuit D escription When measurements are requested in this table, use

When the ignition switch is first turned to RUN, the J 39200 Digital Multimeter with the correct terminal
GAUGES Fuse applies battery voltage to the AIR adapter from J 35616-A Connector Test Adapter Kit.
BAG warning lamp that is connected to INFLATABLE When a check for proper connection is requested,
RESTRAINT INDICATOR, terminal 7. The AIR BAG refer to Intermittents and Poor Connections. When a
Fuse applies battery voltage to the IGNITION 1 wire, connector or terminal repair is requested, use
input, terminal 10. The inflatable restraint Sensing J 38125-A Terminal Repair Kit and refer to Wiring
and Diagnostic Module (SDM) responds by flashing Repair.
the AIR BAG warning lamp seven times. If IGNITION
Test Description
1 is outside of the normal operating voltage range
(8.2 volts - 17.1 volts), the AIR BAG warning lamp The numbers below refer to the step numbers on the
will come ON solid with no DTCs set. diagnostic table:
2. This test checks for sufficient IGNITION 1
D iagnostic A ids voltage applied to the SDM.
In order to disable the shorting bar from terminal 6 to 3. This test checks for excessive IGNITION 1
terminal 7 inside the inflatable restraint Sensing and voltage applied to the SDM.
Diagnostic Module (SDM) harness connector, the 4. This test checks for a properly installed CPA.
following two conditions must be met:
6. This test determines if the SDM is turning on
• The SDM harness connector must be properly the AIR BAG warning lamp.
connected to the SDM.
7. This test checks for a damaged shorting bar.
• The Connector Position Assurance (CPA) must
be properly installed in the SDM harness 15. This test determines whether the malfunction is
connector. a short to ground in CKT 358.
16. This test checks for a short between 24. This test determines whether the short to
CKTs 358 and 1751. ground is due to a short in the wiring or
20. An open Air Bag Fuse would cause the AIR internal to the inflatable restraint IP
BAG warning lamp to come on steady. module switch.
21. This test checks whether a short to ground 29. This test checks for a disconnected SDM.
caused the Air Bag Fuse to open. 35. This test checks for an open in the
22. This test determines whether the short to IGNITION 1 circuit.
ground is due to a short in the wiring or
internal to the SDM.
AIR BAG W arning Lam p Com es On Steady

Was the SIR Diagnostic System Check performed? Go to S I R
1 — D ia g n o s t ic
G o to S t e p 2 Sy ste m C h eck

2. Connect a scan tool to the Data Link
Connector (DLC).
2 8.2 V
4. Request the SIR data list display.
Is IGNITION more than the specified value? G o to S t e p 3 G o to S t e p 2 0
1. Set the parking brake.

3 17.1 V
3. Using the scan tool, read the SIR data list. Go to C h a r g in g
Is IGNITION more than the specified value? Sy ste m C h eck G o to S t e p 4

4 2. Inspect the SDM harness connector CPA. —
Is the CPA properly installed? G o to S t e p 6 G o to S t e p 5
Properly install the CPA. Go to S I R

5 Are the repairs complete? — D ia g n o s t ic —
S y ste m C h eck
1. Disconnect the inflatable restraint steering wheel and

IP module yellow 2-way connectors located near the
base of the steering column.
2. Disconnect the SDM harness connector. Refer to In fl
R s t S e n s i n g a n d D ia g n o s t ic M o d u le R e p la c e m e n t .
6
3. Install J 3 8 7 1 5 - 9 6 SIR Shorting Bar Tool within the
—
SDM harness connector.
4. Install the CPA.
5. Turn the ignition switch to the RUN position. Go to S D M
Does the AIR BAG warning lamp come ON steady? G o to S t e p 7 In t e g rit y C h e c k

2. Remove J 3 8 7 1 5 - 9 6 from the SDM harness
connector.
7 —
3. Inspect the shorting bar within the SDM harness
connector.
Is the shorting bar damaged or corroded? G o to S t e p 8 G o to S t e p 9
AIR BAG W arning Lam p Com es On Steady (cont’d)
Replace the SDM harness connector.
8 — —
Are the repairs complete? G o to S t e p 3 6
1. Install J 3 8 7 1 5 - 9 6 within the SDM harness connector.

2. Install the CPA.
3. Disconnect the IP harness connector C232. Refer to
9 S IR C o m p o n e n ts. —
4. Inspect the shorting bar within the IP harness side
of connector C232.
Is the shorting bar damaged or corroded? G o to S t e p 1 0 G o to S t e p 11
Replace the IP harness side of connector C232. Refer to

W ir in g R e p a ir
10 — —
Has the IP harness side of connector C232 been
replaced? G o to S t e p 11
Check for proper connection at terminal A1 and A2 on the

11 IP harness side of connector C232. —
Are the terminals damaged or corroded? G o to S t e p 1 2 G o to S t e p 1 3
Replace the IP harness side of connector C232.

12 — —
Has the IP harness side of connector been replaced? G o to S t e p 1 3
Check for proper connection at terminals A1 and A2 on the

13 harness side of connector C232. —
Replace the harness side of connector C232.

14 — —
Has the harness side of connector C232 been replaced? G o to S t e p 3 6
1. Disconnect the instrument cluster. Refer to

Instrument Cluster Replacement in Instrument Panel
And Gauges.
15 OL
2. Measure the resistance from the SDM harness
connector terminal 7 to ground.
Is the resistance reading less than the specified value? G o to S t e p 1 6 G o to S t e p 1 9
1. Disconnect CKT 1751 from ground. Refer to

S IR C o m p o n e n ts.
16 2. Measure the resistance from the SDM harness OL

connector terminal 7 to terminal 6.
Is the resistance reading less than the specified value? G o to S t e p 1 8 G o to S t e p 1 7
Repair a short to ground condition in CKT 358.

17 — —
1. Repair the short between CKTs 358 and 1751.

18 2. Inspect CKT 1751 for any cutting or chaffing. — —
Service the instrument cluster. Refer to Instrument Cluster

19 Replacement in Instrument Panel And Gauges. — —

2. Remove the Air Bag Fuse.
20 —
3. Inspect the Air Bag Fuse.
Is the Air Bag Fuse good? G o to S t e p 2 9 G o to S t e p 2 1
1. Replace the Air Bag Fuse.
2. Turn the ignition switch to the RUN position for
10 seconds.
21 3. Turn the ignition switch to the OFF position. —

Is the Air Bag Fuse good? G o to S t e p 2 8 Go to S t e p 2 2
1. Disconnect the SDM. Refer to In f l R s t S e n s i n g a n d
D ia g n o s t ic M o d u le R e p la c e m e n t

22 10 seconds. —
Does this vehicle have a inflatable restraint IP module

23 —
switch? G o to S t e p 2 4 G o to S t e p 2 6
1. Disconnect the inflatable restraint IP module switch.

Refer to In f l R s t I P M o d u le S w it c h R e p la c e m e n t .
24 3. Turn the ignition switch to the RUN position, wait —
10 seconds, then turn the ignition switch Off.
4. Remove and inspect the Air Bag Fuse.
1. Replace the inflatable restraint IP module switch.

Refer to In f l R s t I P M o d u le S w it c h R e p la c e m e n t .
25 2. Install the Air Bag Fuse. — —
Has the inflatable restraint IP switch been replaced and
the Air Bag Fuse installed? G o to S t e p 3 7
1. Repair a short to ground condition in CKT 1139.

2. Connect the SDM.
26 — —

27 — —
2. Install the Air Bag Fuse.
Install the Air Bag Fuse.

28 — —
Inspect the SDM harness connector.

29 —
Is the connector securely connected to the SDM? G o to S t e p 3 1 G o to S t e p 3 0
1. Properly connect the SDM harness connector.

30 2. Install the CPA. — —
IP module yellow 2-way connectors located neat the
31 D ia g n o s t ic M o d u le R e p la c e m e n t . —
3. Check for proper connection to the SDM at
terminal 10.
Is the SDM harness connector terminal damaged or
corroded? G o to S t e p 3 2 G o to S t e p 3 3
Replace the SDM harness connector. Refer to

32 W ir in g R e p a ir. — —
Inspect the SDM terminals for damage or corrosion.

33 —
Are any terminals damaged or corroded? G o to S t e p 3 4 G o to S t e p 3 5
Replace the SDM. Refer to In fl R s t S e n s i n g a n d

34 D ia g n o s t ic M o d u le R e p la c e m e n t . — —
Measure the resistance from the SDM harness connector

terminal 10 to each terminal of the Air Bag Fuse
35 0 -5 Q.
fuseholder. Go to S D M
Is either resistance reading within the specified values? In t e g rit y C h e c k G o to S t e p 3 6
Repair an open condition in CKT 1139.

36 — —

37 — —
properly mounted? Sy ste m C h eck
A IR B A G W a rn in g L a m p D o e s N o t C o m e O n
Hot With Headlamp

Switch In Park Or Headlight Hot In Run, Test, Or Start |
-► Power ■*Fuse
J
ILLUM
E3
FU86 14
H6 iy GAUGES Distribution • Block
Fuse 4 cell 10
D4 10 A J7 10 A
0.35 GRY instrument ranei

0.8 PNK 39
1139 Fuse Block
Details
Dimming Cell 117
S213< 1-------►
Fuse Block
Details
A
0.35 4
cr
S217 Cell 11
0.35 PNK 39
Cell 11
8 0.8 PPL/WHT
4>S216
1382 0.8 ** Instrument
8 X ' Inflatable PPL/ 1382 Cluster
Restraint
(D
IP Module WHT
______ i ___________________________ AIRBAG
1 Solid State 1 Switch Indicator
0.8 i_____________ 2:________ 4 ______ only)
(Pickup
N
YEL 1139 0.8 A F ■*Headlamp
0.5 BLK 150 0.8
LTGRN 371 1And Panel
S218 < BLK/
I Dimmer WHT
B1 B2^C232 o.8 2 BLK 150 J Switch 0.8
Shorting Bars
PNK 353 BRN 358 Close To Short
Ground Shorting
0.8 S204* - -
Connectors When
A2 C232 Connectors
BLK/WHT 371
Distribution A1-As' Bar ^ Are
0.8 Cell 14 ---------------------------s
A$C231 0.8
Separated_______
YEL 1139 3 BLK 150 1 BLK
0.8 PNK 353 0.8 BRN 358 BLK/WHT 1751 >
150
10 11 121 G200 7 Shorting Bar g
Ignition 1 Passenger Passenger Air Bag ■* Inflatable
Airbag
Enable
Airbag
Disable
Indicator
1 Ground 1Restraint
Control I Sensing And
J Diagnostic
Case Ground Module
207858
C ircuit D escription 3. This test determines whether voltage is present

When the ignition switch is first turned to RUN, the in the warning lamp circuit.
GAUGES Fuse applies battery voltage to the AIR 4. This test isolates CKT 358 and checks for a
BAG warning lamp that is connected to Air Bag short in CKT 358 to B+.
Indicator Control, terminal 7. The AIR BAG Fuse 6. This test determines if the malfunction is in the
applies battery voltage to the IGNITION 1 input,
instrument cluster connector.
terminal 10. The inflatable restraint Sensing and
Diagnostic Module (SDM) responds by flashing the 8. This test determines if the open is due to a bad
AIR BAG warning lamp seven times. bulb.
When measurements are requested in this table, use 10. This test isolates an open in the warning lamp
J 39200 Digital Multimeter with the correct terminal circuitry.
adapter from J 35616-A Connector Test Adapter Kit. 13. This test checks whether power is available to
When a check for proper connection is requested,
the instrument cluster power feed circuit.
refer to Intermittents and Poor Connections. When
a wire, connector or terminal repair is requested, 14. This test checks for a short from the instrument
use J 38125-A Terminal Repair Kit and refer to cluster power feed circuit to ground.
Wiring Repair. 15. This test determines whether the short to
Test D escription ground is due to a short in the wiring or
internal to the instrument cluster.
diagnostic table: 19. This test determines if the malfunction is in the
2. This test determines whether the malfunction is instrument cluster connector.
in the inflatable restraint Sensing and 21. This test determines whether the malfunction is
Diagnostic Module (SDM) circuitry or in the due to an open power feed circuit from the
instrument cluster power feed circuitry. GAUGES Fuse.
AIR BAG W arning Lam p Does Not Com e On
G o to S t e p 2 S y ste m C h eck
1. Set the parking brake.

2 2. Turn the ignition switch to the RUN position. —
Does the BRAKE indicator light? G o to S t e p 3 G o to S t e p 1 3

3. Disconnect the SDM. Refer to In fl R s t S e n s i n g a n d
3 4. Install J 3 8 7 1 5 - 9 6 SIR Shorting Bar Tool to the 10.0 V

SDM harness connector.
5. Install the CPA.
7. Measure the voltage on the SDM harness connector
from terminal 7 to ground.
Is the voltage more than the specified value? G o to S t e p 4 G o to S t e p 6

And Gauges.
4 1.0 V
from terminal 7 to ground. Go to S D M
Is the voltage less than the specified value? In te g rity C h e c k G o to S t e p 5

2. Repair a short to B+ condition in CKT 358.
5 — —
3. Reconnect the instrument cluster.

2. Remove the instrument cluster. Refer to Instrument
Cluster Replacement in Instrument Panel And
6 Gauges. —
3. Check for proper connection to the instrument
cluster at terminal 1.
Is the connector damaged or corroded? G o to S t e p 7 G o to S t e p 8
Repair the instrument cluster harness connector.

7 Refer to W irin g R e p a ir. — —
1. Remove the AIR BAG warning lamp bulb. Refer to

A IR B A G W a r n in g L a m p R e p la c e m e n t .
8 —
2. Inspect the bulb.
Is the bulb good? G o to S t e p 1 0 G o to S t e p 9
AIR BAG W arning Lam p Does Not Com e On (cont’d)
1. Replace the AIR BAG warning lamp bulb refer to
A IR B A G W a r n in g L a m p R e p la c e m e n t .
9 — —
2. Install the instrument cluster.
1. Install the AIR BAG warning lamp bulb.

2. Measure the resistance from the instrument cluster
10 harness connector terminal 1 to the SDM harness 0 -5 Q
connector terminal 7.
Is the resistance within the specified values? G o to S t e p 1 2 G o to S t e p 11
1. Repair an open condition in CKT 358.

11 2. Install the instrument cluster. — —
Service the instrument cluster. Refer to Instrument Cluster

12 Replacement in Instrument Panel And Gauges. — —

2. Remove the GAUGES Fuse.
13 —
3. Inspect the fuse.
Is the fuse good? G o to S t e p 1 9 G o to S t e p 1 4
1. Replace the GAUGES Fuse.

10 seconds.
14 3. Turn the ignition switch to the OFF position. —

And Gauges.
3. Replace the GAUGES Fuse.
15 —
10 seconds.
1. Repair a short to ground condition in CKT 39.

16 2. Replace the GAUGES Fuse. — —
1 / Service the instrument cluster. Refer to

Instrument Cluster Replacement in Instrument
17 Panel And Gauges. — —
2. Install the GAUGES Fuse.
AIR BAG W arning Lam p Does Not Com e On (cont’d)
Install the GAUGES Fuse.
18 — —
1. Remove the instrument cluster. Refer to Instrument

Cluster Replacement in Instrument Panel And
Gauges.
19 —
2. Check for proper connection to the instrument
cluster at terminal 22.
Is the connector damaged or corroded? G o to S t e p 2 0 G o to S t e p 2 1
Repair the instrument cluster harness connector.

20 Refer to W ir in g R e p a ir. — —
Measure the resistance between the instrument cluster

harness connector terminal 22 to each terminal of the
21 0 -5 Q
GAUGES Fuse fuseholder.
Is either reading within the specified values? G o to S t e p 2 3 G o to S t e p 2 2
1. Repair an open condition in CKT 39.

22 2. Install the GAUGES Fuse. — —
1. Repair an open condition in the power feed to the

GAUGES Fuse.
23 — —
2. Install the GAUGES Fuse.

24 — —
properly mounted? Sy ste m C h e ck
D T C B 1 0 1 5 P a s s e n g e r D e p lo y . L o o p R e s is ta n c e H ig h
To Prevent Accidental Inflatable

Deployment, Shorting JU lr Restraint
Bare Close To Short IP Module
Connectors When
Connectors Are 1 WHT/BLK 1403 1 DK GRN/WHT 1404
Separated
^ —
1 WHT/BLK 1403 1DK GRN/WHT 1404
A Shorting Bar B Q 233 A
1 WHT/BLK 1403 1 DK GRN/WHT 1404

E F|C231
0.8 WHT/BLK 1403 0.8 DK GRN/WHT 1404
1 4
r
Passenger Passenger *• Inflatable Restraint
I Side High Side Low I Sensing And *
I I Diagnostic
L . ■•Module
187167
C irc u it D e s c rip tio n The RESISTANCE MEASUREMENT test checks for

When you first turn the ignition switch to the RUN this malfunction. This test only occurs once each
position, the inflatable restraint Sensing and ignition cycle when IGNITION 1 is within the normal
Diagnostic Module (SDM) perform tests to diagnose operating voltage range.
critical malfunctions within itself. Next the SDM A ctio n Taken W h en th e D TC S ets
measures IGNITION 1 and the deployment loop
• The SDM sets a Diagnostic Trouble Code.
voltages to make sure they are within their
respective normal voltage ranges. Then the SDM • The SDM turns ON the AIR BAG warning lamp.
proceeds with the RESISTANCE MEASUREMENT C o n d itio n s fo r C le a rin g th e D TC
test. During one portion of the RESISTANCE
MEASUREMENT test, the SDM does the following: • Current DTC
. Grounds the PASSENGER SIDE LOW The resistance of the passenger deployment
loop is less than 3.0 ohms and the ignition
terminal 4 through an internal current sink.
switch is cycled.
. Connects the PASSENGER SIDE HIGH
• History DTC
terminal 1 to an internal constant current
source. This current produces proportional - You issue a scan tool CLEAR CODES
voltage drops in the deployment loop. command.
• Measures the voltage difference between - Once 250 malfunction free ignition cycles
PASSENGER SIDE HIGH and PASSENGER have occurred.
SIDE LOW. When you issue a scan tool CLEAR CODES
• Calculates the resistance of the passenger command and the malfunction is still present, the
deployment loop using the measured voltage. DTC will not reappear until the next ignition cycle.
D iag n o stic A id s
C o n d itio n s fo r S e ttin g th e D TC
A poor connection can cause an intermittent
• The driver and passenger deployment loops are condition. Check the following for a poor connection:
not open.
• The inflatable restraint IP module harness
• The driver and passenger deployment loops are connector terminals A and B.
not shorted to voltage.
• The SDM terminals 1 and 4.
• The passenger deployment loop is not shorted
to ground. • The wire to terminal connections in CKT 1403.
• The passenger deployment loop resistance is • The wire to terminal connections in CKT 1404.
more than 3.0 ohms. The passenger The diagnostic table directs the technician to note
deployment loop consists of the following the entry value of PASSENGER RESISTANCE.
components: Comparing the value of PASSENGER RESISTANCE
- Inflatable restraint IP module. over multiple ignition cycles can be helpful in
determining if an intermittent condition exists.
- Harness wiring of CKT 1403.
When measurements are requested in this table, use
- Harness wiring of CKT 1404. J 39200 Digital Multimeter with the correct terminal
- Connector terminal contact. adapter from J 35616-A Connector Test Adapter Kit.
When a check for proper connection is requested, 10. This test isolates the malfunction to one side of
refer to Intermittents and Poor Connections. When the inflatable restraint IP module yellow 2-way
a wire, connector or terminal repair is requested, connector.
use J 38125-A Terminal Repair Kit and refer to 11. This test checks for proper contact or corrosion
Wiring Repair. of the inflatable restraint IP module jumper
connector.
Test Description 16. This test determines whether the malfunction is
The numbers below refer to the step numbers on the due to the inflatable restraint IP module or the
diagnostic table: module jumper.
2. This test determines the deployment loop 19. This test checks for proper contact or corrosion
resistance measured by the inflatable restraint of the SDM connector.
Sensing and Diagnostic Module (SDM). 24. This test determines whether the malfunction is
3. This test checks for proper contact or corrosion in CKT 1403.
of the yellow 2-way connector. 26. This test determines whether the malfunction is
in CKT 1404.
DTC B1015 Passenger Deploy. Loop R esistance High

Step Action Valuefs) Yes No
Was the SIR Diagnostic System Check performed? Refer to S IR
G o to S t e p 2 S y ste m C h e ck

2. Connect a scan tool to the DLC.
2 — —
5. Read and record on the repair order the passenger
deployment loop resistance PASSENGER
RESISTANCE.
Has the PASSENGER RESISTANCE been read and
recorded on the repair order? G o to S t e p 3

IP module yellow 2-w ay connectors near the base of
the steering column.
3 —
3. Check for proper connection at terminals A and B on
the IP harness side of the inflatable restraint IP
module yellow 2-w ay jumper connector.
Are the terminals damaged or corroded? G o to S t e p 4 G o to S t e p 6
Replace the inflatable restraint IP module yellow 2-w ay IP

4 harness connector. Refer to W ir in g R e p a ir. — —
Are the repairs complete? G o to S t e p 5
Check for proper connection at terminals A and B on the

inflatable restraint IP module yellow 2-w ay jumper
5 connector.
—
Are the terminals damaged or corroded? G o to S t e p 7 G o to S t e p 2 8

inflatable restraint IP module yellow 2-w ay jumper
6 —
connector.
Repair the inflatable restraint IP module jumper harness.

D T C B 1 0 1 5 P a s s e n g e r D e p lo y . L o o p R e s is ta n c e H ig h (c o n t’d )
1. Reconnect the yellow 2-w ay connectors near the
8 3. Using the scan tool, request the SIR data list display. 3.0 Q
4. Read the passenger deployment loop resistance
PASSENGER RESISTANCE.
Is the passenger resistance more than the specified value? G o to S t e p 1 0 G o to S t e p 9

2. Replace the inflatable restraint IP module yellow
9 — —
2-w ay IP harness connector. Refer to W ir in g R e p a ir.

IP module yellow 2-w ay connectors near the base of
3. Connect the J 3 8 7 1 5 - A SIR Driver/Passenger Load
10 Tool to the connectors. 3.0 Q
5. Using the scan tool, request the data list display.
Is the passenger resistance more than the specified value? G o to S t e p 1 9 G o to S t e p 11

2. Disconnect the inflatable restraint IP module pigtail
connector at the module jumper.
11 —
3. Check for proper connection at terminals A and B of
the 2-w ay jumper connector.


inflatable restraint IP module yellow 2-way pigtail
13 connector. —

14 connector. —
Replace the inflatable restraint IP module. Refer to In fl R s t

15 In s t r u m e n t P a n e l M o d u le R e p la c e m e n t . — —
1. Disconnect the inflatable restraint IP module jumper

harness connector from the J 3 8 7 1 5 -A .
2. Connect the connector to the jumper harness.
3. Connect J 3 8 7 1 5 - A to the inflatable restraint IP
module side of the jumper.
16 3.0 Q
5. Using the scan tool, request the SIR data list display.
Is the passenger resistance more than the specified value? G o to S t e p 1 7 G o to S t e p 1 8
D T C B 1 0 1 5 P a s s e n g e r D e p lo y . L o o p R e s is ta n c e H ig h (c o n t’d )
2. Repair the high resistance condition in the inflatable
17 restraint IP module jumper harness. Refer to W ir in g — —
R e p a ir.

2. Replace the inflatable restraint IP module. Refer to
18 — —
In f l R s t In s t r u m e n t P a n e l M o d u le R e p la c e m e n t

19 3. Disconnect the J 3 8 7 1 5 -A . —
4. Check for proper connection at terminals 1 and 4 on
the SDM harness connector.
Is the harness connector damaged or corroded? G o to S t e p 2 0 G o to S t e p 2 2
Replace the SDM harness connector. Refer to W ir in g

20 R e p a ir. — —
Check for proper connection at terminals 1 and 4 on

21 the SDM. —
Check for proper connection at terminals 1 and 4 on

22 the SDM. —

1. Zero the J 3 9 2 0 0 Digital Multimeter.

24 connector terminal 1 to the inflatable restraint IP 0 -0 .5 C l
module yellow 2-way harness connector terminal A.
Is the resistance reading within the specified values? G o to S t e p 2 6 G o to S t e p 2 5
Repair the high resistance condition in CKT 1403.

25 — —

terminal 4 to the inflatable restraint IP module yellow 2-way
26 0 -0 .5 C l
harness connector terminal B. Go to S D M
Is the resistance reading within the specified values? In te g rity C h e c k G o to S t e p 2 7

27 — —
Reconnect all the SIR components, make sure all the

components are properly mounted.
28 — —
Have all the SIR components been reconnected and
properly mounted? G o to S t e p 2 9
Clear all the SIR DTCs. Refer to S I R

29 — D ia g n o s t ic —
Have all the DTCs been cleared?
S y ste m C h e ck
D T C B 1 0 1 6 P a s s e n g e r D e p lo y m e n t L o o p R e s is ta n c e L o w

Deployment, Shorting ■nili- Restraint
Bare Close To Short IP Module
Connectors When
Connectors Are 1 WHT/BLK 1403 1 DKGRN/WHT 1404
Separated i ,----------------------------------------- ,
1 WHT/BLK 1403
A /
1 DK GRN/WHT 1404
Shorting Bar
'
B C233
\,
A
E F C231
0.8 WHT/BLK 1403 0.8 DKGRN/WHT 1404

1 4
r 1 Inflatable Restraint
Passenger Passenger
Side High Side Low •SensingAnd *
I I Diagnostic . A
J Module
187167
C ircuit D escription The RESISTANCE MEASUREMENT test checks for

operating voltage range.
Diagnostic Module (SDM) performs tests to diagnose
critical malfunctions within itself. Next the SDM Action Taken W hen the DTC Sets
voltages to make sure they are within their • The SDM sets a diagnostic trouble code.
proceeds with the RESISTANCE MEASUREMENT
test. During one portion of the RESISTANCE C onditions for Clearing the DTC
MEASUREMENT test, the SDM does the following: • Current DTC
• Grounds the PASSENGER SIDE LOW terminal The resistance of the passenger
4 through an internal current sink. deployment loop is more than 1.4 ohm
. Connects the PASSENGER SIDE HIGH and the ignition switch is cycled.
terminal 1 to an internal constant current • History DTC
source. This current produces proportional - You issue a scan tool CLEAR CODES
voltage drops in the deployment loop. command.
• Measures the voltage difference between - Once 250 malfunction free ignition cycles
PASSENGER SIDE HIGH and PASSENGER have occurred.
SIDE LOW. When you issue a scan tool CLEAR CODES
• Calculates the resistance of the passenger command and the malfunction is still present, the
C onditions fo r S etting the DTC D iagnostic Aids

• The driver and passenger deployment loops The following can cause an intermittent condition:
are not open. • A short circuit between CKT 1403 and
• The driver and passenger deployment loops CKT 347.
are not shorted to voltage. • A short circuit between CKT 1403 and
• The passenger deployment loop is not CKT 348.
shorted to ground. • A short circuit between CKT 1403 and
• The passenger deployment loop resistance is CKT 1404.
less than 1.4 ohms. The passenger deployment • A malfunctioning shorting bar on the inflatable
loop consists of the following components: restraint IP module connector.
- Inflatable restraint IP module. The diagnostic table directs the technician to note
- Harness wiring of CKT 1403. the entry value of PASSENGER RESISTANCE.
Comparing the value of PASSENGER RESISTANCE
- Harness wiring of CKT 1404. over multiple ignition cycles can be helpful in
- Connector terminal contact. determining if an intermittent condition exists.
When measurements are requested in this table, use 6. This test isolates the malfunction to one side of
J 39200 Digital Multimeter with the correct terminal the inflatable restraint IP module yellow 2-way
adapter from J 35616-A Connector Test Adapter Kit. connector.
When a check for proper connection is requested, 7. This test checks for proper contact or corrosion
refer to Intermittents and Poor Connections. When a of the inflatable restraint IP module jumper
wire, connector or terminal repair is requested, use connector.
J 38125-A Terminal Repair Kit and refer to Wiring
12. This test determines whether the malfunction is
Repair.
due to the inflatable restraint IP module or the
Test Description module jumper.
The numbers below refer to the step numbers on the 15. This test checks for a short from CKTs 1403
diagnostic table: to 1404.
2. This test determines the deployment loop 17. This test checks for a short from CKTs 1403
resistance measured by the SDM. to 348.
DTC B1016 Passenger Deploym ent Loop Resistance Low


2
5. Read and record on the repair order the passenger —
deployment loop resistance PASSENGER
RESISTANCE.
6. Request the SIR DTC display.
Is DTC B1022 also present? G o to S t e p 3 G o to S t e p 4

IP module yellow 2-way connectors near the base of
3 — —
3. Repair the short from CKT 347 to CKT 1403.

2. Disconnect the inflatable restraint IP module yellow
2-way connector near the base of the steering
column.
3. Reconnect the 2-way connector.
4. Make sure that the CPA is properly installed.
4 1.4 O
6. Using a scan tool, request the SIR data list display.
Is PASSENGER RESISTANCE less than the specified
value? G o to S t e p 6 G o to S t e p 5

5 — —
2-way harness connector. Refer to W ir in g R e p a ir.
D T C B 1 0 1 6 P a s s e n g e r D e p lo y m e n t L o o p R e s is ta n c e L o w (c o n t’d )

3. Connect J 3 8 7 1 5 - A SIR Driver/Passenger Load Tool
to the connectors.
6 1.4 Q
Is PASSENGER RESISTANCE less than the
specified value? G o to S t e p 1 5 G o to S t e p 7

2. Disconnect the inflatable IP module pigtail connector
from the module jumper.
7 —
the jumper connector.


9 connector. —

10 connector. —
Replace the inflatable restraint IP module. Refer to In fl R s t

11 In s t r u m e n t P a n e l M o d u le R e p la c e m e n t . — —

harness connector from J 3 8 7 1 5 -A .
12 1.4 Q
Is PASSENGER RESISTANCE less than the
specified value? G o to S t e p 1 4 G o to S t e p 1 3

2. " Replace the inflatable restraint IP module. Refer to
13 — —
In f l R s t In s t r u m e n t P a n e l M o d u le R e p la c e m e n t .
1. Turn the ignition to the OFF position.

2. Repair the short from CKT 1403 to CKT 1404 in the
14 — —
jumper harness.
DTC B1016 Passenger Deploym ent Loop Resistance Low (cont’d)
2. Disconnect the SDM. Refer to Infl Rst Sensing and
Diagnostic Module Replacement.
3. Disconnect J 38715-A.
15 OL
Is the resistance less than the specified value? G o to Step 16 Go to Step 17

16 2. Repair the short from CKT 1403 to CKT 1404. — —
Are the repairs complete? G o to Step 19

17 terminal 1 to terminal 3. OL Go to S D M
Is the resistance less than the specified value? Go to Step 18 Integrity Check
Repair the short from CKT 1403 to CKT 348.

18 — —
Are the repairs complete? Go to Step 19

19 — —
properly mounted? Go to Step 2 0
Clear the SIR DTCs. Go to S IR
20 Have all the SIR DTCs been cleared? — Diagnostic —
System Check
D T C B 1 0 1 7 P a s s e n g e r D e p lo y m e n t L o o p O p e n

Restraint
------------- O IL-------------
Deployment, Shorting
Bare Close To Short
Connectors When
-I IP Module H
Separated / 1,1 — ■ s, , □
A Shorting Bar B C233 A.
. / ■* .

E C231
0.8 WHT/BLK 1403 0.8 DK GRN/WHT 1404
1 4
Passenger Passenger
I Side High Side Low •SensingAnd *
I Diagnostic
J Module
187167
C ircuit Description C onditions fo r C learing the DTC

When you first turn the ignition switch to the RUN • Current DTC
position, the inflatable restraint Sensing and The voltage difference between PASSENGER
Diagnostic Module (SDM) performs tests to diagnose SIDE HIGH terminal 1 and PASSENGER SIDE
critical malfunctions within itself. Next the SDM LOW terminal 4 is less than 400 millivolts for
measures IGNITION 1 voltage to make sure it is 500 milliseconds.
within its respective normal voltage range. Then the
SDM proceeds with the DEPLOYMENT LOOP • History DTC
CONTINUITY test. During the DEPLOYMENT LOOP - You issue a scan tool CLEAR CODES
CONTINUITY test, the SDM measures the voltage command.
difference between PASSENGER SIDE HIGH and - Once 250 malfunction free ignition cycles
PASSENGER SIDE LOW. have occurred.
C onditions fo r Setting the DTC D iagnostic Aids

• The voltage difference between PASSENGER The following can cause an intermittent condition:
SIDE HIGH terminal 1 and PASSENGER SIDE • A poor connection at the inflatable restraint IP
LOW terminal 4 is more than or equal to module harness connector terminals A and B.
400 millivolts.
• A poor connection at the SDM terminals 1
• The malfunction must be present for at least and 4.
500 milliseconds during one of the following
tests: • An open in CKT 1403.
- DEPLOYMENT LOOP CONTINUITY • An open in CKT 1404.
If the malfunction is detected in this test, the
J 39200 Digital Multimeter with the correct terminal
RESISTANCE MEASUREMENT test will not
adapter from J 35616-A Connector Test Adapter Kit.
be performed.
- CONTINUOUS MONITORING refer to Intermittents and Poor Connections. When
a wire, connector or terminal repair is requested,
A ction Taken W hen th e DTC Sets use J 38125-A Terminal Repair Kit and refer to
• The SDM sets a Diagnostic Trouble Code. Wiring Repair.
• The SDM turns ON the AIR BAG warning lamp.
Test Description 11. This test checks for proper contact or corrosion
The numbers below refer to the step numbers on the of the inflatable restraint IP module jumper
diagnostic table: connector.
2. This test determines the deployment loop 16. This test determines whether the malfunction is
voltage difference measured by the inflatable due to the inflatable restraint IP module or the
restraint Sensing and Diagnostic Module (SDM). module jumper.
3. This test checks for proper contact or corrosion 19. This test checks for proper contact or corrosion
of the yellow 2-way connector. of the SDM harness connector.
10. This test isolates the malfunction to one side of 24. This test determines whether the malfunction is
the inflatable restraint IP module yellow 2-way in CKT 1403.
connector. 26. This test determines whether the malfunction is
in CKT 1404.
DTC B1017 Passenger Deploym ent Loop Open

S tep A ctio n V alu e(s) Yes No
Was the SIR Diagnostic System Check performed? Go to S IR
1 — Diagnostic
Go to Step 2 System Check
2 — —
5. Read and record on the repair order the
passenger deployment loop voltage difference
PASSENGER VDIF.
Has the PASSENGER VDIF been read and recorded on
the repair order? G o to Step 3
3 —
the IP harness side of the inflatable restraint IP
module yellow 2-way jumper connector.
Are the terminals damaged or corroded? Go to Step 4 Go to Step 6
Replace the inflatable restraint IP module yellow 2-way IP
4 harness connector. Refer to Wiring Repair. — —
5 inflatable restraint IP module yellow 2-way jumper connector. —
Are the terminals damaged or corroded? Go to Step 7 Go to Step 2 8
6 inflatable restraint IP module yellow 2-way jumper connector. —
7 Refer to Wiring R epair — —
Are the repairs complete? Go to Step 2 8
1. Connect the inflatable restraint steering wheel and IP
module yellow 2-way connectors near the base of
8 400 mV
4. Read the passenger deployment loop voltage
difference PASSENGER VDIF.
Is the PASSENGER VDIF less than the specified value? G o to Step 9 Go to Step 10
DTC B1017 Passenger Deploym ent Loop Open (cont’d)
1. Turn the ignition to the OFF position.
9 — —
2-way IP harness connector. Refer to Wiring Repair.
1. Turn the ignition switch to the OFF position,
IP module yellow 2-way connectors at the base of
3. Connect the J 3 8 7 1 5-A SIR Driver/Passenger Load
10 Tool to the connectors. 400 mV
Is the PASSENGER VDIF less than the specified value? Go to Step 11 Go to Step 19
2. Disconnect the inflatable restraint IP module pigtail
connector from the module jumper.
11 —
3. Check for proper connection at terminals A and B of
the 2-way jumper connector.
Are the terminals damaged or corroded? Go to Step 12 G o to Step 14
12 Refer to Wiring Repair. — —
13 connector. —
Are the terminals damaged or corroded? Go to Step 15 Go to Step 2 8

14 connector. —

Replace the inflatable restraint IP module. Refer to Infl Rst
15 Instrument P anel Module Replacement. — —

harness connector from the J 3 8 7 1 5-A.
2. Connect the connector to the jumper harness.
3. Connect J 3 8 7 1 5-A to the inflatable restraint IP
16 400 mV
Is PASSENGER VDIF less than the specified value? Go to Step 17 Go to Step 18
17 — —
Infl Rst Instrument P anel Module Replacement.
DTC B1017 Passenger Deploym ent Loop Open (cont’d)
S tep A ctio n V a lu e(s) Yes No
2. Repair the high resistance condition in the inflatable
18 restraint IP module jumper harness. Refer to Wiring — —
Repair.
2. Disconnect the SDM. Refer to Infl Rst Sensing and
Diagnostic Module Replacement.
19 3. Disconnect the J 38715-A. —
the SDM harness connector.
Is the connector damaged or corroded? Go to Step 2 0 Go to Step 2 2
Replace the SDM harness connector. Refer to Wiring
20 Repair. — —
Check for proper connection at terminals 1 and 4 of
21 the SDM. —
Are the terminals damaged or corroded? Go to Step 2 3 Go to Step 2 8
Check for proper connection at terminals 1 and 4 of
22 the SDM. —
Are the terminals damaged or corroded? Go to Step 2 3 Go to Step 24
Replace the SDM. Refer to Infl Rst Sensing and
23 Diagnostic Module Replacement. — —
24 connector terminal 1 to the inflatable restraint IP 0 -0 .5 n
module yellow 2-way harness connector terminal A.
Is the resistance reading within the specified values? Go to Step 2 6 Go to Step 2 5
25 — —
terminal 4 to the inflatable restraint IP module yellow 2-way
26
harness connector terminal B. 0 -0 .5 Q
Go to S D M
Is the resistance reading within the specified values? Integrity Check Go to Step 2 7
27 — —
Reconnect all the SIR system components, make sure
all the components are properly mounted.
28 — —
properly mounted? Go to Step 2 9
Clear all the SIR DTCs. Go to S IR

29 Have all the SIR DTCs been cleared? — Diagnostic —
System Check
D T C B 1 0 1 8 P a s s e n g e r D e p lo y m e n t L o o p S h o rt to G N D

Bars Close To Short
JUIr Restraint
IP Module
Connectors When
Connectors Are 1 WHT/BLK 1403 1 DKGRN/W HT 1404
Separated
H
1 WHT/BLK 1403
A ./ "" 1
1 DKGRN/W HT
Shorting Bar B
\■
1404
C233
A
1 WHT/BLK 1403 1 DKGRN/W HT 1404
E F C231
0.8 WHT/BLK 1403 0.8 DKGRN/W HT 1404

1 4
r Inflatable Restraint
Passenger Passenger
Side High Side Low •SensingAnd *
I Diagnostic
-* Module
187167
C ircu it Description Action Taken W hen the DTC Sets

When you first turn the ignition switch to the RUN • The SDM sets DTC B1018 and also
position, the inflatable restraint Sensing and DTC B1071.
Diagnostic Module (SDM) performs tests to diagnose • The SDM turns ON the AIR BAG warning lamp.
critical malfunctions within itself. Upon passing these
tests IGNITION 1, 23VLR and the deployment loop C onditions fo r C learing the DTC
voltages are measured to make sure they are within DTC B1018 is a latched code. You cannot clear a
their respective normal voltage ranges. The SDM latched code. Repair the malfunction that set this
monitors the voltages at DRIVER SIDE LOW DTC before you replace the SDM.
terminal 3 and PASSENGER SIDE LOW terminal 4
to detect shorts to ground in the inflator module D iagnostic Aids
circuits. The service wait time is 10 minutes. Refer to
A short to ground in the inflatable restraint IP
ENABLE/DISABLE procedures.
module circuit can cause an intermittent condition. A
C onditions fo r Setting the DTC DTC B1018 would be accompanied by DTC B1071.
Inspect CKT 1403 and CKT 1404 carefully for cutting
• The driver and passenger deployment loops are or chafing. Wiring pigtail damage requires
not open. replacement of the inflatable restraint IP module. A
• The driver deployment loop is not shorted to careful inspection of the circuits and components
voltage. indicated on the DTC B1018 table is essential in
• The voltage at DRIVER SIDE LOW terminal 3 order to prevent damage to the replacement
is more than 3.3 volts. inflatable restraint Sensing and Diagnostic Module
. The voltage at PASSENGER SIDE LOW (SDM). The diagnostic table directs the technician to
terminal 4 is less than 3.3 volts for note the entry value of PASSENGER SENSELO.
500 milliseconds. Comparing the value of PASSENGER SENSELO
can be helpful in determining if an intermittent
The following tests check for this DTC. These tests
condition exists.
occur when IGNITION 1 is within the normal
operating voltage range. When measurements are requested in this table, use
J 39200 Digital Multimeter with the correct terminal
• POWER-ON-When the malfunction is detected
in this test, the RESISTANCE MEASUREMENT
test will not be performed.
. CONTINUOUS MONITORING a wire, connector or terminal repair is requested,
use J 38125-A Terminal Repair Kit and refer to
Wiring Repair.
Test Description 4. This test determines whether the malfunction is
The numbers below refer to the step numbers on the due to the inflatable restraint IP module or the
diagnostic table: module jumper.
2. This test determines the passenger side low 7. This test determines whether the malfunction is
voltage measured by the inflatable restraint in CKT 1403.
Sensing and Diagnostic Module (SDM). 9. This test determines whether the malfunction is
3. This test isolates the malfunction to one side of in CKT 1404.
the inflatable restraint IP module yellow 2-way
connector.
DTC B1018 Passenger Deployment Loop Short to GND


2 4. Request the SIR data list display. — —

side low voltage PASSENGER SENSELO.
Has the PASSENGER SENSELO been read and recorded
on the repair order? G o to S t e p 3

3 to the connectors. 3.3 V
6. Read the passenger side low voltage PASSENGER
SENSELO.
Is PASSENGER SENSELO less than the specified value? G o to S t e p 7 G o to S t e p 4

3. Connect the connector to the jumper.
4 module side of the jumper. 3.3 V
SENSELO.
Is PASSENGER SENSELO less than the specified value? G o to S t e p 5 G o to S t e p 6

2. Repair the short to ground condition in the
5 — —
jumper harness.
DTC B1018 Passenger Deployment Loop Short to GND (cont’d)
2. Inspect the inflatable restraint IP module pigtail for
damage and proper routing.
6 — —
In f l R s t In s t ru m e n t P a n e l M o d u le R e p la c e m e n t

7 3. Disconnect the J 3 8 7 1 5 -A . OL
4. Measure the resistance on the SDM harness
connector from terminals 1 to 6 (ground).
Is the resistance less than the specified value? G o to S t e p 8 G o to S t e p 9

8 — —
Measure the resistance on the SDM harness connector

9 from terminals 4 to 6 (ground). OL Go to S D M
Is the resistance less than the specified value? G o to S t e p 1 0 In t e g rit y C h e c k

10 — —
1. Reconnect all the SIR system components, make

sure all the components are properly mounted.
3. Make sure PASSENGER SENSELO is more than
11 the specified value. 3.3 V —

D ia g n o s t ic M o d u le R e p la c e m e n t . Go to S I R
D T C B 1 0 19 P a s s e n g e r D ep lo y. L o o p S h o rt to V o lta g e

Deployment, Shorting JUlr Restraint
Bars Close To Short IP Module
Connectors When
Separated 4, /
Shorting Bar B C233 A ,
A .✓ i i i i .ii i i -- „ <

E F C231
0.8 WHT/BLK 1403 0.8 DK GRN/WHT 1404

1 4
Passenger Passenger
I Side High Side Low 1Sensing And *
I I Diagnostic
L_ _ _ _ _ ■•Module
187167
C ircuit Description D iagnostic Aids

When you first turn the ignition switch to the RUN A short to B+ in the inflatable restraint IP module
position, the inflatable restraint Sensing and circuit can cause an intermittent condition. Inspect
Diagnostic Module (SDM) performs tests to diagnose CKT 1403 and CKT 1404 carefully for cutting or
critical malfunctions within itself. Upon passing these chafing. Wiring pigtail damage requires replacement
tests IGNITION 1, 23 VLR and the deployment loop of the inflatable restraint IP module. The diagnostic
voltages are measured to make sure they are within table directs the technician to note the entry value of
their respective normal voltage ranges. The SDM PASSENGER SENSELO. Comparing the value of
monitors the voltages at DRIVER SIDE LOW PASSENGER SENSELO can be helpful in
terminal 3 and PASSENGER SIDE LOW terminal 4 determining if an intermittent condition exists.
to detect shorts to B+ in the inflator module circuits. When measurements are requested in this table, use
C onditions for S etting the DTC J 39200 Digital Multimeter with the correct terminal
• The voltage at DRIVER SIDE LOW terminal 3 When a check for proper connection is requested,
is less than 4.8 volts. refer to Intermittents and Poor Connections. When
. The voltage at PASSENGER SIDE LOW a wire, connector or terminal repair is requested,
terminal 4 is more than 4.8 volts for use J 38125-A Terminal Repair Kit and refer to
500 milliseconds. Wiring Repair.
The CONTINUOUS MONITORING test checks for
Test Description
this DTC. This test occurs when IGNITION 1 is
within the normal operating voltage range. The numbers below refer to the step numbers on the
diagnostic table:
Action Taken W hen the DTC Sets 2. This test determines the passenger side low
• The SDM sets a Diagnostic Trouble Code. voltage measured by the inflatable restraint
• The SDM turns ON the AIR BAG warning lamp. Sensing and Diagnostic Module (SDM).
3. This test isolates the malfunction to one side of
C onditions fo r C learing the DTC the inflatable restraint IP module yellow 2-way
• Current DTC-The voltage at PASSENGER connector.
SIDE LOW terminal 4 is less than 4.8 volts 4. This test determines whether the malfunction is
for 500 milliseconds. due to the inflatable restraint IP module or the
• History DTC module jumper.
- You issue a scan tool CLEAR CODES 7. This test determines whether the malfunction
command. is in CKT 1403.
- Once 250 malfunction free ignition cycles 9. This test determines whether the malfunction
have occurred. is in CKT 1404.
D T C B 1 0 1 9 P a s s e n g e r D e p lo y . L o o p S h o rt to V o lta g e
G o to S t e p 2 Sy ste m C h e ck

2
4. Request the SIR data list display. — —
side low voltage PASSENGER SENSELO.
Has the PASSENGER SENSELO been read and recorded

3 to the connectors. 4.8 V
SENSELO.
Is PASSENGER SENSELO more than the specified value? G o to S t e p 7 G o to S t e p 4

3. Connect the connector to the jumper.
4. Connect J 3 8 7 1 5 - A to the inflatable restraint
4 IP module side of the jumper. 4.8 V
SENSELO.
Is PASSENGER SENSELO more than the specified value? G o to S t e p 5 G o to S t e p 6

2. Repair the short to B+ condition in the inflatable
5 — —
restraint IP module jumper harness.

2. Inspect the inflatable restraint IP module pigtail for
damage and proper routing.
6 — —
In f l R s t In s t r u m e n t P a n e l M o d u le R e p la c e m e n t .
DTC B1019 Passenger Deploy. Loop Short to Voltage (cont’d)
3. Disconnect the J 3 8 7 1 5-A

7 1.0 V
from terminal 1 to terminal 6 (ground).
Is the measured voltage less than the specified value? G o to S t e p 9 G o to S t e p 8

8 2. Repair a short to B+ condition in CKT 1403. — —
Measure the voltage on the SDM harness connector from

9 terminal 4 to terminal 6 (ground). 1.0 V Go to S D M
Is the measured voltage less than the specified value? In t e g rit y C h e c k G o to S t e p 1 0


11 — —
Clear all the SIR DTCs. Go to S I R

12 Have all the SIR DTCs been cleared? — D ia g n o s t ic —
Sy ste m C h eck
D T C B 1021 D riv e r D e p lo y m e n t L o o p R e s is ta n c e H igh
To Prevent Accidental Inflatable Restraint

Deployment, Shorting Shorting Bar Steering Wheel
Bare Close To Short Module
Connectors When
Connectors Are 0.8 WHT 347 0.8 DKGRN 348
Separated
Inflatable Restraint □
Steering Wheel
Module Coil
0.8 WHT 347 0.8 DK GRN 348
Shorting Bar B
A , C234
0.8 WHT 3 4 7 0.8 DK GRN 348

C D C231
0.8 WHT 347 0.8 DK GRN 348
2 3
r 1 Inflatable
Drivers Drivers
Side High Side Low I Restraint .
I I Sensing And A
t ------------------------------------------------------------------j Diagnostic
187164
C ircuit Description The RESISTANCE MEASUREMENT test checks for

Diagnostic Module (SDM) performs tests to diagnose operating voltage range.
critical malfunctions within itself. Next the SDM
measures IGNITION 1 and the deployment loop Action Taken W hen the DTC Sets
voltages to make sure they are within their • The SDM sets a Diagnostic Trouble Code.
test. During one portion of the RESISTANCE C onditions fo r C learing the DTC
MEASUREMENT test, the SDM does the following:
The DTC will clear when one of the following
• Grounds the DRIVER SIDE LOW terminal 3
conditions is met:
through an internal current sink.
• Connects the DRIVER SIDE HIGH terminal 2 to • Current DTC
an internal constant current source. This current The resistance of the driver deployment loop
produces proportional voltage drops in the is less than 3.8 ohms and the ignition switch
deployment loop. is cycled.
• Measures the voltage difference between • History DTC
DRIVER SIDE HIGH and DRIVER SIDE LOW.
- You issue a scan tool CLEAR CODES
• Calculates the resistance of the driver command.
deployment loop using the measured voltage.
- Once 250 malfunction free ignition cycles
C onditions fo r Setting the DTC have occurred.
• The driver and passenger deployment loops are When you issue a scan tool CLEAR CODES
not open. command and the malfunction is still present, the
• The driver and passenger deployment loops are DTC will not reappear until the next ignition cycle.
not shorted to voltage.
D iagnostic Aids
• The driver deployment loop is not shorted to
ground. A poor connection can cause an intermittent
condition. Check the following for a poor connection:
• The driver deployment loop resistance is more
than 3.8 ohms. The driver deployment loop • The inflatable restraint steering wheel module
consists of the following components: steering column connector terminals A and B.
- Inflatable restraint steering wheel module. • The upper inflatable restraint steering wheel
- Inflatable restraint steering wheel module module coil connector terminals A and B.
coil. • The SDM terminals 2 and 3.
- Harness wiring of CKT 347. • The wire to terminal connections in CKT 347.
- Harness wiring of CKT 348. • The wire to terminal connections in CKT 348.
- Connector terminal contact.
The diagnostic table directs the technician to note 3. This test checks for proper contact or corrosion
the entry value of DRIVER RESISTANCE. of the yellow 2-way connector.
Comparing the value of DRIVER RESISTANCE over 10. This test isolates the malfunction to one side of
multiple ignition cycles can be helpful in determining
the inflatable restraint steering wheel module
if an intermittent condition exists.
yellow 2-way connector.
J 39200 Digital Multimeter with the correct terminal 11. This test determines whether the malfunction is
adapter from J 35616-A Connector Test Adapter Kit. due to the inflatable restraint steering wheel
When a check for proper connection is requested, module or the module coil.
refer to Intermittents and Poor Connections. When 14. This test checks for proper contact or corrosion
a wire, connector or terminal repair is requested, of the SDM connector.
use J 38125-A Terminal Repair Kit and refer to
Wiring Repair. 19. This test determines whether the malfunction
is in CKT 347.
Test Description
21. This test determines whether the malfunction
The numbers below refer to the step numbers on the is in CKT 348.
diagnostic table:
2. This test determines the deployment loop
resistance measured by the inflatable restraint
Sensing and Diagnostic Module (SDM).
DTC B1021 Driver Deploym ent Loop Resistance High



5. Read and record on the repair order the driver
deployment loop resistance DRIVER RESISTANCE.
Has the DRIVER RESISTANCE been read and recorded

3 3. Check for proper connection at terminals A and B on —
the harness side of the inflatable restraint steering
wheel module yellow 2-way connector at the base of
Replace the yellow 2-way harness connector at the base

4 of the steering column. Refer to W irin g R e p a ir. — —
Check for proper connection at terminals A and B of the

inflatable restraint steering wheel module coil side of the
5 connector. —
Check for proper connection at terminals A and B of the

inflatable restraint steering wheel module coil side of the
6 connector. —

D T C B 1021 D riv e r D e p lo y m e n t L o o p R e s is ta n c e H ig h (c o n t’d )

Replace the inflatable restraint IP module coil. Refer to In fl
7 R s t S t e e r in g W h e e l M o d u le C o il R e p la c e m e n t . — —
Are the repairs complete? Go to S t e p 2 3
1. Connect the inflatable restraint steering wheel and IP
module yellow 2-way connectors near the base of
8 3.8 Q
4. Read the driver deployment loop resistance DRIVER
RESISTANCE.
Is DRIVER RESISTANCE more than the specified value? G o to S t e p 1 0 G o to S t e p 9

2. Replace the yellow 2-way harness connector at the
9 — —
base of the steering column. Refer to W ir in g R e p a ir.

10 to the harness connectors. 3.8 Q
RESISTANCE.
Is DRIVER RESISTANCE more than the specified value? G o to S t e p 1 4 G o to S t e p 11

2. Remove the inflatable restraint steering wheel
module. Refer to In fl R s t S t e e r in g W h e e l M o d u le
R e p la c e m e n t .
3. Disconnect J 3 8 7 1 5 - A from the driver 2-way

connector.
4. Connect the 2-way connector.
11 5. Connect J 3 8 7 1 5 - A to the upper inflatable restraint 3.8 n
steering wheel module coil connector on the steering
column.
RESISTANCE.
Is DRIVER RESISTANCE more than the specified value? G o to S t e p 13 G o to S t e p 1 2

2. Replace the inflatable restraint steering wheel
12 module. Refer to In fl R s t S t e e r in g W h e e l M o d u le — —

13 module coil. Refer to In fl R s t S t e e r in g W h e e l M o d u le — —
C o il R e p la c e m e n t .
D T C B 1021 D riv e r D e p lo y m e n t L o o p R e s is ta n c e H ig h (c o n t’d )

3. Disconnect J 3 8 7 1 5 -A .
14 —
4. Check for proper connection at terminal 2 and
terminal 3 on the harness side of the SDM
connector.

Check for proper connection at terminal 2 and

16 terminal 3 on the SDM. —
Check for proper connection at terminal 2 and

17 terminal 3 on the SDM. —


connector terminal 2 to the inflatable restraint
19 0 -0 .5 Q
steering wheel module yellow 2-way harness
connector terminal A.

20 — —

terminal 3 to the inflatable restraint steering wheel module
21 0 -0 .5 Q
yellow 2-way harness connector terminal B. Go to S D M
Is the resistance reading within the specified values? In t e g rit y C h e c k G o to S t e p 2 2

22 — —

23 — —

S y ste m C h eck
D T C B 1 0 2 2 D riv e r D e p lo y m e n t L o o p R e s is ta n c e L o w
To Prevent Accidental Inflatable Restraint

— 1U li—
Deployment, Shorting Shorting Bar Steering Wheel
Bars Close To Short Module
Connectors When
Connectors Are 0.8 WHT 347 0.8 DK GRN 348
Separated
Inflatable Restraint
Steering Wheel
Module Coil
0.8 WHT 347 0.8 DK GRN 348
Shorting Bar B
A1 . C234
0.8 WHT 347 0.8 DK GRN 348

D v C231
0.8 WHT 347 0.8 DK GRN 348
2 3
r 1 Inflatable
Drivers Drivers
I Sensing And A
■•Diagnostic
187164
Circuit Description The RESISTANCE MEASUREMENT test checks for

Diagnostic Module (SDM) performs tests to diagnose operating voltage range.
critical malfunctions within itself. Next the SDM Action Taken When the DTC Sets
voltages to make sure they are within their • The SDM sets a Diagnostic Trouble Code.
test. During one portion of the RESISTANCE Conditions for Clearing the DTC
MEASUREMENT test, the SDM does the following: • Current DTC-The resistance of the driver
• Grounds the DRIVER SIDE LOW terminal 3 deployment loop is more than 1.7 ohm and the
through an internal current sink. ignition switch is cycled.
• Connects the DRIVER SIDE HIGH terminal 2 to • History DTC
an internal constant current source. This current - You issue a scan tool CLEAR CODES
produces proportional voltage drops in the command.
deployment loop. - Once 250 malfunction free ignition cycles
• Measures the voltage difference between have occurred.
DRIVER SIDE HIGH and DRIVER SIDE LOW. When you issue a scan tool CLEAR CODES
• Calculates the resistance pf the driver command and the malfunction is still present, the
Conditions for Setting the DTC Diagnostic Aids

• The driver and passenger deployment loops are The following can cause an intermittent condition:
not open. • A short circuit between CKT 347 and CKT 348.
• The driver and passenger deployment loops are • A short circuit between CKT 347 and
not shorted to voltage. CKT 1403.
• The driver deployment loop is not shorted to • A short circuit between CKT 347 and
ground. CKT 1404.
• The driver deployment loop resistance is less • A malfunctioning shorting bar on the inflatable
than 1.7 ohm. The driver deployment loop restraint steering wheel module connector.
consists of the following components: • A malfunctioning shorting bar on the inflatable
- Inflatable restraint steering wheel module. restraint steering wheel module coil steering
- Inflatable restraint steering wheel column connector.
module coil. The diagnostic table directs the technician to note
- Harness wiring of CKT 347. the entry value of DRIVER RESISTANCE.
Comparing the value of DRIVER RESISTANCE over
- Harness wiring of CKT 348. multiple ignition cycles can be helpful in determining
- Connector terminal contact. if an intermittent condition exists.
J 39200 Digital Multimeter with the correct terminal the inflatable restraint steering wheel module
adapter from J 35616-A Connector Test Adapter Kit. coil yellow 2-way connector.
7. This test determines whether the malfunction is
a wire, connector or terminal repair is requested, due to the inflatable restraint steering wheel
use J 38125-A Terminal Repair Kit and refer to module or the module coil.
Wiring Repair. 10. This test checks for a short from CKT 347
to CKT 348.
Test Description
12. This test checks for a short from CKT 347
diagnostic table: to CKT 1404.
resistance measured by the inflatable restraint
Sensing and Diagnostic Module (SDM).
DTC B1022 Driver Deploym ent Loop R esistance Low


2 —
deployment loop resistance DRIVER RESISTANCE.
6. Request the SIR DTC display.
Is DTC B1016 also present? G o to S t e p 3 G o to S t e p 4

3 — —
3. Repair the short from CKT 347 to CKT 1403.

2. Disconnect the inflatable restraint steering wheel
module yellow 2-way connector near the base of the
steering column.
3. Reconnect the 2-way connector.
4 4. Inspect that the CPA is properly installed. 1.7 Q
6. Using a scan tool, request the SIR data list display.
RESISTANCE.
Is DRIVER RESISTANCE less than the specified value? G o to S t e p 6 G o to S t e p 5

2. Replace the yellow 2-way harness connector near
5 the base of the steering column. Refer to W irin g — —
R e p a ir.

D T C B 1 0 2 2 D riv e r D e p lo y m e n t L o o p R e s is ta n c e L o w (c o n t’d )

6 to the harness connectors. 1.7 Q
RESISTANCE.
Is DRIVER RESISTANCE less than the specified value? G o to S t e p 1 0 G o to S t e p 7


connector.
4. Connect the 2-way connector at the base of the
steering column.
7 1.7 Q
5. Connect J 3 8 7 1 5 - A to the upper inflatable restraint
steering wheel module coil connector on the steering
column.
RESISTANCE.
Is DRIVER RESISTANCE less than the specified value? G o to S t e p 9 G o to S t e p 8


9 module coil. Refer to In f l R s t S t e e r in g W h e e l M o d u le — —

10 3. Disconnect J 3 8 7 1 5 -A . OL
Is the resistance reading less than the specified value? G o to S t e p 11 G o to S t e p 1 2
Repair a short from CKT 347 to CKT 348.

11 — —
DTC B1022 D river Deploym ent Loop Resistance Low (cont’d)
Step Action Value(s) Yee No
12 terminal 2 to terminal 4. OL Go to S D M
Is the resistance reading less than the specified value? G o to S t e p 1 3 In t e g rit y C h e c k
Repair a short from CKT 347 to CKT 1404.

13 — —

14 — —

S y ste m C h eck
D T C B 1 0 2 4 D riv e r D e p lo y m e n t L o o p S h o rt to G ro u n d
To Provent Accidental
■njv
Shorting Bar
Steering Wheel
Bars Close To Short Module
Connectors When
Separated Inflatable Restraint
Steering Wheel
Module Coil
0.8 WHT 347 0.8 DK GRN 348
Shorting Bar Q
Aw , C234
0.8 WHT 347 0.8 DK GRN 348

D C231
0.8 WHT 347 0.8 DK GRN 348
2 3
r 1 Inflatable
Drivers Drivers
I Sensing And A
L -I Diagnostic
187164
C ircuit D escription D iagnostic Aids

When you first turn the ignition switch to the RUN A short to ground in the inflatable restraint steering
position, the inflatable restraint Sensing and wheel module circuit can cause an intermittent
Diagnostic Module (SDM) performs tests to diagnose condition. A DTC B1024 would be accompanied by
critical malfunctions within itself. Upon passing these DTC B1071. Inspect CKT 347 and CKT 348 carefully
tests IGNITION 1, 23VLR and the deployment loop for cutting or chafing. A careful inspection of the
voltages are measured to make sure they are within circuits and components indicated on the DTC B1024
their respective normal voltage ranges. The SDM table is essential in order to prevent damage to the
monitors the voltages at DRIVER SIDE LOW replacement inflatable restraint Sensing and Diagnostic
terminal 3 and PASSENGER SIDE LOW terminal 4 Module (SDM). The diagnostic table directs the
to detect shorts to ground in the inflator module technician to note the entry value of DRIVER
circuits. The service wait time is 10 minutes. Refer to SENSELO. Comparing the value of DRIVER
ENABLE/DISABLE procedures. SENSELO can be helpful in determining if an
intermittent condition exists.
C onditions fo r S etting the DTC
• The driver and passenger deployment loops are When measurements are requested in this table, use
not open. J 39200 Digital Multimeter with the correct terminal
• The passenger deployment loop is not shorted When a check for proper connection is requested,
to voltage. refer to Intermittents and Poor Connections. When
. The voltage at PASSENGER SIDE LOW a wire, connector or terminal repair is requested,
terminal 4 is more than 3.3 volts. use J 38125-A Terminal Repair Kit and refer to
• The voltage at DRIVER SIDE LOW terminal 3 Wiring Repair.
is less than 3.3 volts for 500 milliseconds.
Test Description
The following tests check for this DTC. These tests
occur when IGNITION 1 is within the normal The numbers below refer to the step numbers on the
operating voltage range. diagnostic table:
• POWER-ON-When the malfunction is detected 2. This test determines the driver side low voltage
in this test, the RESISTANCE MEASUREMENT measured by the inflatable restraint Sensing
test will not be performed. and Diagnostic Module (SDM).
. CONTINUOUS MONITORING 3. This test isolates the malfunction to one side of
the inflatable restraint steering wheel module
A ction Taken W hen the DTC Sets coil yellow 2-way connector.
• The SDM sets DTC B1024 and also 4. This test determines whether the malfunction
DTC B1071. is due to the inflatable restraint steering wheel
• The SDM turns ON the AIR BAG warning lamp. module or the module coil.
C onditions fo r C learing the DTC 7. This test determines whether the malfunction
DTC B1024 is a latched code. You cannot clear a is in CKT 347.
latched code. Repair the malfunction that set this 9. This test determines whether the malfunction
DTC before you replace the SDM. is in CKT 348.
DTC B1024 Driver Deploym ent Loop Short to Ground


5. Read and record on the repair order the driver side
low voltage DRIVER SENSELO.
Has the DRIVER SENSELO been read and recorded on
the repair order? G o to S t e p 3

3 to the harness connectors. 3.3 V

6. Read the driver side low voltage DRIVER SENSELO.
Is DRIVER SENSELO less than the specified value? G o to S t e p 7 G o to S t e p 4


harness connector.
4 4. Connect the driver 2-way connector. 3.3 V

steering wheel module connector.
Is DRIVER SENSELO less than the specified value? G o to S t e p 6 G o to S t e p 5

5 module. Refer to In f l R s t S t e e r in g W h e e l M o d u le — —

module coil. Refer to In f l R s t S t e e r in g W h e e l M o d u le
6 3. Inspect the coil and the wires for damage. — —

module coil. Refer to In fl R s t S t e e r in g W h e e l M o d u le
D T C B 1 0 2 4 D riv e r D e p lo y m e n t L o o p S h o rt to G ro u n d (c o n t’d )

3. Disconnect the J 3 8 7 1 5 -A .
7 OL
5. Measure the resistance on the SDM harness
connector from terminal 2 to terminal 6 (ground).
Is the resistance reading less than the specified value? G o to S t e p 8 G o to S t e p 9

8 — —
Measure the resistance on the SDM harness connector

9 from terminal 3 to terminal 6 (ground). OL Go to S D M
Is the resistance reading less than the specified value? G o to S t e p 1 0 In t e g rit y C h e c k

10 — —
1. Reconnect all the SIR system components, make

sure all the components are properly mounted.
3. Make sure that DRIVER SENSELO is more than the
11 specified value. 3.3 V —

D ia g n o s t ic M o d u le R e p la c e m e n t . Go to S I R
D T C B 1 0 2 5 D riv e r D e p lo y m e n t L o o p S h o rt to V o lta g e
To Prevent Accidental
JlRr
Shorting Bar Steering Wheel
Bars Close To Short
Connectors When
Module
Connectors Are 0.8 WHT 347 0.8 DK GRN 348
Separated
Steering Wheel
Module Coil
0.8 WHT 347 0.8 DK GRN 348
A
Shorting Bar Q
A; ,,C234
0.8 WHT 347 0.8 DK GRN 348

C D C231
0.8 WHT 347 0.8 DK GRN 348
2 3_
r n Inflatable
Drivers Drivers
I I Sensing And A
l -------------------------------------------------- j Diagnostic i l g
187164
C ircuit Description D iagnostic Aids

When you first turn the ignition switch to the RUN A short to B+ in the inflatable restraint steering
position, the inflatable restraint Sensing and wheel module circuit can cause an intermittent
Diagnostic Module (SDM) performs tests to diagnose condition. Inspect CKT 347 and CKT 348 carefully
critical malfunctions within itself. Upon passing these for cutting or chafing. The diagnostic table directs the
tests IGNITION 1, 23 VLR and the deployment loop technician to note the entry value of DRIVER
voltages are measured to make sure they are within SENSELO. Comparing the value of DRIVER
their respective normal voltage ranges. The SDM SENSELO can be helpful in determining if an
monitors the voltages at DRIVER SIDE LOW intermittent condition exists.
terminal 3 and PASSENGER SIDE LOW terminal 4 When measurements are requested in this table, use
to detect shorts to B+ in the inflator module circuits. J 39200 Digital Multimeter with the correct terminal
C onditions for Setting the DTC adapter from J 35616-A Connector Test Adapter Kit.
. The voltage at PASSENGER SIDE LOW refer to Intermittents and Poor Connections. When
terminal 4 is less than 4.8 volts. a wire, connector or terminal repair is requested,
• The voltage at DRIVER SIDE LOW terminal 3 use J 38125-A Terminal Repair Kit and refer to
is more than 4.8 volts for 500 milliseconds. Wiring Repair.
Test Description
within the normal operating voltage range. The numbers below refer to the step numbers on the
diagnostic table:
Action Taken W hen the DTC Sets 2. This test determines the driver side low voltage
• The SDM sets a Diagnostic Trouble Code. measured by the inflatable restraint Sensing
• The SDM turns ON the AIR BAG warning lamp. and Diagnostic Module (SDM).
3. This test isolates the malfunction to one side of
C onditions fo r C learing the DTC the inflatable restraint steering wheel module
• Current DTC-The voltage at DRIVER SIDE coil yellow 2-way connector.
LOW terminal 3 is less than 4.8 volts for 4. This test determines whether the malfunction
500 milliseconds. is due to the inflatable restraint steering wheel
• History DTC module or the module coil.
- You issue a scan tool CLEAR CODES 7. This test determines whether the malfunction
command. is in CKT 347.
- Once 250 malfunction free ignition cycles 9. This test determines whether the malfunction
have occurred. is in CKT 348.
DTC B1025 D river D eploym ent Loop Short to Voltage


2
4. Request the SIR data list display. — —
5. Read and record on the repair order the driver side
low voltage DRIVER SENSELO.
Has the DRIVER SENSELO been read and recorded on
the repair order? G o to S t e p 3

3 to the harness connectors. 4.8 V

Is DRIVER SENSELO more than the specified value? G o to S t e p 7 G o to S t e p 4

module. Refer to In f l R s t S t e e r in g W h e e l M o d u le
3. Disconnect J 3 8 7 1 5 - A from the driver 2-way harness

connector.
4 4. Connect the driver 2-way connector. 4.8 V

steering wheel module connector.
Is DRIVER SENSELO more than the specified value? G o to S t e p 6 G o to S t e p 5

5 module. Refer to In f l R s t S t e e r in g W h e e l M o d u le — —

6 3. Inspect the coil and the wires for damage. — —

D T C B 1 0 2 5 D riv e r D e p lo y m e n t L o o p S h o rt to V o lta g e (c o n t’d )
3. Disconnect the J 3 8 7 1 5 -A .
7 1.0 V
from terminal 2 to terminal 6 (ground).
Is the measured voltage less than the specified value? G o to S t e p 9 G o to S t e p 8

Measure the voltage on the SDM harness connector from

9 terminal 3 to terminal 6 (ground). 1.0 V Go to S D M

Reconnect all the SIR components, make sure all the

components are properly mounted.
11 — —

S y ste m C h e ck
D T C B 1 0 2 6 D riv e r D e p lo y m e n t L o o p O p e n
To Prevent Accidental
-Shorting
rUli— Bar Steering Wheel
Bare Close To Short Module
Connectors When
Separated
Steering Wheel
Module Coil
0.8 WHT 347 0.8 DKGRN 348
Shorting Bar B
A j,* - C234
0.8 WHT 347 0.8 DK GRN 348

C C231
0.8 WHT 347 0.8 DKGRN 348
2 3 JL
[" Drivers Drivers 1 1nflatable
I Side High Side Low I Restraint .
I Sensing And A
l ------------------------------------------------------------------ j Diagnostic
187164
C irc u it D esc rip tio n C o n d itio n s fo r C learin g th e D TC

When you first turn the ignition switch to the RUN • Current DTC
position, the inflatable restraint Sensing and The voltage difference between DRIVER SIDE
Diagnostic Module (SDM) performs tests to diagnose HIGH terminal 2 and DRIVER SIDE LOW
critical malfunctions within itself. Next the SDM terminal 3 is less than 400 millivolts for
measures IGNITION 1 voltage to make sure it is 500 milliseconds.
within its respective normal voltage range. Then the
• History DTC
SDM proceeds with the DEPLOYMENT LOOP
CONTINUITY test. During the DEPLOYMENT LOOP - You issue a scan tool CLEAR CODES
CONTINUITY test, the SDM measures the voltage command.
difference between DRIVER SIDE HIGH and - Once 250 malfunction free ignition cycles
DRIVER SIDE LOW. have occurred.
C o n d itio n s fo r S e ttin g th e D TC D iag n o s tic A id s

• The voltage difference between DRIVER SIDE The following can cause an intermittent condition:
HIGH terminal 2 and DRIVER SIDE LOW • A poor connection at the inflatable restraint
terminal 3 is more than or equal to steering wheel module column connector
400 millivolts. terminals A and B.
• The malfunction must be present for at least • A poor connection at the upper inflatable
500 milliseconds during one of the following restraint steering wheel coil connector terminals
tests: A and B.
- DEPLOYMENT LOOP CONTINUITY • A poor connection at the SDM terminals 2
If the malfunction is detected in this test, the and 3.
RESISTANCE MEASUREMENT test will not • An open in CKT 347.
be performed.
• An open in CKT 348.
- CONTINUOUS MONITORING
An intermittent open in the inflatable restraint
A c tio n Taken W h en th e D TC S ets steering wheel module coil could also set this DTC.
To test for a bad inflatable restraint steering wheel
• The SDM sets a Diagnostic Trouble Code. module coil, clear the DTCs, then turn the steering
• The SDM turns ON the AIR BAG warning lamp. wheel back and forth with the ignition switch in the
RUN position. If the AIR BAG warning lamp comes
ON and DTC B1026 has set again, it is likely the
inflatable restraint steering wheel module coil is
malfunctioning.
J 39200 Digital Multimeter with the correct terminal the inflatable restraint steering wheel module
adapter from J 35616-A Connector Test Adapter Kit. coil yellow 2-way connector.
11. This test determines whether the malfunction
refer to Intermittents and Poor Connections. When a
wire, connector or terminal repair is requested, use is due to the inflatable restraint steering wheel
J 38125-A Terminal Repair Kit and refer to Wiring module or the module coil.
Repair. 14. This test checks for proper contact or corrosion
of the inflatable restraint sensing and diagnostic
Test Description
module connector.
diagnostic table: 19. This test determines whether the malfunction
is in CKT 347.
voltage difference measured by the inflatable 21. This test determines whether the malfunction
restraint sensing and diagnostic module. is in CKT 348.
3. This test checks for proper contact or corrosion
of the yellow 2-way connector.
DTC B1026 D river Deploym ent Loop Open



deployment loop voltage difference DRIVER VDIF.
Has the DRIVER VDIF been read and recorded on the
repair order? G o to S t e p 3

3 —
3. Inspect for proper connection at terminals A and B
on the harness side of the inflatable restraint steering
wheel module yellow 2-way connector.
Replace the inflatable restraint steering wheel module

4 yellow 2-way harness connector. Refer to W ir in g R e p a ir. — —

5 coil side of the connector. —

6 coil side of the connector. —
Replace the inflatable restraint steering wheel module coil.

7 Refer to In f l R s t S t e e r in g W h e e l M o d u le C o il R e p la c e m e n t . — —
D T C B 1 0 2 6 D riv e r D e p lo y m e n t L o o p O p e n (c o n t’d )
1. Connect the 2-way harness connectors.
8 400 mV
4. Read the driver deployment loop voltage difference
DRIVER VDIF.
Is the DRIVER VDIF less than the specified value? G o to S t e p 9 G o to S t e p 1 0

9 module yellow 2-way harness connector. — —
Refer to W ir in g R e p a ir.

IP module yellow 2-way connectors at the base of
3. Connect the J 3 8 7 1 5 - A SIR Driver/Passenger Load
10 Tool to the harness connectors. 400 mV
6. Read the driver deployment loop voltage difference
DRIVER VDIF.
Is the DRIVER VDIF less than the specified value? G o to S t e p 11 G o to S t e p 1 4

3. Disconnect the J 3 8 7 1 5 - A from the driver yellow

2-way harness connector.
4. Reconnect the driver yellow 2-way connector.
11 400 mV
5. Connect the J 3 8 7 1 5 - A to the upper inflatable
restraint steering wheel module coil.
8. Read the driver deployment loop voltage
difference VDIF.
Is the DRIVER VDIF less than the specified value? G o to S t e p 1 2 G o to S t e p 1 3


13 module coil. Refer to In f l R s t S t e e r in g W h e e l M o d u le — —
D T C B 1 0 2 6 D riv e r D e p lo y m e n t L o o p O p e n (c o n t’d )
14 3. Disconnect the J 3 8 7 1 5 -A . —
the harness side of the SDM connector.
Replace the SDM harness connector.

Check for proper connection at terminals 2 and

16 3 of the SDM. —
Check for proper connection at terminals 2 and

17 3 of the SDM. —
Replace the SDM. Refer to in fl R s t S e n s i n g a n d


connector terminal 2 to the inflatable restraint
19 0-0.5 a
steering wheel module yellow 2-way harness
connector terminal A.

20 — —

terminal 3 to the inflatable restraint steering wheel module
21
yellow 2-way harness connector termin 0-0.5 Q
Go to S D M
Is the resistance reading within the specified values? In t e g rit y C h e c k G o to S t e p 2 2

22 — —

23 — —

S y ste m C h e ck
D T C B 1 0 3 5 D is c r. S e n s o r C lo s e d o r S h o rt to G N D
iA V v— j Inflatable L
Restraint °r
Front End
J Discriminating
B Sensor
0.8 BLK/WHT 1834
0.8
BLK/
WHT 1751
A
\4 B1 C110
0.8 YEL 1834
0.8
BLK/
WHT 1751
H C231 0.8 BLK/WHT Ground
Distribution
1751 Cell 14
0.8 YEL 1834 k cG201
Discriminating "■Inflatable Restraint

I Sensor I Sensing And A
L ______________________________ j Diagnostic Module A A
207583
C irc u it D e s c rip tio n C o n d itio n s fo r C le a rin g th e D TC

When you first turn the ignition switch to the RUN • Current DTC-The voltage at front-end sensor
position, the inflatable restraint Sensing and signal terminal 9 is more than 2.4 volts for
Diagnostic Module (SDM) performs tests to diagnose 500 milliseconds.
critical malfunctions within itself. Next the SDM • History DTC
measures IGNITION 1, 23 VLR and the deployment - You issue a scan tool CLEAR CODES
loop voltages to make sure they are within their command.
respective normal voltage ranges. Then the SDM - Once 250 malfunction free ignition cycles
proceeds to CONTINUOUS MONITORING. The SDM have occurred.
contains a resistor network connected to 5 volts,
ground, and to the SDM front-end sensor signal D iag n o s tic A id s
terminal 9. The 1.0 K ohm resistor in the inflatable A short to ground in the inflatable restraint front end
restraint front end discriminating sensor parallel to discriminating sensor circuit can cause an intermittent
the normally open switch provides a parallel path to condition. Inspect CKT 1834 carefully for cutting or
ground. This causes a specified percentage of chafing.
voltage to appear at the SDM front-end sensor signal When measurements are requested in this table, use
input. The SDM monitors this voltage to detect J 39200 Digital Multimeter with the correct terminal
shorts to ground or a closed discriminating sensor. adapter from J 35616-A Connector Test Adapter Kit.
C o n d itio n s fo r S e ttin g th e D TC refer to Intermittents and Poor Connections. When
• The SDM is configured for an inflatable restraint use J 38125-A Terminal Repair Kit and refer to
front end discriminating sensor Wiring Repair.
• The voltage at front-end sensor signal terminal
Test D escrip tio n
9 is less than 0.5 volts for 500 milliseconds.
The numbers below refer to the step numbers on
the diagnostic table:
within the normal operating voltage range. 2. This test checks for a malfunctioning
discriminating sensor.
A c tio n Taken W h en th e D TC S ets 4. This test checks for a short to ground in
• The SDM sets a Diagnostic Trouble Code. CKT 1834.
5. This test isolates the short to ground in
CKT 1834 to one side of C110.
D T C B 1 0 3 5 D is c r. S e n s o r C lo s e d o r S h o rt to G N D

2. Disconnect the inflatable restraint front end
discriminating sensor. Refer to In fl R s t F r o n t
E n d D is c r im in a t in g S e n s o r R e p la c e .
2 950 Q
3. Zero the J 3 9 2 0 0 .
4. Measure the resistance between the sensor
terminals A and B.
Is the resistance reading more than the specified value? G o to S t e p 4 G o to S t e p 3
Replace the inflatable restraint front end discriminating

sensor. Refer to In fl R s t F r o n t E n d D is c r im in a t in g S e n s o r
3 — —
R e p la c e .

4 2. Measure the resistance from the sensor harness OL
connector terminal A to ground. Go to S D M
Is the resistance reading less than the specified value? G o to S t e p 5 In t e g rit y C h e c k
1. Disconnect C110. Refer to S I R C o m p o n e n t s .

2. Measure the resistance from the sensor harness
5 OL
connector terminal A to ground.
Is the resistance reading less than the specified value? G o to S t e p 6 G o to S t e p 7
Repair a short to ground condition in CKT 1834

6 between C110 and the sensor harness connector. — —
Repair a short to ground condition in CKT 1834

7 between C110 and the SDM harness connector. — —

8 — —
properly mounted? G o to S t e p 9

Sy ste m C h e ck
D T C B 1 0 3 6 D is c r. S e n s o r O p e n o r S h o rt to V o lta g e
HWV— Inflatable L
Restraint °c
Front End
J Discriminating ra n
B
0.8 BLK/WHT 1834
0.8
BLK/
WHT 1751
A
A J, B , , C110
0.8 YEL 1834
0.8
BLK/
WHT 1751
H l C231 0.8 BLK/WHT Ground
Distribution
1751 Cell 14
0.8 YEL 1834 G201
9
r — — "* Inflatable Restraint
Discriminating
Sensor I Sensing And A
L ____________________ j Diagnostic Module A A
207583
C irc u it D escrip tio n • History DTC

When you first turn the ignition switch to the RUN - You issue a scan tool CLEAR CODES
position, the inflatable restraint Sensing and command.
Diagnostic Module (SDM) performs tests to diagnose - Once 250 malfunction free ignition cycles
critical malfunctions within itself. Next the SDM have occurred.
measures IGNITION 1, 23 VLR and the deployment D iag n o stic A id s
loop voltages to make sure they are within their
A broken or chafed wire in the inflatable restraint
respective normal voltage ranges. Then the SDM
front end discriminating sensor circuit can cause an
proceeds to CONTINUOUS MONITORING. The SDM
intermittent condition. Inspect CKT 1834 and
contains a resistor network connected to 5 volts, CKT 1751 carefully for cutting or chafing.
ground, and to the SDM front-end sensor signal
terminal 9. The 1.0 K ohm resistor in the inflatable J 39200 Digital Multimeter with the correct terminal
restraint front end discriminating sensor parallel to adapter from J 35616-A Connector Test Adapter Kit.
the normally open switch provides a parallel path to When a check for proper connection is requested,
ground. This causes a specified percentage of refer to Intermittents and Poor Connections. When
voltage to appear at the SDM front-end sensor signal a wire, connector or terminal repair is requested,
input. The SDM monitors this voltage to detect use J 38126-A Terminal Repair Kit and refer to
shorts to power or an open discriminating sensor. Wiring Repair.
C o n d itio n s fo r S e ttin g th e D TC T est D escrip tio n
• The SDM is configured for an inflatable restraint The numbers below refer to the step numbers on the
diagnostic table:
front end discriminating sensor
2. This test checks for proper contact or corrosion
• The voltage at front-end sensor signal terminal
of the yellow 2-way connector.
9 is more than 5.0 volts for 500 milliseconds.
7. This test checks for a malfunctioning
The CONTINUOUS MONITORING test checks for discriminating sensor.
within the normal operating voltage range. 8. This test checks for an open in CKT 1751.
11. This test isolates the open in CKT 1751 to one
A ctio n Taken W h en th e D TC S ets side of C110.
• The SDM sets a Diagnostic Trouble Code. 14. This test checks for proper contact or corrosion
of the inflatable restraint Sensing and
Diagnostic Module (SDM) connector.
C o n d itio n s fo r C le a rin g th e D TC 19. This test checks for an open in CKT 1834.
• Current DTC-The voltage at front-end sensor 22. This test isolates the open in CKT 1834 to
signal terminal 9 is less than 3.2 volts for one side of C110.
500 milliseconds. 25. This test checks for a short to voltage in
CKT 1834.
DTC B1036 Discr. Sensor Open or Short to Voltage
S tep A ction Value(s) Yes No

discriminating sensor. Refer to In fl R s t F r o n t E n d
2 D is c r im in a t in g S e n s o r R e p la c e . —
3. Check for proper connection at the sensor harness
connector terminals A and B.
Replace the sensor harness connector.

Check for proper connection at the sensor connector

4 terminals A and B. —
Check for proper connection at the sensor connector

5 terminals A and B. —
Replace the inflatable restraint front end discriminating

sensor. Refer to In fl R s t F r o n t E n d D is c r im in a t in g S e n s o r
6 R e p la c e .
— —

2. Measure the resistance between the sensor
7 1050 Q
connector terminals A and B.
Is the resistance reading more than the specified value? G o to S t e p 6 G o to S t e p 8
Measure the resistance from the sensor harness connector

8 terminal B to ground. 0 -5 Q
Is the resistance reading within the specified values? G o to S t e p 1 4 G o to S t e p 9

9 2. Check for proper connection at C110 terminal B. —
Is the terminal damaged or corroded? G o to S t e p 1 0 G o to S t e p 11
Replace C110.
10 — —
1. Zero the J 3 9 2 0 0 .
2. Measure the resistance between the sensor harness
11 0 -5 Q
connector terminal B and C110 terminal B.
Repair an open condition in CKT 1751 between

12 C110 and G201. — —
Repair an open condition in CKT 1751 between C110 and

the inflatable restraint front end discriminator sensor
13 harness connector. — —

14 2. Check for proper connection at terminal 9 on the —
harness side of the SDM connector.
DTC B1036 Discr. Sensor Open or Short to Voltage (cont’d)

Step A ction Value(s) Yes No

Check for proper connection at terminal 9 of the SDM.

16 —
Is the terminal damaged or corroded? G o to S t e p 1 8 G o to S t e p 2 7
Check for proper connection at terminal 9 of the SDM.

17 —


19 2. Measure the resistance between the sensor harness 0 -5 Cl
connector terminal A and the SDM harness
connector terminal 9.

20 2. Check for proper connection at C110 terminal A. —
Replace C110. Refer to W ir in g R e p a ir.

21 — —

2. Measure the resistance between the sensor harness
22 0 -5 Cl
connector terminal A and the C110 terminal A.

23 the SDM harness connector. — —

24 the sensor harness connector. — —

2. Measure the voltage on the sensor harness
25 1.0 V
connector from terminal A to ground. Go to S D M


27 — —

S y ste m C h eck
DTC B1051 Deployment Commanded
Circuit Description Action Taken When the DTC Sets
The inflatable restraint Sensing and Diagnostic • The SDM sets a Diagnostic Trouble Code.
Module (SDM) contains a sensing device that • The SDM turns ON the AIR BAG warning lamp.
converts vehicle velocity changes to an electrical
signal. The SDM processes the generated electrical • The SDM records crash data.
signal and compares it to a value stored in memory.
When the generated signal exceeds the stored
Conditions for Clearing the DTC
value, the SDM performs additional signal processing DTC B1051 is a latched code. You cannot clear a
and compares the generated signals to signals latched code. Replace the SDM after following the
stored in memory. When two of the generated instructions in the diagnostic table.
signals exceed the stored values, the SDM will
cause current to flow through the inflator modules, Test Description
deploying the air bags and causing DTC B1051 The numbers below refer to the step numbers on the
to set. diagnostic table:
Conditions for Setting the DTC 2. If the inflator module(s) has not deployed,
The SDM detects a frontal crash, up to 30 degrees DTC B1051 may have set falsely.
off the centerline of the vehicle, of sufficient force to 3. If DTC B1051 has set with no signs of frontal
warrant deployment of the air bags. impact, the DTC has set falsely.
DTC B1051 Deployment Commanded

Turn the ignition switch to the OFF position.

2 —
Has the inflator module(s) deployed? G o to S t e p 5 G o to S t e p 3
Inspect the front of the vehicle and the undercarriage for

3 signs of impact. —
Are there signs of impact? G o to S t e p 5 G o to S t e p 4

Replace components and perform inspections as required

following an accident. Refer to R e p a ir s a n d In s p e c t io n s
5 R e q u ir e d A fte r a n A c c id e n t .
— —
Have the appropriate inspections and repairs been made? G o to S t e p 6

6 — —
DTC B1053 Deployment Commanded w/Loop Malfunction

The inflatable restraint Sensing and Diagnostic • The SDM sets a Diagnostic Trouble Code.
Module (SDM) contains a sensing device that • The SDM turns ON the AIR BAG warning lamp.
converts vehicle velocity changes to an electrical
• The SDM records crash data.
signal. The SDM processes the generated electrical
signal and compares it to a value stored in memory. Conditions for Clearing the DTC
When the generated signal exceeds the stored DTC B1053 is a latched code. You cannot clear a
value, the SDM performs additional signal processing latched code. Replace the SDM after following the
and compares the generated signals to signals instructions in the diagnostic table.
stored in memory. When two of the generated
signals exceed the stored values, the SDM will Diagnostic Aids
cause current to flow through the inflator modules, DTC B1053 will be accompanied by another DTC
deploying the air bags. DTC B1053 will set instead (other than DTC B1071). Repair the malfunction
of a DTC B1051 when a deployment occurs while an causing the other DTC(s) before installing a new SDM.
inflator circuit fault is present that could possibly
result in a non-deployment situation in one or both Test Description
inflator modules. The numbers below refer to the step numbers on the
diagnostic table:
Conditions for Setting the DTC
2. If the inflator module(s) has not deployed,
The SDM detects a frontal crash, up to 30 degrees
DTC B1053 may have set falsely.
off the centerline of the vehicle, of sufficient force to
warrant deployment of the air bags. 3. If DTC B1053 has set with no signs of frontal
impact, the DTC has set falsely.
DTC B1053 Deployment Commanded w/Loop Malfunction

Turn the ignition switch to the OFF position.

2 —
Has the inflator modules deployed? G o to S t e p 5 G o to S t e p 3
Inspect the front of the vehicle and the undercarriage for

3 signs of impact. —
Are there signs of impact? G o to S t e p 5 G o to S t e p 4

4 D ia g n o s t ic M o d u le R e p la c e m e n t — —
Replace components and perform inspections as required

following an accident. Refer to R e p a ir s a n d In s p e c t io n s
5 R e q u ir e d A fte r a n A c c id e n t .
— —
Have the appropriate inspections and repairs been made? G o to S t e p 6

6 — —
DTC B1054 Infl Rst IP Module Switch CKT Failure
Hot In Run, Hot With Headlamp

Test Or Start Switch In Park Or Headlight | Hot In Run, Test, Or Start |
°C
r - r - -
E3 ILLUM H6 r GAUGES Distribution I Block
D4
Fuse 14
10 A
Fuse 4
J7 T 10 A
Cell 10
H
0.35 GRY
0.8 YEL 1139
0.35 S217
Fuse Block
Details
Cell 11
instrument ranei
Dimming Cell 117
4
0.8 PNK 39
S213< 1----------- ►
Puse£iock
Details
Cell 11
A.
0.35 PNK 39
GRY 8 0.8 PPL/WHT
D, 4IS216
BJL 1382 0.8
I T Inflatable
Restraint PPU 1382
®
Y IP Module WHT
Solid State Switch
(Pickup
0.8 f
l ___________________ S
only)
YEL 1139 0.8 A E F Headlamp
LTGRN 371 0.5 BLK 150 1And Panel
S218< h - l Dimmer n a
B1 f
C232 0.8 2 BLK 150 tw it c h « Shorting Bars
f
PNK 353 358 Close To Short
Ground Shorting
0.8 S204* - - Bar A2 C232 Connectors When
Distribution A1
0.8 BLK/WHT 371 A; CH14____ Connectors Are
Separated
0.8
YEL 1139 3 BLK 150 1 BLK
0.8 PNK 353 0.8 BRN 358 BLK/WHT 1751 >
150
10 11 12J G200 7 Shorting Bar 6
Ignition 1 Passenger Passenger Air Bag > 1 1nflatable
Airbag Airbag Indicator A Ground ’ Restraint
Enable Disable Control I Sensing And
----------J Diagnostic
“ Case Ground Module

In the RUN position, the ignition switch applies • The inflatable restraint Sensing and Diagnostic
battery voltage to the AIR BAG warning lamp and to Module (SDM) attempts to illuminate the AIR
the IGNITION 1 input terminal 10. The inflatable BAG OFF lamp.
restraint sensing and diagnostic module responds by
• The inflatable restraint IP module switch is
flashing the AIR BAG warning lamp seven times.
defaulted to the disabled state.
The inflatable restraint sensing and diagnostic
module monitors the voltage levels at the • The SDM sets a diagnostic trouble code.
PASSENGER AIR BAG ENABLE terminal 11 and • The SDM turns ON the AIR BAG warning lamp.
PASSENGER AIR BAG DISABLE terminal 12 of the
inflatable restraint sensing and diagnostic module to Conditions for Clearing the DTC
determine the position of the inflatable restraint IP
• Current DTC: The voltage at PASSENGER AIR
module switch.
BAG ENABLE terminal 11 is greater than
Conditions for Setting the DTC 4.0 volts for 500 milliseconds and the voltage at
PASSENGER AIR BAG DISABLE terminal 12 is
• The voltage detected at PASSENGER AIR BAG
less than 1.0 volts for 500 milliseconds when
ENABLE terminal 11 and PASSENGER AIR
BAG DISABLE terminal 12 are less than the AIR BAG ON lamp is commanded ON.
1.0 volt when the AIR BAG ON lamp is • History DTC:
commanded on. - You issue a scan tool CLEAR CODES
• The voltage detected at PASSENGER AIR BAG command.
ENABLE terminal 11 and PASSENGER AIR - Once 250 malfunction free ignition cycles
BAG DISABLE terminal 12 are greater than have occurred
4.0 volts when the AIR BAG ON lamp is
commanded OFF.
• The voltage detected at PASSENGER AIR BAG
ENABLE terminal 11 and PASSENGER AIR
BAG DISABLE terminal 12 are greater than
1.0 volt when the AIR BAG OFF lamp is
commanded ON.
Diagnostic Aids 16. This test checks for an open circuit in CKT 371.
Refer to A I R B A G W a r n i n g L a m p C o m e s O n S t e a d y 18. This test checks for a short to ground in
and A I R B A G W a r n in g L a m p D o e s N o t C o m e O n to CKT 371.
diagnose warning lamp circuit malfunctions. 21. This test determines if the state of terminal 12
When measurements are requested in this table, use of the SDM (Pass Air Bag Disable) is correct
J 3 9 2 0 0 Digital Multimeter with the correct terminal when the IP module switch is in the ON
adapter from J 3 5 6 1 6 - A Connector Test Adapter Kit. position.
When a check for proper connection is requested, 24. This test checks for a short to voltage in
refer to In t e r m it t e n t s a n d P o o r C o n n e c t i o n s . When CKT 353.
use J 3 8 1 2 5 - A Terminal Repair Kit and refer to 26. This test checks for a short circuit between
W ir in g R e p a ir .
CKT 353 and 371.
28. This test determines if the AIR BAG OFF lamp
Test Description illuminates when the IP module switch is in the
The numbers below refer to the step numbers on the OFF position.
diagnostic table: 39. This test checks for a short to voltage in
2. This test determines if the AIR BAG ON lamp CKT 353.
illuminates when the IP module switch is in the 41. This test checks for a short to voltage in
ON position. CKT 371.
3. This test checks for a poor connection at the 43. This test checks for an open circuit in CKT 353.
yellow 6-way IP module switch harness
connector. 46. This test determines if the state of terminal 11
of the SDM (Pass Air Bag Enable) is correct
8. This test determines whether the malfunction is when the IP module switch is in the OFF
in CKT 150. position.
10. This test determines whether the malfunction is 47. This test determines if the state of terminal 12
in CKT 1139 between the fuse block and the IP of the SDM (Pass Air Bag Disable) is correct
module switch. when the IP module switch is in the OFF
13. This test determines if the state of terminal 11 position.
of the SDM (Pass Air Bag Enable) is correct 48. This test determines if the state of the internal
when the IP module switch is in the ON SDM suppression lamp driver is correct when
position. the IP module switch is in the OFF position.
14. This test checks for proper contact or corrosion 49. This test checks for a short to ground in
of the SDM harness connector. CKT 353.
DTC B1054 InfI Rst IP Module Switch CKT Failure


ON position. —
2
Does the AIR BAG ON lamp illuminate in the IP module
switch? G o to S t e p 1 3 G o to S t e p 3

2. Remove the IP module switch from the instrument
panel. Refer to In f l R s t I P M o d u le S w it c h
3
3. Inspect the connection of the yellow 6-way IP module —

switch harness connector to the IP module switch.
Is the yellow 6-way IP module switch harness connector
properly connected to the IP module switch? G o to S t e p 5 G o to S t e p 4
DTC B1054 Infl Rst IP Module Switch CKT Failure (cont’d)
Connect the yellow 6-way IP module switch harness
connector
4 Is the yellowsecurely to the IP module switch. Go to S I R —
6-way IP module switch harness connector —
D ia g n o s t ic
securely connected to the IP module switch? Sy ste m C h eck
1. Disconnect the yellow 6-way IP module switch

harness connector from the IP module switch.
5 2. Inspect the terminals of the yellow 6-way IP module —
switch harness connector.
Repair the yellow 6-way IP module switch harness

6 connector. Refer to W ir in g R e p a ir. — —
Is the repair complete? G o to S t e p 5 2
Carefully inspect the IP module switch terminals for damage

7 or corrosion. —
Are the terminals damaged or corroded? G o to S t e p 5 1 G o to S t e p 8

module and inflatable restraint IP module yellow
2-way connectors located near the base of the
steering column.
8 2. Zero the J 3 9 2 0 0 Digital Multimeter. 5Q
3. Measure the resistance from the yellow 6-way IP
module switch harness connector terminal F to
ground (G200) or known good ground.
Is the resistance reading greater than the specified values? G o to S t e p 9 G o to S t e p 1 0
Repair a high resistance or open circuit in CKT 150

9 connectortheterminal
between yellow 6-way IP module switch harness
F and ground (G200). — —

2. Using the J 39200 measure the voltage from the
10 yellow 6-way IP module switch harness connector 1V
terminal B to terminal F (ground).
Is the voltage reading greater than the specified values? G o to S t e p 1 2 G o to S t e p 11

2. Repair a high resistance or open circuit condition in
11 CKT 1139 between the yellow 6-way IP module switch —
harness connector terminal B and the Fuse Block.
—

12 2. Reconnect the IP module switch to the yellow 6-way — —
IP module switch harness connector.
Has the IP module switch been reconnected? G o to S t e p 1 3
1. Connect a scan tool to the data link connector.

2. Turn the ignition switch to the RUN position. High
13
Does Pass Air Bag IP module show the specified level? G o to S t e p 2 1 G o to S t e p 1 4
DTC B1054 Infl Rst IP M odule Sw itch CKT Failure (cont’d)
harness connector from the IP module switch.
14 —
steering column.
5. Check for proper connection at terminals 11 and 12

on the harness side of the SDM harness connector.
Is the SDM harness connector damaged or corroded? G o to S t e p 3 5 G o to S t e p 1 5
Check for proper connection at terminals 11 and 12

15 on the SDM. —
Are the SDM terminals damaged or corroded? G o to S t e p 3 8 G o to S t e p 1 6

16 module switch harness connector terminal A to 5 ft
terminal 11 on the SDM harness connector.
Is the resistance reading greater than the specified values? G o to S t e p 1 7 G o to S t e p 18
Repair a high resistance or open circuit condition

17 in CKT 371. — —
Measure the resistance from the yellow 6-way IP module

18 switch harness connector terminal A to terminal F (ground). OL
Is the resistance reading less than the specified values? G o to S t e p 1 9 G o to S t e p 2 0

19 — —

20 2. Reconnect the SIR components. — —
Have the SIR components been reconnected? G o to S t e p 2 1
1. Connect a scan tool to the Data Link

Connector (DLC).
21 2. Turn the ignition switch to the RUN position. Low
3. Request the SIR datp list display.
Does Pass Air Bag Disable show the specified level? G o to S t e p 2 8 G o to S t e p 2 2

harness connector from the IP module switch. Refer
to In fl R s t I P M o d u le S w it c h R e p la c e m e n t .
22 2-way connectors located near the base of the —
steering column.

on the harness side of the SDM harness connector.
D T C B 1 0 5 4 In f I R s t IP M o d u le S w itc h C K T F a ilu re (c o n t’d )
23 on the SDM. —

2. Measure the voltage from the yellow 6-way IP module
24 switch harness connector terminal E to terminal F 1V
(ground).
Is the voltage reading greater than the specified values? G o to S t e p 2 5 G o to S t e p 2 6


26 module switch harness connector terminal A to OL
terminal E.
Repair a short circuit between CKT 353 and CKT 371.

27 — —

OFF position.
28 —
Does the AIR BAG OFF lamp illuminate in the IP
module switch? G o to S t e p 4 6 G o to S t e p 2 9

2. Remove the IP module switch from the instrument
panel. Refer to In fl R s t I P M o d u le S w it c h
29 —
3. Inspect the connection of the yellow 6-way IP module
switch harness connector to the IP module switch.
Is the yellow 6-way IP module switch harness connector
properly connected to the IP module switch? G o to S t e p 3 1 G o to S t e p 3 0
Connect the yellow 6-way IP module switch harness

connector securely to the IP module switch. Go to S I R
30 — —
Is the yellow 6-way IP module switch harness connector D ia g n o s t ic
securely connected to the IP module switch? S y ste m C h eck

harness connector from the IP module switch. Refer
to In fl R s t I P M o d u le S w it c h R e p la c e m e n t .
31 —
2. Inspect the terminals of the yellow 6-way IP module
switch harness connector.
Repair the yellow 6-way IP module switch harness

32 connector. Refer to W ir in g R e p a ir. — —
Carefully inspect the IP module switch terminals for damage

33 or corrosion. —
D TC B 1054 Inf I R st IP M odule S w itch C K T Failure (co n t’d)

steering column.
34 2. Disconnect the SDM harness connector. Refer to In fl —

on the SDM harness connector.
Replace the SDM harness connector

35 Refer to W ir in g R e p a ir. —
Has the SDM harness connector been replaced? G o to S t e p 3 6

36 on the SDM. —

37 on the SDM. —

Has the SDM been replaced? G o to S t e p 5 2

2. Measure the voltage from the yellow 6-way IP module
39 switch harness connector terminal E to terminal F 1V
(ground).

Measure the voltage from the yellow 6-way IP module

41 switch harness connector terminal A to terminal F (ground). 1V


43 module switch harness connector terminal E to 50
terminal 12 on the SDM harness connector.
Is the resistance reading greater than the specified values? G o to S t e p 4 4 G o to S t e p 4 5
Repair a high resistance or open circuit condition in

44 CKT 353 — —

45 2. Reconnect the SIR system components. — —
Have the SIR system components been reconnected? G o to S t e p 4 6
1. Connect a scan tool to the data link connector.

46 Low
3. Request the SIR data list display. Go to S D M
Does Pass Air Bag IP module show the specified level? G o to S t e p 4 7 In t e g rit y C h e c k
DTC B1054 Inf I Rst IP M odule Sw itch CKT Failure (cont’d)
Does Pass Air Bag Disable show the specified level? Go to S D M
47 Low
G o to S t e p 4 8 In t e g rit y C h e c k
Does Suppression Lamp Driver show the specified level? Go to S D M

48 On
G o to S t e p 4 9 In te g rity C h e c k

steering column.
49 3. Disconnect the SDM harness connector. Refer to In fl OL
4. Zero the J 3 9 2 0 0 Digital Multimeter and measure the

resistance from the yellow 6-way IP module switch
harness connector terminal E to terminal F (ground).

50 — —
Replace the inflatable restraint IP module switch. Refer to

51 In fl R s t I P M o d u le S w it c h R e p la c e m e n t — —
Reconnect all the SIR system components. Make sure all

the SIR system components are properly mounted.
52 — —
Clear the SIR diagnostic trouble codes. Go to S I R

53 Have all the SIR diagnostic trouble codes been cleared? — D ia g n o s t ic —
S y ste m C h eck
DTC B1061 Lamp Circuit Failure
Hot In Run, Hot With Headlamp L_

Test Or Start Switch In Park Or Headlight | Hot In Run, Test, Or Start |
°c
r — i- — “
E3 ILLUM H6 r GAUGES Distribution I Block
Fuse 14 Fuse 4 Cell 10
D4 10 A J7 > 10 A I
0.35 GRY insirumem ranei

0.8 YEL 1139 Puse Block
Details
Dimming Cell 117
0.8 PNK 39
S213< i-------- ►
'T u s e B lo d T
Details
A
0.35 S217 Cell 11 4 0.35 PNK 39
Cell 11
cr
GRY 8 0.8 PPL/WHT 22
OS216
D. 1382 ------------- ■* Instrument
0.8
c * 5 Inflatable
PPU 1382 •’SSr* !auster
Restraint
(D IP Module
WHT Cell 81 |
Y ( T ) AIRBAG
I Solid State I Switch Indicator
(Pickup
0.8 t _____________ 2 i ________ 2 t N
only) k -4 .
YEL 1139 0.8 A F ■' Headlamp 1
LTGRN 371 0.5 BLK 150 1And Panel
S2181 I Dimmer
B1 B2 C232 0.8 2 BLK 150 J Switch
0.8
Shorting Bars
BRN 358 Close To Short
PNK 353 Ground Shorting
0.8
' 1 " A2
Connectors When
S204+ — - Distribution Bar
A1 C232 Connectors Are
BLK/WHT 371 Cell 14
0.8 :C231 Separated
“ " ' 0“8 "
YEL 1139 3 BLK 150 1 BLK
0.8 PNK 353 0.8 BRN 358 BLK/WHT 1751
150 Shorting Bar 6
A
10. 11 12. G200 7
Ignition 1 Passenger Air Bag "* Inflatable
Airbag
Enable
Airbag
Disable
Indicator
Control
1 Ground 1Restraint
I Sensing And
J Diagnostic
Case Ground Module
207858
C ircuit D escription • History DTC

In the RUN position, the ignition switch applies - You issue a scan tool CLEAR CODES
battery voltage to the AIR BAG warning lamp and to command.
the IGNITION 1 input terminal 10. The inflatable - Once 250 malfunction free ignition cycles
restraint Sensing and Diagnostic Module (SDM) have occurred.
responds by flashing the AIR BAG warning lamp
seven times. The SDM monitors the lamp driver D iagnostic Aids
output by comparing the output state at the
INFLATABLE RESTRAINT INDICATOR terminal 7 to Refer to A I R B A G W a r n i n g L a m p C o m e s O n S t e a d y
the microprocessor commanded state. and A I R B A G W a r n i n g L a m p D o e s N o t C o m e O n to
diagnose warning lamp circuit malfunctions.
C onditions fo r S etting the DTC
The output state at the INFLATABLE RESTRAINT
J 3 9 2 0 0 Digital Multimeter with the correct terminal
INDICATOR terminal 7 does not match the
commanded state of the lamp driver for adapter from J 3 5 6 1 6 - A Connector Test Adapter Kit.
400 milliseconds. When a check for proper connection is requested,
refer to In t e r m it t e n t s a n d P o o r C o n n e c t i o n s . When
this DTC. This test occurs when IGNITION 1 is a wire, connector or terminal repair is requested,
within the normal operating voltage range. use J 3 8 1 2 5 - A Terminal Repair Kit and refer to
A ction Taken W hen the DTC Sets
• The SDM sets a Diagnostic Trouble Code. Test Description
• The SDM attempts to turn ON the AIR BAG The number below refers to the step number on the
warning lamp. diagnostic table:
C onditions fo r Clearing the DTC 2. When the inflatable restraint Sensing and
• Current DTC- The output state at the Diagnostic Module (SDM) is configured for a
INFLATABLE RESTRAINT INDICATOR serial data controlled warning indicator (smart
terminal 7 matches the commanded state cluster), DTC B1061 will set.
of the lamp driver for 400 milliseconds.
D T C B 1061 L a m p C irc u it F a ilu re

G o to S t e p 2 Sy ste m C h e ck
1. Malfunctions within the AIR BAG warning lamp

circuitry can set this DTC. These malfunctions are
addressed via the SIR Diagnostic System Check.
Failure to properly perform the SIR Diagnostic
System Check may result in misdiagnosis.
• When the AIR BAG warning Lamp comes on
steady, refer to A IR B A G W a r n in g L a m p C o m e s
O n Ste a d y .
2 —
• When the AIR BAG warning Lamp does not
comes on, refer to A I R B A G W a r n in g L a m p D o e s
N o t C o m e O n.

3. Clear the SIR DTC codes.
Go to S I R
4. Request the SIR DTC display. Go to S D M D ia g n o s t ic
Is DTC B1061 set? In te g rity C h e c k S y ste m C h e ck
DTC B1071 Internal SDM Failure

Circuit Description
D T C B1071 is an indication of a potential internal
inflatable restraint Sensing and Diagnostic M odule
(S D M ) m alfunction. D T C B1071 will set upon
detection of any condition in the table below.
Conditions for Setting the DTC
Malfunction Detection Test

23 VLR voltage out of normal operating range. Power-On, Continuous monitoring
Crash data recording reserve voltage discharge time failure
Power-On
for three consecutive ignition cycles.
The calculated checksum for internal memory does not
Power-On
match the stored value.
The driver or passenger deployment loop is shorted to
Continuous monitoring
ground.
The Accelerometer is malfunctioning. Power-On, Continuous monitoring
The driver or passenger current source is malfunctioning. Resistance measurement
The temporary memory storage area is malfunctioning. Power-On
The Inflatable Restraint Sensing and Diagnostic Module
Power-On
(SDM) is unable to read from or write to EEPROM.
The arming sensor inside the Inflatable Restraint Sensing
and Diagnostic Module (SDM) is not closed during a Asynchronously
deployment event.
The voltage measured at DRIVER SIDE LOW and
Power-On, Continuous monitoring
PASSENGER SIDE LOW is too low.
The device inside the Inflatable Restraint Sensing and
Diagnostic Module that arms the system for deployment is Power-On, Continuous monitoring
malfunctioning.
The permanent memory storage area is malfunctioning. Power-On
Action Taken When the DTC Sets W hen m easurem ents a re requested in this table, use
J 3 9 2 0 0 Digital M ultim eter with the correct terminal
• T h e S D M sets a Diagnostic Trouble C ode.
adapter from J 3 5 6 1 6 - A C onnector Test A dapter Kit.
• T h e S D M turns O N the A IR BAG warning lamp.
W hen a check for proper connection is requested,
Conditions for Clearing the DTC refer to In t e r m it t e n t s a n d P o o r C o n n e c t i o n s . W h en
• C urrent D T C - T h e malfunction has not been a wire, connector or term inal repair is requested,
detected for 5 0 0 milliseconds. use J 3 8 1 2 5 - A Terminal R ep air Kit and refer to
• History D T C
- You issue a scan tool C L E A R C O D E S N o t i c e : W h en D T C B 1 0 1 8 or B 1 0 2 4 has been set it
com m and. is necessary to replace the inflatable restraint
Sensing and Diagnostic M odule (S D M ). Setting
- O n ce 2 5 0 malfunction free ignition cycles
D T C B 10 18 or B 1 0 2 4 will also cause D T C B1071 to
h ave occurred.
set. W h en a scan tool c lear codes com m and is
Diagnostic Aids issued and the m alfunction is no longer present,
W hen you issue a scan tool C L E A R C O D E S D T C B 1 0 1 8 or B 1 0 2 4 and D T C B1071 will remain
com m and, som e of the indicated malfunctions will current. M ake sure that the short to ground condition
only allow the A IR BAG warning lamp to go out is repaired prior to installing a replacem ent S D M to
briefly then com e back O N . avoid dam aging the S D M .
D T C B 1071 In te rn a l S D M F a ilu re

Is DTC B1018 set? Go to D T C B 1 0 1 8

P a sse n g e r
2 —
D e p lo y m e n t L o o p
S h o r t to G N D G o to S t e p 3
Is DTC B1024 set? Go to D T C B 1 0 2 4

D r iv e r
3 —
D e p lo y m e n t L o o p
S h o r t to G r o u n d G o to S t e p 4

2. Replace the SDM. Refer to In fl R s t S e n s i n g a n d Go to S I R
4 — —
D ia g n o s t ic M o d u le R e p la c e m e n t . D ia g n o s t ic
Are the repairs complete? Sy ste m C h e ck
Repair Instructions
SIR Service Precautions
Service Precautions
Caution: When you are perform ing service on or
near the SIR components o r the SIR wiring, you
m ust disable the SIR system. Use the follow ing
procedure to tem porarily disable the SIR system.
Failure to follow the correct procedure could
cause a ir bag deployment, personal injury, or
unnecessary SIR system repairs.
The inflatable restraint Sensing and Diagnostic
Module (SDM) maintains a reserve energy supply.
Ignition voltage can provide deployment energy if the
23 Volt Loop Reserve malfunction. Deployment
power is available for as much as 10 minutes after
disconnecting the vehicle power by any of the
following methods:
• You turn the ignition switch to the OFF position.
• You remove the fuse that provides power to
the SDM.
• You disconnect the vehicle battery from the
vehicle electrical system.
Performing the following procedure prevents
deploying of the air bags from the reserve
energy supply power.
Disabling the SIR System
1. Turn the steering wheel so that the vehicle’s
wheels are pointing straight ahead.
2. Turn the ignition switch to the LOCK position.
3. Remove the key from the ignition switch.
Important: With the AIR BAG Fuse removed
and the ignition switch in the RUN position, The
AIR BAG warning lamp illuminates. This is
normal operation, and does not indicate an SIR
system malfunction.
4. Remove the AIR BAG Fuse from the IP
fuse block.
5. Remove the Connector Position Assurance
(CPA) (1) from the driver yellow 2-way
connector located at the base of the steering
column.
6. Disconnect the driver yellow 2-way connector
(2) located at the base of the steering column.
(CPA) (2) from the passenger yellow 2-way
connector located near the base of the steering
column.
8. Disconnect the passenger yellow 2-way
connector (1) located near the base of the
steering column.
Enabling the SIR System

1. Remove the key from the ignition switch.
2. Connect the passenger yellow 2-way connector
(1) located near the base of the steering
column.
3. Install the Connector Position Assurance (CPA)
(2) to the passenger yellow 2-way connector
located near the base of the steering column.
4. Connect the driver yellow 2-way connector (2)

located at the base of the steering column.
(1) to the driver yellow 2-way connector located
at the base of the steering column.
6. Install the sound insulator-LH. Refer to
Instrument Panel Sound Insulator Replacement
in Interior Trim.
7. Install the AIR BAG Fuse to the IP fuse block.
8. Staying well away from both air bags, turn the
8.1. The AIR BAG warning lamp will flash
seven times.
8.2. The AIR BAG warning lamp will then
turn OFF.
9. Perform the SIR Diagnostic System Check if
the AIR BAG warning lamp does not operate
as described.
• When you replace the SDM, verify that the
General Service Instructions following conditions are met:
• Do not expose the inflator modules to - The mounting surface is clean.
temperatures above 65* C (150'F). - The arrow on the module points toward the
• Verify the correct replacement part number. Do front of the vehicle.
not substitute a component from a different - The module is flat on the mounting surface,
vehicle. parallel to the vehicle datum line.
• Service these components by replacement only. - The module fasteners are installed and
• Do not repair any of the following components: tightened as specified.
- The inflatable restraint Sensing and • In order to avoid setting false diagnostic trouble
Diagnostic Module (SDM). codes, only apply power to the SIR system when
- The inflatable restraint IP (inflator) module. one of the following two conditions is met:
- The inflatable restraint IP module switch. - All SIR system components are properly
- The inflatable restraint steering wheel mounted and electrically connected.
(inflator) module. - A diagnostic procedure directs you to apply
- The inflatable restraint steering wheel power.
module coil. • Begin diagnosis of malfunctions with the SIR
- The inflatable restraint front end Diagnostic System Check. Perform the SIR
discriminating sensor. Diagnostic System Check in order to verify the
following:
• Use only new or remanufactured parts from an
authorized original equipment manufacturer - The proper operation of the AIR BAG
dealer. Do not use salvaged parts for repairs to warning lamp.
the SIR system. - Communication with the SDM through the
• Do not install the component in a vehicle. serial data line.
• Discard any of the following components if it - The presence or absence of diagnostic
has been dropped from a height of trouble codes.
91 centimeters (3 feet) or greater. - Whether additional diagnosis is required and
- The inflatable restraint Sensing and where the information resides.
Diagnostic Module (SDM). Not beginning with the SIR Diagnostic System Check
could cause extended diagnostic time, incorrect
- The inflatable restraint IP (inflator) module.
diagnosis, and unneeded parts replacement.
- The inflatable restraint IP module switch.
- The inflatable restraint steering wheel
(inflator) module.
- The inflatable restraint steering wheel
module coil.
- The inflatable restraint front end
Infl Rst Sensing and Diagnostic Module

Replacement
Caution: Be careful when you handle a Sensing
and Diagnostic Module (SDM). Do not strike or
jo lt the SDM. Before applying pow er to the SDM:
• Remove any dirt, grease, etc. from the
m ounting surface
• Position the SDM horizontally on the
m ounting surface
• Point the arrow on the SDM toward the fron t
o f the vehicle
• Tighten a ll o f the SDM fasteners and SDM
bracket fasteners to the specified torque
value
Caution: If any water enters the vehicle’s in terio r
up to the level o f the carpet o r higher and soaks
the carpet, the Sensing and Diagnostic Module
(SDM) and the SDM harness connector m ay need
to be replaced. The SDM could be activated when
powered, which could cause deploym ent o f the
a ir bag(s) and result in personal injury. Before
attem pting these procedures, the SIR system
m ust be disabled. Refer to Disabling SIR System
in this section. With the ignition OFF, inspect the
SDM m ounting area, including the carpet. If any
significant soaking o r evidence o f significant
soaking is detected, you MUST:
• Remove a ll water
• Repair the water damage
• Replace the SDM harness connector
• Replace the SDM
Failure to follow these procedures could result in
possible a ir bag deployment, personal injury, or
otherwise unneeded SIR system repairs.
1. Disable the SIR system. Refer to Disabling the
SIR System.
2. Remove the drivers seat, Refer to Front Seat
Replacement in Seats.
3. Remove the carpet retaining sill trim molding —
LH, Refer to Sill Trim Plate Replacement in
Interior Trim.
4. Fold back the carpet to access the inflatable
restraint Sensing and Diagnostic Module (SDM).
(CPA) from the inflatable restraint Sensing and
Diagnostic Module (SDM) harness connector.
6. Disconnect the SDM harness connector (3)
from the SDM (1).
7. Remove the SDM mounting fasteners (2).
8. Remove the SDM (1) from the vehicle. (4). 188585
In s ta lla tio n P ro c e d u re
1. Install the SDM (1) to the vehicle (4).
2. Install the SDM mounting fasteners (2).
T ighten
Tighten fasteners to 12 N-m (106 lb in).
and Notices.
3. Install the SDM harness connector (3) to
the SDM.
to the SDM harness connector.
5. Position the carpet to cover the inflatable
restraint Sensing and Diagnostic Module (SDM).
6. Install the carpet retaining sill trim molding —
LH, Refer to Sill Trim Plate Replacement in
Interior Trim.
7. Install the driver seat, Refer to Front Seat
1885B 5 Replacement in Seats.
8. Enable the SIR system. Refer to Enabling the
SIR System.
Infl Rst Instrument Panel Module

Replacement
Refer to Inflatable Restraint IP Module replacement
in Interior Trim for replacement of the inflatable
restraint IP module.
Infl Rst Front End Discriminating

Sensor Replace
Caution: Be careful when you handle a sensor.
Do not strike o r jo lt a sensor. Before applying
pow er to a sensor:
• Remove any dirt, grease, etc. from the
m ounting surface.
• Position the sensor horizontally on the
m ounting surface.
• Point the arrow on the sensor toward the
front o f the vehicle.
• Tighten a ll o f the sensor fasteners and
sensor bracket fasteners to the specified
torque value.
1. Disable the SIR system. Refer to Disabling the
SIR System.
2. Remove the Off Road Skid Plate (if equipped).
(CPA) from the inflatable restraint front end
discriminating sensor harness connector.
189976

discriminating sensor harness connector from
the sensor.
189982
5. Remove the mounting fasteners.
189984
6 . Remove the inflatable restraint front end

discriminating sensor from the vehicle.
Important: The following procedures should be
utilized in the event that sensor mounting holes
or fasteners are damaged to the extent that the
sensor can no longer be properly mounted.
189986
Fastener Repair
1. Remove and discard the fastener.
2. Chisel off the damaged weld nut.
3. Condition the front end lower tie surface where
the new weld nut is to be installed.
4. Install the new weld nut (part # 11514034) or
equivalent into position.
5. Migweld the new weld nut to the front end
lower tie surface in the correct location.
6. Use the new fastener (part # 11515926) or
equivalent.
1. Install the inflatable restraint front end
discriminating sensor to the front end lower tie
surface make sure the arrow is pointing toward
the front of the vehicle.
189986
2. Install the inflatable restraint front end
discriminating sensor mounting fasteners.
Tighten
Tighten fasteners to 8 N.m (71 lb in).
and Notices.
189984
3. Connect the inflatable restraint front end

discriminating sensor harness connector to the
sensor.
189982

to the inflatable restraint front end discriminating
sensor harness connector.
5. Enable the SIR system. Refer to Enabling the
SIR System.
18 99 76
The J 38125-A Terminal Repair Kit also serves as a
Infl Rst IP Module Switch Replacement generic terminal repair kit. The kit contains the
Refer to Inflatable Restraint IP Module Switch following:
Replacement in Interior Trim for replacement of • A large sampling of common GM electrical
the inflatable restraint IP module switch. terminals.
• The correct tools to attach the terminals
Infl Rst Steering Wheel Module to wires.
Replacement • The correct tools to remove the terminals
Refer to Inflatable Restraint Driver Inflator Module from connectors.
Replacement in Steering Wheel and Column for
replacement of the inflatable restraint driver SIR Connector (Plastic Body and Terminal
inflator module. Metal Pin) Repair
Repair damaged SIR wire harness connectors and
Infl Rst Steering Wheel Module Coil terminals (except pigtails) using the connector repair
Replacement assembly packs. These kits include an instruction
Refer to Inflatable Restraint Steering Wheel Module sheet and the sealed splices. Use the sealed splices
Coil in Inflatable Restraint Steering Column for to splice the new wires, connector, and terminals to
replacement of the inflatable restraint steering wheel the harness. The splice crimping tool is color keyed
module coil. to match the splices from J 38125-A Terminal Repair
Kit. You must use the splice crimping tool to apply
AIR BAG Warning Lamp Replacement these splices.
Refer to Instrument Cluster Bulb Replacement in The terminals in the SIR system are made of a
Instrument Panel And Gauges for replacement of the special metal. This special metal provides the
AIR BAG warning lamp bulb. necessary contact integrity for the sensitive, low
energy circuits. These terminals are only available in
Wiring Repair the connector repair assembly packs. Do not
The Supplemental Inflatable Restraint (SIR) system substitute any other terminals for those in the
requires special wiring repair procedures due to the assembly packs.
sensitive nature of the circuitry. These specific If individual terminals are damaged on the Sensing
procedures and instructions must be followed when and Diagnostic Module (SDM) harness connector,
working with the SIR system wiring, and the wiring you must replace the SDM harness connector using
components (such as connectors and terminals). one of the following two components:
Terminal Repair Kit J 38125-A • SDM harness connector pigtail assembly.
• SDM harness connector replacement kit.
Important: Do not use the terminals in the kit to
If individual terminals are damaged on any other SIR
replace damaged SIR system terminals unless
connection, the entire connection should be replaced.
specifically indicated by the terminal package.
Use the appropriate connector repair assembly pack.
Essential tool kit J 38125-A Terminal Repair Kit You should replace the entire SIR wiring harness, if
contains the following: necessary to maintain SIR circuit integrity.
• Special sealed splices to repair the SIR
system wiring SIR Wire Pigtail Repair
• Wire stripping tool Important: Do not make wire, connector, or terminal
• Special crimping tool repairs on components with wire pigtails.
• Heat torch A wire pigtail is a wire or wires attached directly to
• Instruction manual the device (not by a connector). If a wiring pigtail is
damaged, the entire component (with pigtail) must be
The two critical features of the sealed splices are:
replaced. The inflatable restraint steering wheel
• A special heat shrink sleeve environmentally module coil is an example of a pigtail component.
seals the splice. Inside the heat shrink sleeve is
a sealing adhesive.
• A cross hatched (knurled) core crimp provides
necessary contact integrity for the sensitive, low
energy circuits.
S IR W ire R e p a ir 4. Select and Position the Splice Sleeve.
Tools Required • Select the proper sealed splice sleeve
J 38125-A Terminal Repair Kit. according to wire size.
Important: Refer to Wiring Repairs in Wiring • See the following table for color coding of
Systems in order to determine the correct wire size the splice sleeves, and the crimp tool nests.
for the circuit you are repairing. You must obtain this
information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the
wire by splicing in a new section of wire of the same
gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the
sealed splices and splice crimping tool from
J 38125-A Terminal Repair Kit. Use the following
wiring repair procedures to ensure the integrity of the
sealed splice.
Important: You must perform the following
procedures in the listed order. Repeat the procedure
if any wire strands are damaged. You must obtain a
clean strip with all of the wire strands intact.
1. Open the Harness.
• Open the harness by removing any tape.
• To avoid wire insulation damage, use a
sewing seam ripper (available from sewing
supply stores) to cut open the harness.
• Use the crimp and sealed splice sleeves on all • Use the Splice Crimp Tool from J 38125-A
types of insulation except tefzel and coaxial. Terminal Repair Kit to position the splice
• Do not use the crimp and sealed splice sleeve in the proper color nest of the Splice
sleeve to form a splice with more than two Crimp Tool.
wires coming together.
2. Cut the Wire.
• Cut as little wire off the harness as possible.
You may need the extra length of wire to
change the location of a splice.
• Adjust splice locations so that each splice is
at least 40 mm (1.5 in) away from the other
splices, harness branches, or connectors.
3. Strip the Insulation.
• When adding a length of wire to the existing
harness, be certain to use the same size
wire as the original wire.
• To find the correct wire size do one of the
following:
- Find the wire on the schematic and convert
the metric size to the equivalent AWG size.
- Use an AWG wire gauge.
- If you are unsure of the wire size, begin
with the largest opening in the wire • Place the splice sleeve in the nest so that
stripper and work down until achieving a the crimp falls midway between the end of
clean strip of the insulation. the barrel and the stop. The sleeve has a
• Strip approximately 7.5 mm (0.313 in) of stop (3) in the middle of the barrel (2) to
insulation from each wire to be spliced. prevent the wire (1) from going further. Close
the hand crimper handles slightly to hold the
• Be careful to avoid nicking or cutting any of splice sleeve firmly in the proper nest.
the strands. Check the stripped wire for nicks
or cut strands.
• If the wire is damaged, repeat this procedure
after removing the damaged section.
Crimp and Seal Splice Table
Splice Sleeve Crimp Tool Nest Wire Gauge mm 2
Color Color / (AWG)
Salmon
Red (1) 0.5-0.8 / (18-20)
(yellow-pink)
Blue Blue (2) 1.0-2.0 / (14-16)
Yellow Yellow (3) 3 .0-5.0 / (10-12)
SIR System Wire Splice Repair

Apply a new splice (not sealed) from the J 38125-A
Terminal Repair Kit if damage occurs to any of the
original equipment splices (three wires or more) in the
SIR wiring harness. Carefully follow the instructions
included in the kit for proper splice clip application.
Connector Position Assurance (CPA)
The Connector Position Assurance (CPA) is a small
9502 plastic insert that fits through the locking tabs of all the
SIR system electrical connectors. The CPA ensures
5. Insert Wires Into Splice Sleeve and Crimp.
that the connector halves cannot vibrate apart. You
• Insert the wire into the splice sleeve barrel must have the CPA in place in order to ensure good
until it hits the barrel stop. contact between the SIR mating terminals.
• Close the handles of the crimp tool tightly
until the crimper handles open when
Terminal Position Assurance (TPA)
released. The crimper handles will not open The Terminal Position Assurance (TPA) insert
until you apply the proper amount of resembles the plastic combs used in the control
pressure to the splice sleeve. Repeat steps 4 module connectors. The TPA keeps the terminal
and 5 for the opposite end of the splice. securely seated in the connector body. Do not
remove the TPA from the connector body unless you
remove a terminal for replacement.
Repairs and Inspections Required

After an Accident
Accident With or Without Air Bag
Deployment — Component Inspections
Caution: Proper operation o f the Supplemental
Inflatable Restraint (SIR) sensing system requires
that any repairs to the vehicle structure return the
vehicle structure to the original production
configuration. Not properly repairing the vehicle
structure could cause non-deployment o f the a ir
bag(s) in a frontal collision or deployment o f the
a ir bag(s) fo r conditions less severe than intended.
After any collision, inspect the following components
as indicated. If you detect any damage, replace the
component. If you detect any damage to the
mounting points or mounting hardware, repair the
9503 component or replace the hardware as needed.
6. Shrink the Insulation Around the Splice. • Steering column - Perform the steering column
accident damage checking procedures. Refer to
• Using the heat torch, apply heat to the
Steering Wheel and Column.
crimped area of the barrel.
• IP Knee Bolsters - Inspect the knee bolsters
• Gradually move the heat barrel to the open for bending, twisting, buckling, or any other type
end of the tubing. of damage.
- The tubing will shrink completely as the • IP brackets, braces, etc. - Inspect for bending,
heat is moved along the insulation. twisting, buckling, or any other type of damage.
- A small amount of sealant will come out of • Seat Belts - Perform the seat belt operational
the end of the tubing when sufficient and functional checks. Refer to Front Seat
shrinkage is achieved. Replacement in Seats.
A ccident W ith A ir Bag D eploym ent — S ensor R eplacem ent G uidelines
Com ponent Replacem ent and Inspections The SIR sensor replacement policy requires
After a collision involving air bag deployment, replace replacing sensors in the area of accident damage.
the following components. If you detect any damage The area of accident damage is defined as the
to the mounting points or mounting hardware, repair portion of the vehicle which is crushed, bent, or
or replace the mounting points and mounting damaged due to a collision. For example, a
hardware as needed. moderate collision where the front of the vehicle
• Inflatable restraint IP (inflator) module impacts a tree. If the vehicle has a SIR sensor
mounted forward of the radiator, it must be replaced.
• Inflatable restraint steering wheel (inflator)
module • Replace the sensor whether or not the air bags
have deployed.
• Inflatable restraint Sensing and Diagnostic
Module (SDM) • Replace the sensor even if it appears to be
undamaged.
• The inflatable restraint front end
Sensor damage which is not visible, such as slight
bending of the mounting bracket or cuts in the wire
After a collision involving air bag deployment, inspect insulation, can cause improper operation of the SIR
the Inflatable restraint steering wheel module coil sensing system. Do not try to determine whether the
and the coil wiring pigtail for melting, scorching, or sensor is undamaged, replace the sensor. Also, if
other damage due to excessive heat. Perform this you follow a Diagnostic Trouble Code (DTC) table
component inspection in addition to the inspections and a malfunctioning sensor is indicated, replace
indicated above in Accident With or Without Air Bag the sensor.
Deployment. If you detect any damage, replace the
component. If you detect any damage to the
mounting points or mounting hardware, repair the
component or replace the hardware as needed.
Inflator Module Handling, Shipping, and

Scrapping
Caution: When you are carrying an undeployed
in fla to r module:
• Do not carry the in fla to r module by the
wires o r connector on the in flato r module
from you
When you are storing an undeployed in flato r
from the surface on which the in fla to r module
rests. When you are storing a steering column,
facing down and the column vertical. Provide free
space fo r the a ir bag to expand in case o f an
accidental deployment. Otherwise, personal
in ju ry may result.
Live (Undeployed) Inflator Module
Take special care when handling or storing a live
(undeployed) inflator m odule. An air bag deploym ent
produces rapid gas generation. This m ay cause the
inflator module, or an object in front of the inflator
m odule, to jettison through the air in the event of an
unlikely deploym ent.
Shipping Procedures
R efer to the latest service bulletins for proper
S IR inflator module shipping procedures.
Scrapping Procedure
During the course of a vehicle’s useful life, certain
situations m ay arise which will necessitate the
disposal of a live (undeployed) inflator module. T h e
following information covers the proper procedures
for the disposing of a live inflator m odule. Deploy the
inflator module before disposal. Do not dispose of
the m odule through normal disposal channels.
Caution: In order to prevent accidental
deploym ent o f the a ir bag which could cause
personal injury, do not dispose o f an undeployed
in fla to r module as norm al shop waste. The
undeployed in flato r module contains substances
that could cause severe illness o r personal in ju ry
if the sealed container is damaged during
disposal. Use the follow ing deploym ent
procedures to safely dispose o f an undeployed
in fla to r module. Failure to dispose o f an in flato r
module as instructed may be a violation o f
federal, state, province, or local laws.
Do not deploy an air bag in the following situations:
• After replacem ent of an inflator m odule under
warranty. T h e module m ay need to be returned
undeployed to the Delphi Interior & Lighting
Group. R efer to the latest service bulletin
regarding S IR shipping procedures.
• If the vehicle is the subject of a Product
Liability report related to the S IR system and is
subject to a Prelim inary Investigation
(G M -1 2 4 1 ). Do not alter the S IR system in any
manner. R efer to the latest service bulletin on
S IR shipping procedures.
• If the vehicle is involved in a campaign
affecting the inflator modules. Follow the
instructions in the Campaign Service Bulletin for
proper SIR handling and shipping procedures.
Deployment Procedures
The inflator module can be deployed inside or
outside of the vehicle. The method used depends
upon the final disposition of the vehicle. Review the
following procedures in order to determine which will
work best in a given situation:
Deployment Outside Vehicle (Inflatable
Restraint Steering Wheel Module)
Tools R equired
• J 38826 SIR Deployment Harness
• An appropriate pigtail adapter
Caution: In order to prevent accidental
deploym ent o f the a ir bag which could cause
personal injury, do not dispose o f an undeployed
in fla to r module as norm al shop waste. The
undeployed in fla to r module contains substances
that could cause severe illness o r personal in ju ry
if the sealed container is damaged during
disposal. Use the follow ing deployment
procedures to safely dispose o f an undeployed
in fla to r module. Failure to dispose o f an in flato r
module as instructed may be a violation o f
federal, state, province, o r local laws.
Caution: When you are deploying an in flato r
module fo r disposal, perform the deployment
procedures in the order listed. Failure to follow
the procedures in the order liste d may result in
personal injury.
Deploy the inflatable restraint steering wheel inflator
module outside of the vehicle when the vehicle will
be returned to service. Situations that require
deployment outside of the vehicle include the
following:
• Using the SIR diagnostics, you determine that
the inflator module does not function properly.
• The inflator module is scratched or ripped on
the cover.
• The inflator module pigtail (if equipped) is
damaged.
• The inflator module connector is damaged.
• An inflator module connector terminal is
damaged.
Deployment and disposal of a malfunctioning inflator
module is subject to any required retention period.
1. Turn the ignition switch to the O F F position.
2. R em ove the ignition key.
3. Put on safety glasses.
4. Inspect the J 3 8 8 2 6 and the appropriate pigtail
a dap ter for dam age. R eplace as needed.
5. Short the two S IR deploym ent harness (1)
leads together using one b an an a plug seated
into the other.
6 . C onnect the appropriate pigtail a dap ter (2) to
the S IR deploym ent harness (1).
7. R em ove the inflatable restraint steering w heel
m odule. R efer to In f l R s t S t e e r i n g W h e e l
M o d u l e R e p l a c e m e n t in Steering W h e el And
Column.
8 . R em ove the horn lead from the back of the
m odule, if equipped.
9. R em ove the redundant steering w heel control
leads from the back of the m odule, if equipped.
10. R em ove all horn/steering w heel control buttons
from the module, if equipped.
Caution: When you are carrying an undeployed

in fla to r module:
• Do not carry the in fla to r module by the
wires o r connector on the in fla to r module
from you
When you are storing an undeployed in flato r
from the surface on which the in fla to r module
rests. When you are storing a steering column,
facing down and the column vertical. Provide free
space fo r the a ir bag to expand in case o f an
accidental deployment. Otherwise, personal in ju ry
may result.
11. Place the module with the vinyl trim cover
facing up and aw ay from the surface on a
work bench.
9427
12. C le ar a space on the ground about 1 .85 M

(6 ft) in diam eter for deploym ent of the m odule.
If possible, use a paved, outdoor location free
of activity. O therw ise, use a space free of
activity on the shop floor. M ake sure you have
sufficient ventilation.
13. M ake sure no loose or flam m able objects are
in the area.
14. Place the module in the space with the vinyl
trim cover facing up.
68646
15. Extend the SIR deployment harness and
adapter to full length from the module.
16. Place a 12V minimum/2A minimum power
source (i.e., vehicle battery) near the shorted
end of the harness.
17. Connect the module (1) to the adapter (2) on

the SIR deployment harness (3).
18. Firmly seat the adapter into the module
connector.
19. Clear the area of people.
Caution: When you are deploying an Inflator

m odule fo r disposal, perform the deployment
the procedures In the order liste d may result in
personal Injury.
20. Separate the two banana plugs on the SIR
deployment harness.
39382
Important: The rapid gas expansion involved with
deploying an air bag is very loud. Notify all the
people in the immediate area that you intend to
deploy the inflator module
Important: When the air bag deploys, the inflator
module may jump about 30 cm (1 ft) vertically. This
is a normal reaction of the inflator module to the
force of the rapid gas expansion inside the air bag.
21. Connect the SIR deployment harness wires to
the power source.
22. Disconnect the SIR deployment harness from

the power source after the air bag deploys.
23. Seat one banana plug into the other in order to
short the deployment harness leads.
24. If the air bag did not deploy, disconnect the
adapter and discontinue the procedure. Contact
the Technical Assistance Group. Otherwise,
proceed to the following steps.
Caution: Imm ediately follow ing the deploym ent o f

an a ir bag, the m etal surfaces o f the in fla to r
module are very hot. Do not place the deployed
in fla to r m odule near any flammable objects. Walt
fo r about ten m inutes before touching any m etal
surface o f the Inflator module. Disregarding these
precautions may cause fire o r personal injury.
25. Put on a pair of shop gloves.
26. Disconnect the pigtail adapter from the inflator
module as soon as possible.
27. Inspect the pigtail adapter and the SIR
deployment harness. Replace as needed.
28. Dispose of the deployed module through normal
refuse channels.
29. Wash hands with a mild soap.
9433
Deploym ent O utside Vehicle

(In flatab le R estraint IP M odule)
D ealers should refer to the latest G eneral Motors
S ervice Bulletins for live (undeployed) inflatable
restraint IP m odule scrapping and disposal
procedures. All others should contact a local
G eneral Motors d ea le r for these procedures.
Dispose of deployed IP m odules through
normal refuse channels.
D eploym ent Inside Vehicle

(Vehicle Scrapping Procedure)
D eploy the inflator m odules inside of the vehicle
w hen destroying the vehicle or when salvaging the
vehicle for parts. This includes but is not limited to
the following situations:
• T h e vehicle has com pleted its useful life.
• Irreparable d am ag e occurs to the vehicle in a
non-deploym ent type accident.
• Irreparable d a m a g e occurs to the vehicle during
a theft.
• T h e vehicle is being salvaged for parts to be
used on a vehicle with a different V IN as
opposed to rebuilding as the sam e V IN .
Caution: When you are deploying an inflator

module for disposal, perform the deployment
the procedures in the order listed may result in
personal injury.
1. Turn the ignition switch to the O F F position.
2. R em o ve the ignition key.
3. Put on safety glasses.
4. R em o ve all loose objects from the front seats.
5. Disconnect the inflatable restraint steering
w heel m odule yellow 2-w a y connector.
6. C ut the yellow 2 -w a y harness connector out of
the vehicle, leaving at least 16 cm (6 in) of wire
at the connector.
7. Strip 13 mm (0 .5 in) of insulation from each of
the connector wire leads.
39 3 9 2
8. Cut two 4 .6 M (15 ft) deploym ent wires from a
0 .8 mm (18 g ag e) or thicker multi-strand wire.
U se these wires to fabricate the driver
deploym ent harness.
9. Strip 13 mm (0 .5 in) of insulation from both
ends of the wires cut in the previous step.
10. Twist together one end from each of the wires
in order to short the wires. Deploym ent wires
shall remain shorted, and not connected to a
pow er source until you are ready to deploy
the air bag.
11. Twist together one connector wire lead to one

deploym ent wire.
12. Inspect that the previous connection is secure.
13. Bend flat the twisted connection.

14. Secu re and insulate the connection using
electrical tape.
39 4 0 8
15. Twist together, bend, and tap e the remaining
connector w ire lead to the remaining
deploym ent wire.
16. C onnect the deploym ent harness to the
inflatable restraint steering w heel module
yellow 2 -w a y connector.
17. Route the deploym ent harness out of the

vehicle’s driver side.
18. Disconnect the inflatable restraint IP module

yellow 2 -w a y harness connector.
19. Cut the harness connector out of the vehicle,
leaving at least 16 cm (6 in) of wire at the
connector.
2 0. Strip 13 mm (0 .5 in) of insulation from each of
the connector wire leads.
68 64 9
2 1 . Cut two 6.1 M (2 0 ft) deploym ent wires from a
0 .8 mm (1 8 gage) or thicker multi-strand wire.
T h e s e wires will be used to fabricate the
passenger deploym ent harness.
2 2 . Strip 13 mm (0 .5 in) of insulation from both
ends of the wires cut in the previous step.
2 3 . Twist together one end from each of the wires
in order to short the wires.
2 4 . Twist together one connector wire lead to one

deploym ent wire.
2 5 . Bend flat the twisted connection.

2 6 . S ecure and insulate the connection using
electrical tape.
68660
2 7. Twist together, bend, and tap e the remaining
connector wire lead to the remaining
deploym ent wire.
2 8. C onnect the deploym ent harness to the
inflatable restraint IP m odule yellow 2-w ay
connector.
2 9. Route the deploym ent harness out of the

passenger side of the vehicle.
30. C lear the inside and outside of the vehicle of
any people or loose and flam m able objects.
31. Stretch the driver harness to full length.
32. Stretch the p assenger harness to full
length.
3 3. C om pletely cover the windshield and front
door window openings with a drop cloth.
34. P lace a pow er source, 12 V minimum 2 A

minimum (i.e., a vehicle battery) near the
shorted end of the harness.
35. S ep arate the two ends of the driver deploym ent
harness wires.
36. C onnect the driver deploym ent harness wires to
the power source in order to deploy the
inflatable restraint steering w heel module.
37. Disconnect the driver deploym ent harness wires
from the power source.
188442
38. S ep arate the two ends of the passenger
deploym ent harness wires.
39. C onnect the p assenger deploym ent harness
wires to the pow er source in order to deploy
the inflatable restraint IP module.
4 0 . Disconnect the passenger deploym ent harness
wires from the pow er source.
41. Twist together one end of each wire on the

driver deploym ent harness in order to short
the wires.
4 2. Twist together one end of each wire on the

passenger deploym ent harness in order to
short the wires.
4 3. R em ove the drop cloth from the vehicle.
44. Disconnect both harnesses from the vehicle.
4 5. Discard the harnesses.
46. Scrap the vehicle in the sam e m anner as a
non-S IR equipped vehicle.
47. If one or both of the m odules did not deploy,
perform the following steps:
4 7 .1 . R em ove the undeployed m odule(s) from
the vehicle. R efer to Infl Rst Steering
Wheel Module Replacement and Infl Rst
Instrument Panel Module Replacement
4 7 .2 . Tem porarily store the m odule(s).
4 7 .3 . Call the Technical Assistance Group for
further assistance.
18 84 40
Handling a Deployed Inflatable R estraint
S teering W heel Inflator M odule
After the inflator module has deployed, the surface
of the air bag m ay contain a powdery residue. This
pow der consists primarily of cornstarch (used to
lubricate the bag as it inflates), and by-products of
the chem ical reaction. T h e deploym ent reaction
produces sodium hydroxide dust (similar to lye soap).
T h e sodium hydroxide quickly reacts with the
atm ospheric moisture. This atm ospheric moisture
converts the sodium hydroxide into sodium carbonate
and sodium bicarbonate (baking soda). Therefore,
you will probably find no sodium hydroxide present
after the deploym ent. G loves and safety glasses are
recom m ended, however, as a precaution. G loves and
safety glasses help to prevent possible irritation of
the skin or eyes.
Description and Operation

SIR System Operation
R estraint Devices
A frontal crash of sufficient force up to 3 0 degrees

off the centerline of the vehicle will deploy the
air bags.
System Description
T h e S IR system consists of the following
components:
• Inflatable Restraint Sensing and Diagnostic
M odule (S D M )
• Inflatable Restraint Steering W h e e l M odule
• Inflatable Restraint Steering W h e e l M odule Coil
• Inflatable Restraint IP M odule
• Inflatable Restraint IP M odule Switch
• Inflatable Restraint Front End Discriminating
Sensor
• A IR BAG warning lam p in the instrument cluster
T h e inflatable restraint Sensing and Diagnostic
M odule (S D M ), inflatable restraint steering w heel
module coil (S IR coil assem bly), inflatable restraint
steering w heel module (driver inflator m odule),
inflatable restraint IP module (passeng er inflator
m odule), and connector wires m ake up the
deploym ent loops. T h e function of the deploym ent
loops is to supply current through the inflator
T h e Supplem ental Inflatable Restraint (S IR ) system
m odules, which will cause deploym ent of the air
supplem ents the protection offered by the driver and
bags. D eploym ent occurs w hen the S D M detects
front passen g er seat belts (2). T h e S IR system
vehicle velocity changes severe enough to w arrant
deploys an air bag (1) from the center of the
deploym ent.
steering w heel and from the right side of the
instrum ent panel. T h e S D M contains a sensing device (Accelerom eter)
that converts vehicle velocity changes to an electrical
T h e knee bolsters (3) and the steering column
signal. T h e S D M com pares this electrical signal to a
absorb crash energy. T h e driver and passenger knee
value stored in memory. W h e n the g enerated signal
bolsters are below the instrument panel.
exceeds the stored value, the S D M performs
additional signal processing and com pares the
generated signals to values stored in m em ory. W hen
two of the generated signals exceed the stored
values, the S D M will cause current to flow through
the inflator modules, deploying the air bags.
An auxiliary inflatable restraint front end T h e A IR BAG warning lam p will com e O N steady
discriminating sensor assists the SDM in determining with pow er applied to the S D M w hen either one of
when a deployment should occur by providing an the following two conditions exist:
input signal to the SDM. • You rem ove the S D M CPA.
The IP Module switch is directly interfaced to the • You disconnect the S D M harness connector.
inflatable restraint Sensing and Diagnostic Module T h e S D M receives pow er w h enever the ignition
(SDM). The SDM senses the state of the IP Module switch is in the R U N or S T A R T positions.
switch. When the switch is in the ON position, the
SDM enables possible deployment of the inflatable AIR BAG W arning Lam p
restraint IP module. When the switch is in the OFF
T h e A IR BAG warning lam p is represented by the
position, the SDM disables or inhibits possible
words A IR Bag for dom estic vehicles. T h e ignition
deployment of the inflatable restraint IP module.
switch applies ignition voltage to the A IR BAG
warning lamp. T h e A IR BAG warning lam p receives
SIR System Component Description and
power w h e n e v er the ignition switch is at the R U N or
Definitions S T A R T positions. T h e inflatable restraint Sensing and
Diagnostic M odule (S D M ) controls the lam p by
Inflatable Restraint Sensing and Diagnostic
providing ground with a lamp driver. T h e S IR system
M odule
uses the A IR BAG warning lamp to do the following:
The inflatable restraint Sensing and Diagnostic • Verify lam p and S D M operation by flashing the
Module (SDM) performs the following functions in the lamp seven tim es when the ignition switch is
SIR system:
first turned to the R U N position.
• Energy Reserve - The SDM maintains 23 Volt • W arn the vehicle driver of S IR electrical system
Loop Reserve (23 VLR) energy supplies to malfunctions which could potentially affect the
provide deployment energy. Ignition voltage can operation of the S IR system. T h es e
provide deployment energy if the 23 Volt Loop malfunctions could result in either of the
Reserves malfunction.
• Frontal Crash Detection - The SDM monitors
- N on-deploym ent in the case of a frontal
vehicle velocity changes to detect frontal crash
crashes that are severe enough to warrant
deployment. - D eploym ent for conditions less severe than
intended
• Air Bag Deployment - During a frontal crash of
T h e A IR BAG warning lamp is the key to driver
sufficient force, the SDM will cause enough
notification of S IR system malfunctions. R efer to S I R
current to flow through the inflator modules to
D i a g n o s t i c S y s t e m C h e c k for proper lam p operation.
deploy the air bags.
• Frontal Crash Recording - The SDM records Inflatable R estraint Steering W heel
information regarding the SIR system status M odule Coil
during a frontal crash.
T h e inflatable restraint steering w heel module coil
• Malfunction Detection - The SDM performs consists of two or more current-carrying coils. T h e
diagnostic monitoring of the SIR system inflatable restraint steering w heel module coil
electrical components. Upon detection of a attaches to the steering column. Two of the
circuit malfunction, the SDM will set a current-carrying coils allow rotation of the steering
Diagnostic Trouble Code (DTC). w heel while m aintaining continuous contact of the
• Malfunction Diagnosis - The SDM displays SIR driver deploym ent loop to the inflatable restraint
Diagnostic Trouble Codes and system status steering w heel m odule.
information through the use of a scan tool. T h e re is a shorting b ar on the yellow 2 -w a y
• Driver Notification - The SDM warns the vehicle connector n ea r the base of the steering column that
driver of SIR system malfunctions by controlling connects the inflatable restraint steering w heel
the AIR BAG warning lamp. module coil to the S IR wiring harness. T h e shorting
The SDM connects to the SIR wiring harness using bar shorts the circuits to the inflatable restraint
a 12-way connector. The SDM harness connector steering w heel m odule coil and inflatable restraint
uses a shorting bar across certain terminals in the steering w heel m odule during the disconnection of
contact area. Removal of the SDM Connector the yellow 2 -w a y connector. T h e shorting of the
Position Assurance (CPA) or the harness connector inflatable restraint steering w heel module coil and
itself will connect the AIR BAG warning lamp to inflatable restraint steering w heel m odule circuitry will
ground through the shorting bar. help prevent unw anted deploym ent of the air bag
w hen servicing the steering column or other S IR
system com ponents.
Inflator M odules In the nonsuppressed state, the inflatable restraint IP
T h e inflator m odules consist of an inflatable bag and m odule will deploy in the event of a severe frontal
an inflator. An inflator consists of a canister of collision. T h e key— switch assem bly also includes a
gas-generating m aterial and an initiating device. T h e backlit switch cover which illuminates when the
initiator is part of the deploym ent loop. W hen the headlights are on.
vehicle is in a frontal crash of sufficient force, the T h e IP M odule switch is directly interfaced to the
inflatable restraint Sensing and Diagnostic M odule inflatable restraint Sensing and Diagnostic M odule
(S D M ) causes current to flow through the (S D M ). T h e S D M senses the state of the IP M odule
deploym ent loops. C urrent passing through the switch. W h en the switch is in the O N position, the
initiator ignites the m aterial in the inflator module. S D M enables possible deploym ent of the inflatable
T h e gas produced from this reaction rapidly inflates restraint IP module. W hen the switch is in the O F F
the air bag. position, the S D M disables or inhibits possible
T h ere is a shorting bar on the inflatable restraint deploym ent of the inflatable restraint IP module.
steering w heel m odule side of the upper steering
column connector that connects the inflatable Inflatable R estraint Front End D iscrim inating
restraint steering w heel m odule coil to the inflatable Sensor
restraint steering w heel m odule. T h e shorting bar
T h e presence of an inflatable restraint front end
shorts across the inflatable restraint steering w heel
discriminating sensor enhances the S IR system
m odule circuits during the disconnection of the upper
perform ance. U se of the inflatable restraint front end
steering column connector. T h e shorting of the
discriminating sensor provides tim ely deploym ent of
inflatable restraint steering w heel module circuitry will
help prevent unw anted deploym ent of the air bag the air bags during som e crashes. Although this is a
w hen servicing the inflatable restraint steering w heel m echanical sensor, it is not a part of the deploym ent
m odule, the steering colum n or other S IR system loop but instead only provides an input signal to the
com ponents. inflatable restraint Sensing and Diagnostic
T h ere is a shorting bar on the inflatable restraint IP M odule (S D M ).
m odule connector that connects to the S IR wiring
S teering Colum n
harness. T h e shorting bar shorts across the inflatable
restraint IP m odule circuits during the disconnection Th e steering column is energy absorbing. Th e steering
of the inflatable restraint IP module connector. Th e column can compress during a frontal crash in order to
shorting of the inflatable restraint IP module circuitry decrease the chance of injury to the driver.
will help prevent unw anted deploym ent of the air bag
w hen servicing the inflatable restraint IP module, the Knee B olster
instrument panel or other S IR system com ponents. T h e knee bolsters absorb energy and control the
In the event of a fault in the inflatable restraint IP forward m ovem ent of the vehicle’s front seat
m odule switch circuitry, the S D M will detect the fault occupants during a frontal crash, by limiting leg
and set Diagnostic Trouble C o de (D T C ) B 1054, the m ovem ent.
S D M will attem pt to illuminate the A IR -B A G O F F
lamp, the A IR BAG w arning lam p will turn O N and D efinitions
the inflatable restraint IP m odule will default to the
A ir Bag: An inflatable cloth cushion designed to
suppressed (disabled) state.
deploy in certain frontal crashes. T h e air bags
Inflatable R estraint IP M odule Sw itch (Pickup distribute the impact load more evenly over the
and Extended Cab O nly) occupant’s head and torso in order to supplem ent
the safety belt protection.
T h e Inflatable Restraint IP M odule Switch is a
m anual two-position key switch located in the A synchronou s: An event that can occur at any tim e
instrum ent panel, to the right of the steering w heel. without a warning and without falling within a defined
This switch gives the vehicle operator the ability to tim e period.
e n ab le or disable inflatable restraint IP module B+: T h e battery voltage available at the tim e of the
(P assen g er Front Air Bag) deploym ent should the
indicated m easurem ent. W ith the ignition switch in
vehicle be involved in a severe frontal collision. Th e
the R U N position and the engine stopped, the
vehicle operator m ay choose to disable the inflatable
voltage is usually 11.5 -1 2 .5 V. W ith the engine at
restraint IP m odule if there is no occupant in the
idle, the voltage m ay be 1 4 .0 -1 6 .0 V. During engine
front seat, or if there is a child in a rear-facing child
cranking, the voltage can be as low as 1 0.0 V.
s eat in the front seat.
T h e m anual key-switch operates in two positions. B ulb Test: T h e inflatable restraint Sensing and
W h e n the key is vertical, the switch is in the O F F Diagnostic M odule (S D M ) will cause the air bag
position and the inflatable restraint IP module is in warning indicator to flash 7 times. U nder normal
th e suppressed (disabled) state. In the suppressed operation, this occurs w hen the ignition is turned
state, the inflatable restraint IP module will not from the O F F position to the R U N position. T h e bulb
deploy in the event of a severe frontal collision. test will also occur if the IG N IT IO N 1 voltage
W h e n the key is horizontal, the switch is in the exceeds 17.1 V and then returns within the normal
O N position and the inflatable restraint IP module operating voltage range. A malfunction could prevent
is in the nonsuppressed (enabled) state. the module from flashing the indicator.
C on tin u o u s M onito ring Test: T h e inflatable restraint H igher P rio rity Fault: Each D T C has an assigned
Sensing and Diagnostic M odule (S D M ) continuously priority based on its detectability with other D TC s
monitors the S IR system during each 100 millisecond present. T h e priority corresponds to the detectability
interval. T h e IG N IT IO N 1 voltage at the module must of the malfunction only. This does not relate to the
be with the normal operating voltage range for the seriousness of the malfunction with respect to
continuous monitoring to occur. T h e s e tests follow deploym ent or non deploym ent under any given
the power-on tests. condition.
D ata Link C o n n ecto r (D L C ): T h e D LC electrically Ig n itio n C ycle: T h e operation of the ignition switch
connects to m any on-board com puters and allows causes this cycle to occur. T h e inflatable restraint
com munication with an off-board com puter such as a Sensing and Diagnostic M odule (S D M ) must first
scan tool. sense IG N IT IO N 1 input greater than 8 .2 V with the
D atum Line: A b ase line parallel to the plane of the ignition switch in the R U N position. T h e IG N IT IO N 1
vehicle underbody or the fram e. All vertical input voltage must remain above 8 .2 V for at least
m easurem ents originate from this base line. 10 seconds before turning the ignition switch to the
O F F position.
D eploy: To inflate the air bag.
Ig n itio n 1 : A B+ circuit receiving p o w er with the
D eploym ent Loop C o n tin u ity Test: T h e inflatable
ignition in the R U N position or the S T A R T position.
restraint Sensing and Diagnostic M odule (S D M )
performs this test in order to inspect for voltage In fla ta b le R estrain t Front End D iscrim in atin g
variations in the D R IV E R S ID E H IG H /L O W and the S ensor: A sensor m ounted on th e front of the
P A S S E N G E R S ID E H IG H /L O W circuitry. T h e module vehicle that supplies an input signal to the inflatable
first m easures the IG N IT IO N 1 and the 2 3 V LR in restraint Sensing and Diagnostic M odule (S D M ).
order to verify that the voltage is within In fla ta b le R estrain t IP M odule: An assem bly
specifications. T h e m odule then performs the located on the RH of the IP consisting of an
deploym ent loop continuity test. Detection of a inflatable air bag, an inflator, and an initiator.
malfunction during these tests m ay prevent the In fla ta b le R estrain t IP M odule S w itch: A m anual
resistance m easurem ent test from occurring until the two-position key switch located in the instrument
next ignition cycle. This test is part of the power-on panel, to the right of the steering w heel. This switch
tests and occurs before the continuous monitoring gives the vehicle operator the ability to enable or
tests. disable inflatable restraint IP module (P assen g er
D eploym ent Loops: T h e circuits that supply the Front Air Bag) deploym ent should the vehicle be
current to the inflator m odules for air bag involved in a severe frontal collision. T h e vehicle
deployment. operator m ay choose to disable the inflatable
D iagnostic T rouble C ode (D T C ): An alphanum eric restraint IP m odule if there is no occupant in the
designator used by the inflatable restraint Sensing front seat, or if there is a child in a rear-facing child
and Diagnostic M odule (S D M ) in order to indicate seat in the front seat.
specific S IR system malfunctions. In fla ta b le R estrain t S ensing and D iag n o stic
D river C u rren t S ink: An output of the inflatable M odule: T h e S D M that provides reserve energy to
restraint Sensing and Diagnostic M odule (S D M ) that the deploym ent loops, deploys the air bags when
supplies a low resistance path to ground for the required, and performs diagnostic monitoring of all
inflatable restraint steering w heel module circuit. S IR system com ponents.
D river C u rren t S ource: An output of the inflatable In fla ta b le R estrain t S teerin g W heel M odule: An
restraint Sensing and Diagnostic M odule (S D M ) that assem bly located in the steering w heel hub
supplies current into the inflatable restraint steering consisting of an inflatable bag, an inflator, and an
w heel module circuit. initiator.
EEPRO M (E le c tric a lly E rasab le P rogram m able In fla ta b le R estrain t S teerin g W heel M odule Coil:
Read O nly M em ory): M em ory that does not require An assem bly of two or m ore current carrying coils
pow er to the inflatable restraint Sensing and mounted within the steering column hub. T h e
Diagnostic M odule (S D M ) in order to retain its assem bly allows the rotation of the steering wheel
contents. while maintaining continuous electrical circuit contact.
Two of the coils provide continuous contact of the
driver deploym ent loop to the inflatable restraint
steering w heel module.
In itiato r: Located in the inflator m odule, the initiator Scan Tool: An off-board com puter that reads
initiates the chem ical reaction that inflates the air on-board com puter diagnostic information through the
bag w h en sufficient current flows through the use of a DLC.
com ponent. S erial D ata: T h e information com m unicated to an
N orm al O p eratin g Voltage R ange: 8.2-17.1 V when off-board com puter using the D LC . S o m e of this data
m easuring betw een the inflatable restraint Sensing represents the status of the S IR system.
and Diagnostic M odule (S D M ) IG N IT IO N 1 terminal SIR : Supplem ental inflatable restraint.
and ground.
SIR W iring H arness: T h e wires and connectors that
P assen g er C u rre n t S ink: An output of the inflatable electrically connect the com ponents in the S IR
restraint Sensing and Diagnostic M odule (S D M ) that system.
supplies a low resistance path to ground for the
23 VLR : T h e 2 3 volt loop reserve. T h e energy
inflatable restraint IP m odule circuit.
supply that is internal to the inflatable restraint
P assen g er C u rren t S ource: An output of the Sensing and Diagnostic M odule (S D M ).
inflatable restraint Sensing and Diagnostic M odule
(S D M ) that supplies current into the inflatable
restraint IP m odule circuit.
P ow er-on Test: Tests that the inflatable restraint
Sensing and Diagnostic M odule (S D M ) performs on
the S IR system once per ignition cycle. T h e s e tests
occur im m ediately after the module receives
IG N IT IO N 1 voltage, and before the continuous
monitoring tests.
R esistan ce M easurem ent Test: A test that the
inflatable restraint Sensing and Diagnostic Module
(S D M ) performs once per ignition cycle in order to
m easure the resistance of the deployment loops. The
module first m easures IG N ITIO N 1, 23 VLR, and the
deployment loop voltages in order to verify readings
within specifications. Th e module then sources a
constant current into the loop. The module measures
the voltage drop across the loop and converts the
value to a resistance value. This resistance value is
within the range of 0 .0 - 6 .3 ohms. Upon the detection
of an open circuit, the module aborts the tests in order
to prevent the calculation of the resistances until the
next ignition cycle. This test also checks for proper
operation of the driver/passenger current sources.
This test is part of the power-on tests and occurs
before the continuous monitoring tests.
S p e c ia l T ools D e s c rip tio n
J 35616-A Connector Test A dapter Kit J 38715-96 SIR Shorting Bar Tool
U se J 3 5 6 1 6-A Connector Test A d ap ter Kit w henever Use J 3 8 7 1 5 -9 6 S IR Shorting Bar Tool only when the
a diagnostic procedure requests checking or probing S IR diagnostics call for it. T h e shorting bar tool lifts
a terminal. Using the appropriate a dap ter will ensure one side of the shorting bar on the inflatable
that no d am ag e to the term inal occurs from the restraint Sensing and Diagnostic M odule (S D M )
D M M probe, such as spreading or bending. Th e harness connector. T h e C onnector Position
adapter will also give an idea of w hether contact Assurance (CPA) lifts the opposite side of the
tension is sufficient, helping to find an open or shorting bar. W h en the CPA and the shorting bar
intermittent open due to poor term inal contact. tool are installed the warning lamp circuit is
disconnected from the ground circuit turning the
J 38125-A Term inal R epair Kit warning lamp OFF.
U se J 3 8 1 2 5 -A Terminal R ep air Kit for S IR wiring
repair. This kit contains a special crimping tool, heat J 38826 SIR Deploym ent Harness
torch, and sealed splices. Do not use the terminals U se J 3 8 8 2 6 S IR Deploym ent Harness in order to
in the kit to replace d am ag ed S IR system terminals deploy a driver inflator module outside of the vehicle.
unless specifically indicated by the term inal package. U se one of the following adapters to connect the
deploym ent harness to the inflator module:
J 38715-A SIR D river/Passenger Load Tool
• J 3 8 8 2 6 -2 0 S IR Deploym ent H arness A dapter
Use J 3 8 7 1 5-A S IR D river/P assen g er Load Tool only (pigtail connector).
when the S IR diagnostics call for it. T h e Load Tool is
• J 3 8 8 2 6 -5 0 S IR Deploym ent H arness A dapter
used as a diagnostic aid and a safety device to
(integral connector).
prevent inadvertent inflator module deploym ent.
T h e load tool has four yellow connectors attached to J 39200 Digital M ultim eter
its case. T h e three small connectors are electrically T h e J 3 9 2 0 0 Digital M ultim eter (D M M ) is the
functional and serve as resistive load substitutions. preferred D M M for use in S IR diagnosis and repair.
T h e large dum m y connector does not serve as a However, J 3 4 0 2 9 -A m ay be used if J 3 9 2 0 0 is
load substitution and is not used. U se no more than not available. No other D M M s are approved for
two connectors at any tim e. S IR diagnosis and repair.
O n e of the small connectors is used to substitute the
load of the inflatable restraint steering w heel module. Scan Tool
It is connected at the top of the column to the T h e scan tool is used for the following reasons:
inflatable restraint steering w heel m odule coil. Use • To read and clear S IR system Diagnostic
one of the following adapters to connect the load Trouble C odes (D TC s).
tool to the steering w heel m odule coil:
• To provide S IR system circuit values using the
• J 3 8 7 1 5 -5 S IR Load Tool A d ap ter (pigtail data list function.
connector).
R efer to the scan tool operator’s m anual for specific
• J 3 8 7 1 5 -3 0 Steering Colum n S IR Load Tool information on how to use it.
A dapter (integral connector).
A nother small connector is used to substitute the
load of the inflatable restraint steering w heel module
and the inflatable restraint steering w heel module
coil. It is connected at the b ase of the column to the
S IR wiring harness. T h e third small connector is
used to substitute for the load of the inflatable
restraint IP module. It is connected to the inflatable
restraint IP module harness connector.
You substitute the resistance of the inflator module
to determ ine w hether an inflator circuit com ponent is
causing a system malfunction. U se the load tool only
w hen specifically called for in the diagnostic
procedures.

Illustration Tool Number/ Description Illustration Tool Num ber/ Description
J 38125-A J 39200
Terminal Repair Kit Digital Multimeter
9081 3430
J 38826 J 35616-A
3^ S 3S
SIR Deployment Harness Connector Test Adapter Kit
9082 8917
J 38715 -A
1 , i l l * ‘
CoiO
SIR Driver/Passenger Scan Tool
Load Tool
9083 39438
J 38715-96
SIR Shorting Bar Tool
39S45
REMOTE KEYLESS ENTRY 9K-1
SECTION 9K

GENERAL DESCRIPTION
The Rem ote Keyless Entry (RKE) system operates by FUNCTIONAL OPERATION
m eans of remote control to lock and unlock the vehicle
doors and to release the endgate or liftgate window on Unlocking the Doors (Figures 1 and 2)
utility models. W h e n the U N L O C K button on the transm itter is
The remote control door lock transmitters, which are pressed once, only the driver’s door is unlocked. W hen
supplied in pairs with each vehicle, are hand-held and the UN LO CK button is pressed a second time within
attached to a key ring. The transmitter for pickup mod five seconds, the remaining doors, including the liftgate
els has two buttons to control the operation of the sys on utility veh icles equipped with this featu re, are
unlocked.
tem. Th e transmitter for utility models has three buttons.
W hen any of the buttons are pushed, the transmitter Locking the Doors (Figures 1 and 2)
sends a coded ultra-high frequency (UH F) radio signal W hen the LOCK button on the transmitter is pressed,
to the receiver. all of the vehicle doors lock at once. W hen the LOCK
T h e tra n s m itte r m u s t b e w ith in a p p ro x im a te ly button is pressed twice, the horn sounds to verify that
10 meters (33 feet) of the vehicle in order for the receiv the doors are locked.
er to detect the coded signal. Th e RKE system has no
E ndgate/Liftgate W indow Release (Figure 2)
effect on the normal operation of the power door locks W hen the R E A R 2 X button on the transm itter is
or the endgate or liftgate window release. pressed twice within five seconds, the liftgate window is
Each receiver is capable of recognizing four transmit u n latched, or cargo doors unlocked. O n veh icles
ters. Replacem ent transmitters may be obtained, but equipped with an automatic transmission, the vehicle
must be matched to the specific receiver. The transmit must be in park or neutral, or on a manual transmission,
ter is powered by a three-volt battery and is water resis the parking brake must be set in order for this feature to
tant. operate.
Figure 1— Rem ote C ontrol Door Lock Transm itter Figure 2— Rem ote Control Door Lock Transm itter
(Pickup) (U tility/S uburban)
9K-2 REMOTE KEYLESS ENTRY
DIAGNOSIS
Perform the following check to diagnose all transmit • If one transmitter will not program, replace the
ter operations, using both transmitters (if available): battery in that transmitter. Refer to Remote Con
trol Door Lock Transmitter Battery Replacement
1. Before attempting any other steps, resynchronize in this section.
the transmitters to the receiver. Refer to Resyn 5. If all functions on all transmitters operate, stand 5
chronization in this section. ft. from the vehicle at several points around the
2. Move the vehicle outside and as far away from vehicle and check the operation of all transmitters
m etal objects as possible. Th e rem ote keyless at each point.
entry system may not operate if there are metal • If one transmitter does not operate at some
objects between the transmitter and the vehicle. points where the other transmitter does operate,
3. Lower the windows, turn the ignition O F F , and replace the battery of the transmitter that does
close the doors. not operate.
4. Stand near the drivers door, aim the transmitter at • If all transmitters operate 5 ft. from the vehicle,
the vehicle, and operate all functions on all trans the system is operating properly and no repairs
mitters (if available). should be attempted.
For additional diagnostic information on the remote
• If a single function on one transmitter is inoper keyless entry system, refer to the Engine Controls,
ative, replace that transmitter. T ra n s m is s io n D ia g n o s is , and E le c tric a l D ia g n o s is
• If all functions on any transmitter are inopera Manual.
tive, reprogram all transmitters and repeat the
diagnosis. Refer to Reprogramming Transmitter
later in this section.
ON-VEHICLE SERVICE
REMOTE CONTROL DOOR LOCK 2. Battery.
TRANSMITTER BATTERY Install or Connect (Figure 4)

REPLACEMENT
U nder normal use, the battery in the transm itter 1. Battery.
should last about two years. For battery replacement, • Install the battery with the (+) positive side
use a Panasonic® 3 volt, type C R 2032, or equivalent. down.
0 Rem ove o r D isconnect (Figures 3 and 4)

2. Close transmitter case.
• Align and snap together the top and bottom
covers.
1. Open the transmitter case. • Check the operation of the transmitter.
• Insert a dime between the two halves of the
transmitter near the key ring hole and twist. CONTROL MODULE
REPLACEMENT
Rem ove o r Disconnect (Figure 5)
1. D RL Module.
3. Control module retainers.
4. Control module.
[+4-| Install or C onnect (Figure 5)
1. Control module.
2. Control module retainers.
4. D RL Module.
Figure 3— O pening Transm itter Case

REMOTE KEYLESS ENTRY 9K-3
Figure 4— Transm itter B attery Replacem ent Legend

(1) Driver Knee Bolster Bracket
RESYNCHRONIZATION (2) Control Module
R esynchronization m ay be necessary due to the (3) Push-in Retainer
security method used by the RKE system. The transmit Figure 5— Control M odule
ter does not send the sam e signal twice to the receiver.
The receiver will not respond to a signal it has been 2. Press and hold the LOCK and U N LO C K buttons
sent previously. This prevents anyone from recording simultaneously, on the first transmitter to be pro
and playing back the signal from the transmitter. gram m ed, until the locks cycle (approxim ately
• Resynchronization will be necessary if: 10 seconds).
1. The transmitter battery is changed. 3. Repeat step 2 for up to four total transmitters to be
2. The vehicle battery is disconnected. programmed (if available).
3. Th e transmitter buttons have been pushed • The receiver will respond by locking and unlock
2 5 6 times out of range of the receiver. ing the doors and activating the liftgate window
To resynchronize the transmitter with the receiver: release (if equipped) within 2 seconds.
• W hile standing close to your vehicle, simultaneous 4. Rem ove the ground applied to the DLC.
ly press and hold the LO CK and U N LO CK buttons 5. Transmitter operation is verified by locking and
on the transmitter for 7 seconds. The door locks unlocking the doors and activating the rear window
should cycle to confirm resynchronization. release.
REPROGRAMMING
TRANSMITTER
1. Ground pin 4 to pin 8 of the Data Link Connector
(DLC).
• T h e receiver will respond by locking and unlock
ing the doors and activating the liftgate window
release (if equipped) within 2 seconds.
9K-4 REMOTE KEYLESS ENTRY
BLANK
Body Table of Contents 1
SECTION 10
Body
D o o r s ..............................................................................10A 1-1 R ear S eat A ccess D oor (E xten d ed C ab )-

General Description ............................................. 10A1-1 On V ehicle S e rv ic e ................................ 10A1-15
D o o r s ....................................................................... 10A1-1 Trim Panel Replacement..........................10A1-15
On-Vehicle Service ................................................10A1 -1 Door Replacement.................................... 10A1-16
Front Doors .............................................................. 10A1-1 Door Hinge Replacement.......................... 10A1-16
W indow R egulator Handle Door Adjustment.........................................10A1-17
R e p la c e m e n t....................................................... 10A1-1 Door Hardware Lubrication.......................10A1 -17
P o w er Accessory Switch Mounting Panel Door Strikers.............................................. 10A1-17
R e p la c e m e n t....................................................... 10A1-1 Door Latches.............................................. 10A1-18
Inside H andle B ezel R ep la ce m e n t............... 10A 1-2 Check Strap................................................ 10A1-19
P o w er Door Lock Switch R e la c e m e n t.........1 0 A 1-2 Door Handle and Linkage.........................10A1-19
Trim Panel U p per Extension R ear D oors (C rew C ab, U tility, and
R e p la c e m e n t....................................................... 10A 1-2

S u burban)-O n V eh icle S e rv ic e ............ 10A1-21
Trim Panel R ep la ce m e n t.................................. 1 0 A 1-3

Ashtray Assembly Replacement.............. 10A1-21
Window Regulator Handle
C ourtesy Lam p R e p la c e m e n t........................ 1 0 A 1-3
Replacement.............................................10A1 -21
Trim P anel M ap Pocket R ep la ce m e n t.........1 0A 1-4
Inside Handle Bezel Replacement.......... 10A1-21
W a ter Deflector R e p la c e m e n t..........................1 0A 1-4
Power Window Switch Replacement....... 10A1-22
Wiring Harness R e p la c e m e n t..........................1 0A 1-4
Courtesy Lamp Replacement.................. 10A1-22
Door R ep lacem e n t.............................................. 10A 1-5
Trim Panel Replacement..........................10A1-22
D oor H inge R e p la ce m e n t...................................10A 1-6
Inner Panel Water Deflector
Door Striker Bolt R e p la c e m e n t....................... 10A 1-8
Replacement.............................................10A1 -23
D oor A djustm ent.................................................. 1 0A 1-8
Wiring Harness Replacement.................. 10A1-23
D oor H ardw are Lubrication............................. 1 0A 1-9
Door Replacement.................................... 10A1-24
Inside Door H andle Assem bly
Door Hinge Replacement..........................10A1-25
R e p la c e m e n t....................................................... 10A1 -9
Door Striker Bolt Replacement................ 10A1-26
Inner Mounting Panel A ssem bly.................. 1 0 A 1 -1 0
Door Adjustment........................................ 10A1 -26
Lock A s s e m b ly .................................................... 1 0 A 1 -1 0
Door Hardware Lubrication...................... 10A1-27
Binding Lock C ylinders..................................... 10A1-11
Inside Door Handle Assembly
Door Lock Cylinder and O utside H andle
Replacement.............................................10A1 -27
R e p la c e m e n t....................................................... 10A1-11 Inside Door Handle Bracket
W indow R egulator R eplacem ent and Replacement.............................................10A1 -27
M otor R ep la ce m e n t.......................................... 1 0A 1-1 2 Armrest Bracket Replacement................. 10A1-28
W in do w R ep lacem en t........................................10 A 1 -1 2 Lock Assembly.......................................... 10A1 -28
W indow Glass W eatherstrip Outside Handle Replacement.................. 10A1-29
R e p la c e m e n t......................................................10A1 -1 3 Window Replacement...............................10A1-29
Front G lass Run Channel Window Glass Weatherstrip
R e p la c e m e n t......................................................10A1 -1 3 Replacement............................................ 10A1 -30
O utside R earview Mirror Window Front Glass Run Channel..........10A1-30
R e p la c e m e n t...................................................... 1 0 A 1 -1 3 Window Regulator Replacement and
O utside R earview Mirror Lens Motor Replacement..................................10A1-31
R e p la c e m e n t......................................................10A1 -1 4 R ear C argo D oors (U tility and S uburban)
Pressure Relief V a lv e ........................................1 0 A 1-1 5 O n-V ehicle S e rv ic e .................................10A1-31
O utside Vent Valve A s s e m b ly .................. 1 0 A 1-1 5 Trim Panel Replacement......................... 10A1-31
Inside M odule Valve A s s e m b ly ................1 0 A 1-1 5 Window Garnish Moldings....................... 10A1-32
2 Table of Contents Body
Inner Panel W a te r Deflector Front Seat Back Hinge/Recliner

R e p la c e m e n t..................................................... 10A 1-3 2 Mechanism................................................. 10A2-4
Access H ole Covers Front Seat Back Cover............................. 10A2-5
(B ase M odels O n ly )....................................... 10A 1-3 2 Front Seat Cushion C over.......................10A2-6
Wiring Harness R e p la c e m e n t...................... 1 0 A 1-3 2 Front Seat Back Frame
C argo Door R e p la c e m e n t............................. 1 0 A 1-3 3 Replacement............................................10A2-6
C argo Door H inge C h eck Assem bly Front Seat Cushion Frame
R e p la c e m e n t..................................................... 10A1 -34 Replacment.............................................. 10A2-8
C argo Door H inge R e p la c e m e n t.............. 1 0A 1-3 4 Power Seat Lumbar Switch
C argo Door Body M ounted S trik e rs ...........1 0A 1-3 5 Replacement............................................10A2-9
C argo Door P rotecto rs.................................. 10A 1-3 5 Manual Seat Lumbar Switch
C argo Door Lock Assem bly R eplacem ent Replacement............................................10A2-9
(Right D o or)......................................................... 10A 1-3 5 Lumbar Bladder Replacement
Lock A ctuator........................................................1 0 A 1-3 6 (Non-Removable Seat Back Panel) ....10A2-10
D oor Lock Cylinder, Rod, and Outside Lumbar Bladder Replacement (Seat with
H an d le R ep lacem en t (Right D o o r)............ 1 0 A 1 -3 6 Removable Seat Back Panel)...............10A2-10
Left Door Latch Control H a n d le .................. 1 0A 1-3 7 Lumbar Bladder Replacement (Seat without
Left Door M ounted S trik e r..............................10A 1-3 7 Removable Seat Back Panel)...............10A2-10
Low er Latch R e p la c e m e n t............................. 1 0A 1-3 8 Lumbar Pump Replacement...................10A2-10
D oor B um per Assem bly R e p la c e m e n t..... 1 0A 1-3 8 Front Split Bench Seat Replacement...... 10A2-11
U p per Latch R e p la c e m e n t..............................10 A 1-3 8 Front Seat Riser....................................... 10A2-11
W e a th e rs trip R e p la c e m e n t........................... 10A1 -3 9 Front Seat Adjuster..................................10A2-11
Side Door W indow Sealing Strip Head Restraint Replacement................. 10A2-11
R e p la c e m e n t...................................................... 1 0 A 1-3 9 Head Restraint Guide Replacement.... 10A2-12
S ide Door O pening W eatherstrip Front Seat Armrest..................................10A2-12
R e p la c e m e n t.......................................................1 0 A 1-3 9 Front Seat Back Recliner Handle......... 10A2-13
Side Door Roof Drip W eathertrip Front Seat Back Hinge/Recliner
R e p la c e m e n t.......................................................1 0 A 1-4 0 Mechanism............................................. 10A2-14
Side Door Auxiliary W eatherstrip Front Seat Back Cover........................... 10A2-16
R e p la c e m e n t.......................................................1 0A 1-4 0 Front Seat Cushion Cover..................... 10A2-16
C argo Door O pening W e a th e rs trip ............. 10A1-41 Front Seat Back Frame
C argo Door U pper W e a th e rstrip .................. 10A1-41 Replacement..........................................10A2-16
C argo Door C o rn er W eath e rstrip ................. 10A1-41 Front Seat Cushion Frame
S p e c ific a tio n s ......................................................... 1 0A 1-4 2 Replacment............................................ 10A2-17
F asten er Tightening S pecifications............. 10A 1-4 2 Power Seat Lumbar Switch
S p e c ia l T o o ls ........................................................ 10A1 -42 Replacement..........................................10A2-17
S e a t s .................................................................................10A 2-1 Manual Seat Lumbar Switch
D ia g n o s is .....................................................................10A2-1 Replacement..........................................10A2-18
Diagnosis of M anual S e a t A d ju s te r.............. 10A2-1 Lumbar Bladder Replacement................10A2-18
Diagnosis of S ix-W ay P o w er S e at Lumbar Pump Replacement...................10A2-18
A d ju s te r................................................................... 10A2-1 Front Bench Seat Replacement................10A2-18
O n -V e h ic le S e r v ic e ..................................................10A 2-2 Front Seat Riser......................................10A2-19
F ro n t S e a t s ................................................................ 10A 2-2 Front Seat Adjuster.................................10A2-19
Front Bucket S e a t R e p la ce m e n t.....................10A 2-2 Head Restraint Replacement.................10A2-19
Front S e a t Trim C over Head Restraint Guide Replacement.... 10A2-19
R e p la c e m e n t.......................................................10A 2-2 Front Seat Armrest..................................10A2-19
Front S e a t R is e r .............................................. 10A 2-3 Front Seat Back Recliner Handle......... 10A2-20
Front S eat A djuster.........................................10A 2-3 Front Seat Back Hinge/Recliner
M anual S e a t A djuster S w itc h ................. 10A 2-3 Mechanism............................................. 10A2-21
Pow er S e a t A djuster S w itc h ................... 10A 2-3 Front Seat Back Cover........................... 10A2-21
H ead Restraint R e p la c e m e n t...................... 10A 2-4 Front Seat Cushion Cover..................... 10A2-22
H ead Restraint G uide R e p la c e m e n t........10A 2-4 Front Seat Back Frame
Front S e a t A rm re s t.........................................10A 2-4 Replacement..........................................10A2-23
Front S e at Back R ecliner H a n d le ............ 10A 2-4
Front Seat Cushion Frame O n -V e h ic le S e r v ic e ................................................. 10A 3-3

Replacment........................................... 10A2-24 R ea r View Mirror M ount Button
Power Seat Lumbar Switch R e p la c e m e n t......................................................... 10A 3-3
Replacement......................................... 10A2-24 W indshield S e rv ic e ............................................... 10A 3-4
Manual Seat Lumbar Switch W indshield R ep la c e m e n t....................................10A 3-4
Replacement..........................................10A2-25 Inspection.............................................................10A 3-5
Lumbar Bladder Replacement............... 10A2-25 Stationary Body Side W indow
Lumbar Pump Replacement.................. 10A2-25 R e p la c e m e n t......................................................... 10A 3 -7
Rear Passenger Seats................................. 10A2-26 Body Side Latched W indow
Rear Seat Replacement............................. 10A2-26 R e p la c e m e n t......................................................... 10A 3-8
Rear Seat Riser...................................... 10A2-26 R ea r W indow R e p la c e m e n t............................. 10A 3-9
Rear Seat Head Restraint......................10A2-27 R ea r W indow D efogger S y s te m .................. 10A 3-10
Rear Seat Head Restraint Guide D ia g n o s is o f th e R e a r W in d o w
Replacement..........................................10A2-27 D e fo g g e r S y s t e m ........................................... 10A3-11
Rear Seat B ack...................................... 10A2-28 Testing R e a r W indow D efogger
Rear Seat Cushion Cover......................10A2-29 Grid L in e s ............................................................. 10A3-11
Rear Seat Back Cover...........................10A2-30 Grid Line R e p a ir ..................................................10A3-11
Rear Bench Seat Back Frame Braided Lead W ire R e p a ir...............................10A 3-12
Replacement..........................................10A2-31 W in d o w P o lis h in g ................................................ 10A 3-12
Rear Bench Seat Cushion Frame Minor Scratch and Abrasion
Replacment............................................10A2-33 R e m o v a l.......................................................... 10A 3-12
Rear Folding Seat Panel R ecom m ended E q u ip m e n t.........................10A 3-12
Replacement..........................................10A2-33 Polishing Proced u re...................................... 10A 3-12
Rear Seat Support Replacement W a te r L e a k T e s t s ................................................. 10A 3-13
(Extended Cab)......................................10A2-33 Checking with W atertest S ta n d s ............. 10A 3-13
Second Rear Seat Assembly W ater Hose T e s t............................................ 10A 3-13
(Suburban).............................................. 10A2-35 Air H ose/B ubble Solution T e s t................. 1 0A 3-13
Rear Seat Head Restraint......................10A2-35 R e p a irin g W a te r L e a k s ...................................... 1 0A 3-14
Rear Seat Head Restraint Guide W in d n o is e D ia g n o s is a n d R e p a ir ................10A 3-14
Replacement..........................................10A2-36 Exterior W in dn o is e .........................................10A 3-16
Rear Seat B ack...................................... 10A2-36 Interior W in d n o is e ..........................................10A 3-17
Rear Seat Cushion Cover......................10A2-36 Tracing P ow der or C halk T e s t................. 10A 3-17
Rear Seat Back Cover...........................10A2-36 Air Pressure T e s t........................................... 1 0A 3-17
Rear Seat Back Frame Soap Solution or Bubble T e s t.................. 10A 3-17
Replacement..........................................10A2-37 S p e c ia l T o o ls .......................................................... 1 0A 3-18
Rear Seat Cushion Frame In te rio r T rim ............................................................... 10A4-1
Replacment............................................10A2-37 O n -V e h ic le S e r v ic e ................................................. 10A4-1
S pe cifica tio ns................................................ 10A2-38 Handling Electrostatic Discharge (E S D )
Fastener Tightening Specifications...... 10A2-38 Sensitive P a r ts ..................................................... 10A4-1
Special T o o ls ................................................. 10A2-38 S unshade R e p la c e m e n t..................................... 10A4-1
W in d o w s .............................................................10A3-1 Assist H andle R e p la c e m e t................................10A 4-2
General In fo rm a tio n ........................................10A3-1 C oat Hook R e p la c e m e n t....................................10A 4-2
Stationary Windows...................................... 10A3-1 K nee Bolster R e p la c e m e n t...............................10A 4-2
Short Method.............................................. 10A3-1 Floor S torage C om partm ent
Extended Method...................................... 10A3-1 R e p la c e m e n t.........................................................10A 4-3
Adhesive Service K it.................................... 10A3-1 U pper W indshield Garnish Molding
Electrochromic Inside Rearview Mirror R e p la c e m e n t.........................................................10A 4 -4
with Compass...........................................10A3-1 W indshield Garnish Molding
Night Vision Mirror Function Check............ 10A3-2 R e p la c e m e n t.........................................................1 0A 4-4
Compass Variance Set-Up.......................10A3-2 R ea r Side Door U pper Garnish Molding
Calibration of Compass............................ 10A3-2 R e p la c e m e n t......................................................... 10A 4-4
Magnetic Field............................................10A3-2 H eadliner R e p la c e m e n t...................................... 10A 4-4
Mirror Autodim ...........................................10A3-3 Pickup, Extended C ab, and
Mirror Clean-Up.........................................10A3-3 C rew C a b .......................................................... 10A 4-4
Suburban and Utility................................. 10A4-5 Front License Plate Bracket

Overhead Console Replacement................ 10A4-6 R e p la c e m e n t.........................................................1 0A 5-8
Rear Window Upper Garnish Molding Tow H o o k s ............................................................... 1 0A 5-8
Replacement................................................ 10A4-6 Engine Protection S hield....................................1 0A 5-8
Rear Window Lower Garnish Molding R e a r B um per Step Pad R ep la ce m e n t.........1 0A 5-9
Replacement................................................ 10A4-7 R e a r B um per B race and Bracket
Quarter Panel Trim Replacement............... 10A4-8 R e p la c e m e n t.........................................................10 A 5 -9
Pickup, Extended Cab, and Hitch Platform and License Plate Bracket
Crew C ab................................................. 10A4-8 R e p la c e m e n t.......................................................10 A 5 -1 1
Suburban and Utility................................. 10A4-9 S p e c ific a tio n s ......................................................... 10 A 5 -1 3
Lower Rear Quarter Trim Panel F asten er Tightening S pecifications..............10A 5-1 3
Replacement............................................. 10A4-11 S h e e t M e ta l ................................................................ 10A6-1
Pickup and Extended Cab..................... 10A4-11 O n -V e h ic le S e r v ic e ..................................................10A6-1
Rear Panel Carpet Replacement.............. 10A4-12 Hood R e p la c e m e n t............................................... 10A6-1
Hinge Pillar Trim Panel Replacement..... 10A4-13 Hood Insulator R ep la ce m e n t............................ 10A6-1
Door Sill Trim Plate Replacement............ 10A4-13 Hood B um per R e p la c e m e n t..............................10A6-1
Pillar Molding Replacement.......................10A4-14 Hood H inge R e p la ce m e n t................................. 1 0A 6-2
Suburban, Utility, and Crew C a b .......... 10A4-14 Link A ssem bly R ep lacem en t............................ 1 0A 6-2
Floor Carpet or Mat Replacement............ 10A4-14 Prim ary Hood Latch and/or Bracket
Pickup........................................................10A4-14 R e p la c e m e n t......................................................... 1 0A 6-3
Suburban........................... 10A4-15 Secondary Hood Latch and/or Spring
Utility..........................................................10A4-17 R e p la c e m e n t......................................................... 10 A 6 -3
Luggage Shade Replacement...................10A4-18 H ood R e lea se C ab le R e p la c e m e n t...............1 0 A 6 -4
Auxiliary Door Lock Switch Cowl Vent Grille R ep la ce m e n t.........................1 0A 6-4
Replacement.............................................. 10A4-18 R adiator Grille R ep la ce m e n t............................ 10A 6-5
Jack Tool and Stowage.............................. 10A4-19 Low er Grille R eplacem ent
Pickup and Crew C a b ............................ 10A4-19 (C 3 5 0 0 H D O n ly )................................................ 1 0A 6-5
Extended C ab..........................................10A4-19 F en d er R ep la ce m e n t........................................... 1 0A 6-6
Suburban.................................................. 10A4-20 Right F e n d e r...................................................... 10A 6-6
Utility..........................................................10A4-20 Left F e n d e r ......................................................... 1 0A 6-8
Flexible Plastic Part Refinishing............... 10A4-22 S tepside Fender R e p la c e m e n t....................... 1 0A 6-9
S p e c ific a tio n s ................................................ 10A4-23 R e a r Fen d er R eplacem ent
Fastener Tightening Specifications........... 10A4-23 (Dual W h e e l)...................................................... 1 0A 6-1 0
Frame and Bum pers ....................................10A5-1 W h eelho u se Panel R ep lacem en t..................10A6-11
General D e scrip tio n ........................................10A5-1 Right Panel R ep la ce m e n t............................10A6-11
Diagnosis o f the F ra m e ................................ 10A5-2 Left Panel R e p la c e m e n t..............................1 0A 6-1 2
M inim izing Frame S e rv ic e ............................ 10A5-3 W h eelho u se Opening F la re s .........................1 0 A 6 -1 3
Checking Frame Alignment.......................... 10A5-4 Front F e n d e r.................................................... 1 0A 6-1 3
Determining the Frame Centerline.......... 10A5-4 R e a r F e n d e r..................................................... 1 0 A 6 -1 3
Horizontal Check........................................10A5-4 Utility and Suburban M o d e ls ..................... 1 0 A 6 -1 4
Datum Plane.............................................. 10A5-5 S h e e t M etal S u p p o rt......................................... 1 0 A 6 -1 4
Center Plane.............................................. 10A5-5 R adiator S u p p o rt................................................ 1 0 A 6 -1 4
Centerline Length.......................................10A5-5 Pickup Box R e p la ce m e n t................................ 1 0 A 6 -1 7
Vertical Body Zero Line............................ 10A5-5 S h e et M etal A djustm ents................................ 1 0 A 6 -1 8
Straightening Frames................................... 10A5-6 C ab M ount R e p la c e m e n t................................ 1 0 A 6 -1 8
Repairing Cracks........................................... 10A5-6 A dhesive-R etained Moldings, Appliques, and
W elding...........................................................10A5-7 Em blem R ep la ce m e n t..................................... 1 0 A 6 -1 8
On-Vehicle S ervice..........................................10A5-7 F en d er Protectors............................................... 1 0 A 6 -2 0
Front Air Deflector Replacement.................10A5-7 Stripe and D ecal R ep la ce m e n t..................... 10A6-21
Front Bumper Replacement......................... 10A5-7 Anti-Corrosion T re a tm e n t................................ 10 A 6 -2 3
Front Bumper Filler Center Panel S h e et M etal R e p a ir........................................... 1 0A 6-2 3
Replacement................................................ 10A5-8 Dinging and F in is h in g ...................................... 1 0 A 6 -2 3
Front Bumper Filler Side Panel Anti-Chip Coating R ep lacem en t....................1 0 A 6 -2 4
Replacement................................................ 10A5-8
P a in t............................................................................. 1 0 A 6-2 4 Endgate Window Striker

Paint C o d e s .......................................................... 1 0 A 6-2 4 Replacement................................................ 10A7-7
S p e c ific a tio n s ......................................................... 1 0A 6-25 Endgate Window Hinge
F astener Tightening S p ecifications............. 1 0A 6-25 Replacement................................................ 10A7-7
S p e c ia l T o o ls .......................................................... 1 0 A 6-2 5 Endgate Window Support
E n d g a t e .......................................................................... 10A7-1 Replacement................................................ 10A7-7
O n -V e h ic le S e rv ic e (P ic k u p M o d e ls ) ............ 10A7-1 S p e c ific a tio n s ...................................................10A7-8
Endgate R e p la c e m e n t......................................... 10A7-1 Fastener Tightening Specifications............. 10A7-8
Endgate Latch O perating H andle Cab and Body Maintenance....................... 10B-1
R e p la c e m e n t......................................................... 10A7-1 O n-V ehicle S e rv ic e ............................................ 10B-1
Endgate Latch and Rod R e p la c e m e n t........ 10A 7-2 Cleaning Agents.............................................. 10B-1
Striker and Striker Bolt R e p la c e m e n t...........10A 7-2 Interior Cleaning.............................................. 10B-1
Side Panel Low er H inge R e p la c e m e n t...... 10A 7-2 Basic Steps Before Cleaning..................... 10B-1
Endgate Hinge R e p la c e m e n t........................... 10A 7-2 General Cleaning of Fabric Trim................10B-1
O n -V e h ic le S e rv ic e (U tility M o d e ls )............ 1 0 A 7-2 3 Spot Cleaning Fabric Trim.......................... 10B-1
E ndgate R ep la c e m e n t.........................................10A 7-3 Removal of Specific Stains........................ 10B-2
Torque Rod R e p la c e m e n t................................. 10A 7-3 Cleaning Vinyl T rim .....................................10B-2
Trim Panel R ep la ce m e n t....................................10A 7-4 Seat Belt Care............................................. 10B-2
Endgate Latch O perating H andle Glass Surfaces................................... 10B-2
R e p la c e m e n t......................................................... 10A 7-4 Exterior Cleaning............................................. 10B-2
Endgate Latch Assem bly R eplacem ent Washing and Waxing...................................10B-2
(Right or L eft)........................................................10A 7-5 Foreign Material Deposits.......................... 10B-2
Endgate Latch Striker A d ju stm e nt................. 10A 7-5 Cleaning Bright Metal Parts....................... 10B-2
Lift Glass Latch R e p la c e m e n t..........................10A 7-5 Weatherstrip Lubrication............................. 10B-2
Endgate W indow Molding Water Leaks.................................................... 10B-2
R e p la c e m e n t......................................................... 10A 7-6 Corrective Measures....................................10B-3
Endgate W indow W eatherstrip Dust Leaks.......................................................10B-3
R e p la c e m e n t......................................................... 10A 7-6
Endgate Belt W eatherstrip
R e p la c e m e n t.........................................................1 0 A 7 -6
BLANK
DOORS 10A1-1
SECTION 10A1
DOORS
GENERAL DESCRIPTION
DOORS N O TIC E :Refer to Engine Controls, Trans
mission Diagnosis, and Electrical Diagnosis
Doors on C /K model trucks use hinges that are weld
Manual for information pertaining to opera
ed to the door and body. No adjustment of this type of
tion, and diagnosis o f electrical components.
hinge is recommended. Replacem ent hinges bolt to the
door and body side pillar and are adjustable.
ON-VEHICLE SERVICE
FRONT DOORS
WINDOW REGULATOR HANDLE 2. W indow regulator handle (Figure 1).
A. Raise window.
REPLACEMENT B. Install the clip onto the handle.
Tool Required: C. Insert handle onto window regulator shaft so the
J 9886-01 Door Handle Rem over handle is pointing toward the front of the door.
D. Push on the handle until the clip engages win
Rem ove or D isconnect (Figure 1) dow regulator shaft.
1. W indow regulator handle from vehicle. POWER ACCESSORY SWITCH

A. Insert J 9886-01 between the handle and bear
ing plate (Figure 1). MOUNTING PANEL
B. Align the tool and push to disengage the clip REPLACEMENT
(Figure 1).
C. Pull the handle from door. 3 Rem ove or D isconnect (Figures 2 and 8)
2. Bearing plate (Figure 1).
44- Install o r C onnect (Figure 1) Caution in General Information.
2. Switch mounting panel (Figure 8).
1. Bearing plate to door (Figure 1). • Use a flat blade tool to carefully pry door acces
sory mounting panel from door trim panel.
Figure 1— W indow R egulator H andle and B earing Figure 2— Front Door Pow er A ccessory Switch
Plate M ounting Panel
10A1-2 DOORS
3. Power accessory electrical connectors from switch Install or Connect (Figure 3)
es and speaker (if applicable).
4. S w it c h e s fro m s w itc h m o u n tin g p a n e l (if 1. Handle bezel to door trim panel.
applicable). A. C onnect wiring connector (if equipped with
• Use a flat blade tool to carefully pry switches power locks).
from accessory mounting panel. B. Snap bezel into place.
5. S p e a k e r grill from sw itch m ounting p an e l (if
applicable). POWER DOOR LOCK SWITCH
• Carefully spread speaker grill retainers. REPLACEMENT
6. S peaker from switch mounting panel (if applicable).
• Rotate speaker counterclockwise. Rem ove or Disconnect (Figure 4)
++ Install or C onnect (Figures 2 and 8) 1. Pow er Accessory Switch Plate. R efer to Power
Accessory Switch Mounting Panel Replacem ent in
1. Speaker to switch mounting panel (if applicable). this section.
2. Power door lock switch wiring connector.
• Rotate speaker clockwise.
3. Power door lock switch.
2. S p e a k e r grill from sw itch m ounting p a n e l (if • C arefully bend retaining tabs outw ard while
applicable). pushing switch out of plate.
• Snap in place.
3. Switches to switch mounting panel. -►4- Install or Connect (Figure 4)
• Snap in place.
1. Power door lock switch.
4. Power accessory electrical connectors to switches 2. Power door lock switch wiring connector.
and speaker (if applicable). 3. Pow er Accessory Switch Plate. R efer to Power
5. Switch mounting panel (Figure 8). Accessory Switch Mounting Panel Replacem ent in
• Snap in place. this section.
TRIM PANEL UPPER EXTENSION
INSIDE HANDLE BEZEL REPLACEMENT
REPLACEMENT Tool Required:
J 3 87 7 8 Trim Panel Remover
” ►[ Rem ove or D isconnect (Figure 3)
Rem ove or Disconnect
1. Handle bezel from door trim panel.
A. Insert a flat blade tool between door inside 1. Trim panel from the door.
bezel and handle assembly. A. C a re fu lly pry th e re ta in e r from door using
B. C arefully bend retaining clips outward while J 38778.
pulling out bezel. R efer to arrows shown in B. Pull upward to re le a s e extension from trim
Figure 3. panel.
C. Disconnect wiring connector (if equipped with 2. Retainer from extension.
power locks).
Figure 3— Front D oor Inside Handle Bezel Figure 4— Pow er Door Lock Sw itch
DOORS 10A1-3
-► * Install or Connect 3. Trim panel to the door.
• Align retainers with holes in door.
1. Retainer to extension. • Carefully apply pressure to seat retainers.
2. Extension to door. 4. W indow regulator handle (if equipped). Refer to
A. Insert extension on to trim panel. W indow R egulator H andle R eplacem ent in this
B. Align retainer into hole in door. Push extension section.
until retainer seats. 5. P o w e r a c c e s s o ry s w itc h m o u n tin g p a n e l (if
equipped with power accessories).
TRIM PANEL REPLACEMENT 6. Trim panel armrest screw.
Tool Required:
Tighten
J 387 78 Trim Panel Remover
• Trim panel armrest screw to 2 N m (18 lb in).
• Insert screw cover.
7. Trim panel upper extension.
1. Door handle bezel. Refer to Inside Handle Bezel
8. Door handle bezel. Refer to Inside Handle Bezel
2. W indow regulator handle (if equipped). Refer to
W indow R egulator H andle R eplacem ent in this
section.
COURTESY LAMP
3. Power accessory switch mounting panel wiring con REPLACEMENT
nector (if equipped with power accessories). Refer Refer to the Engine Controls, Transmission Diagnosis,
to P o w e r A c c e s s o ry S w itc h M o u n tin g P a n e l and Electrical Diagnosis Manual for electrical diagnosis.
4. Trim panel upper extension. Refer to Trim Panel Rem ove or Disconnect
Upper Extension Replacement in this section.
5. Trim panel armrest screws. 1 . Trim panel. Refer to Trim Panel Replacem ent in
• Carefully pry off trim panel armrest screw cover this section.
with a flat blade tool to access screw. 2. Lamp from trim panel.
6. Trim panel from the door. • Disconnect wiring connector.
• Carefully pry the retainers from their seats using • Carefully release lamp assembly retainers with
J 38778. a flat-blade tool.
• D is c o n n e c t c o u r te s y lig h t c o n n e c to r (if
equipped). Install o r Connect
7. Courtesy lamp lens or reflector.
8. Retainers from trim panel (Figure 6). 1. Lamp to trim panel.
• Pull retainers from slot. • Snap lamp assem bly into trim panel.
• Connect wiring connector.
++ Install or Connect (Figures 5 and 6) 2. Trim panel. Refer to Trim Panel Replacem ent in
this section.
1. Retainers to trim panel (Figure 6).
• Push retainer from slot.
2. Courtesy lamp lens or reflector.
10A1-4 DOORS
TRIM PANEL MAP POCKET WATER DEFLECTOR
Tool Required: W aterproof deflectors are used to seal the inner panel
J 38778 Trim Panel Remover and prevent water from entering into the body. The
deflector is secured by a strip of adhesive between the
Rem ove or D isconnect (Figure 7) deflector and door.
1 . Trim panel. Refer to Trim Panel Replacem ent in Rem ove o r Disconnect (Figure 9)
this section.
2. M ap pocket from trim panel. 1. Trim panel. Refer to Trim Panel Replacem ent in
• Pry the retainers from their seats using J 38778. this section.
2. W ater deflector.
+ 4- Install or C onnect (Figure 7) A. Pull th e w a te rp ro o f s e a lin g ta p e from th e
deflector.
1. M ap pocket to trim panel. B. Break the bond between the sealer and the
• Snap retainers into seats. door with a flat-blade tool.
1. W ater deflector to the door.

• Use waterproof tape or 3 M ® 7 7 7 adhesive.
2. Trim panel to the door.
WIRING HARNESS
REPLACEMENT
Rem ove or Disconnect (Figures 10 and 11)
1. Cowl kick panel.

2. Cross body wiring harness.
3. Conduit.
4. Trim panel. Refer to Trim Panel Replacem ent in
this section.
5. W ater deflector. Refer to Inner Panel W ater Deflec
tor Replacem ent in this section.
6. Power mirror connector if equipped.
7. Keyless entry connector if equipped.
8. Power door lock actuator connector if equipped.
9. Power window motor wiring connector if equipped.
10. Courtesy lamp harness retainers if equipped.
11. Speaker.
12. S peaker wiring harness connector if equipped.
13. Door wiring harness from door.
Figure 8— Accessory Sw itch Plate Mounting Figure 9— Front Door Inner Panel W ater D eflectors
DOORS 10A1-5
■M - Install or Connect (Figures 10 and 11)
1. Door wiring harness to door.

2. Speaker wiring harness connector if equipped.
3. Speaker.
4. Courtesy lamp harness retainers if equipped.
5. Power window motor wiring connector if equipped.
6. Power Door lock actuator connector into latch if
equipped.
7. Keyless entry connector if equipped.
8. Power mirror connector if equipped.
9. W ater deflector. Refer to Inner Panel W ater Deflec
tor Replacement in this section.
10. Trim panel. Refer to Trim Panel Replacem ent in
this section.
11. Conduit.
12. Cross body wiring harness.
13. Cowl kick panel.
DOOR REPLACEMENT
Figure 10— Front Door C ross Body W iring Harness Tools Required:
and Conduit J 366 04 Door Hinge Spring Compressor
Legend
(1) Power Rearview Mirror Connector (7) Power Door Lock Switch Connector
(2) Keyless Entry Wiring Connector (8) Power W indow Switch Connector
(3) Tweeter Connector (9) Power Mirror Switch Connector
(4) P o w er R e a r W in d o w Lock O u t S w itch W irin g (10) Power W indow Motor Connector
Connector (11) Speaker Connector
(5) Power Door Lock Wiring Connector
(6) Courtesy Light Wiring Connector
Figure 11— Front Door W iring H arness C onnectors
10A1-6 DOORS

2. Cowl side vent cover.
3. W ire harness connectors under the instrum ent
panel.
A. Receptacles from the wire harness.
B. Retainer from the wire harness grommet.
C. Rubber conduit from the door pillar by pushing it
from the vent cover side.
4. Door hinge spring using J 3 66 0 4 (Figure 12).
• Insert the blades of the tool between the spring
coils and turn the barrel nut to compress and
hold the spring during removal.
5. Lower hinge pin retainer (Figure 13).
6. Lower hinge pin using a soft-faced ham m er and a

pair of locking pliers to grasp the pin and drive it
out (Figure 13).
• Install a bolt through the lower hinges tem po
rarily to hold the door in place while removing
the upper hinge pin.
7. Upper hinge pin retainer (Figure 12).
8. Upper hinge pin (Figure 12).
9. Bolt in lower hinge pin hole.
10. Door from the vehicle.
-M - Install or C onnect (Figures 12 through 14)
1. Door to the vehicle.

2. Bolt temporarily through the lower hinge pin holes.
3. U p p e r h in g e p in w ith th e p o in te d e n d up
(Figure 12).
4. N ew hinge pin retainer (Figure 12).
• Rem ove temporary bolt from the lower hinge.
5. Low er hinge pin with th e pointed e d g e down
(Figure 13).
6. N ew hinge pin retainer (Figure 13).
7. Door hinge spring using J 3 66 0 4 (Figure 12).
8. Harness connectors.
A. Rubber conduit through the body pillar.
B. Retainer around the wire harness grommet.
C. Receptacles to the harness under the instru
ment panel.
9. Cowl side vent cover.
11. Lubricate bushing with engine oil.
DOOR HINGE REPLACEMENT

1. Door from body. Refer to Door Replacem ent in this

section.
2. Excess sealer surrounding hinge.
Legend 3. Door hinges.
A. Scribe the location of the existing hinges on the
(1) Spring
body pillar and door.
(2) Hinge Pin
Figure 13— Upper Hinge Pin and Spring
DOORS 10A1-7
B. Center punch each of the weld marks on the
original hinge (Figure 15). It is critical to punch
the center of the weld so that all of the weld is
removed during drilling.
C. Drill a 3 mm (1/8 inch) pilot hole through the
welds deep enough to penetrate the hinge base
only (Figure 16).
D. Drill a 13 mm (1/2 inch) hole through the hinge
base only using the smaller hole as a pilot
(Figure 16).
E. Drive a chisel between the hinge and door pillar
(Figure 17).
Left Hinge Replacem ent:
1. Sill plate. Refer to Sill Plate Replacement in Interior
Trim.
2. Kick pad by lifting from the retainers.
3. Parking brake assembly. Refer to Parking Brake
Lever in Parking Brake.
• Carefully pry away the cowl side panel insulator
over the lower access hole and set aside to
reuse.
R ight Hinge Replacem ent:
1. Sill plate. Refer to Sill Plate Replacement in Interior
Trim.
2. Kick pad by lifting from the retainers.
3. Storage compartment. Refer to Storage Compart
ment Replacement in Instrument Panel and
Gauges.
• Carefully pry the cowl side panel insulator away
from the lower access hole and set aside to
reuse.
-► * Install or C onnect (Figures 18 through 20)
1. Hinges to pillar or door.

A. Position the bolt-on service replacement hinges
within the scribe marks made on the body hinge
pillar and the door at the time of removal.
B. Center punch each bolt hole location on the
body hinge pillar and/or door.
Figure 17—Chiseling Welded-On Hinge Figure 18—Replacement Hinges (Body Side)

10A1-8 DOORS
C. Drill a 13 mm (1/2 inch) hinge attaching hole in 2. Parking brake assembly. Refer to Paking Brake
three steps to ensure placing the hinge in the Lever in Parking Brake.
proper position. 3. Kick pad and sill plate.
2. Prepare the surface for the replacement hinges
Right Side:
using a file or equivalent.
• Coat the mating surface of the hinges with a 1. Cowl side panel insulator over the lower access
medium bodied sealer. hole.
3. Hinges, backing plate, bolts, and nuts. 2. Glove compartment.
A. Align the hinge and backing plate with the holes 3. Kick pad and sill plate.
in the hinge pillar and door. 4. Door to the cab. Refer to Door Replacement in this
B. Place the bolts through the hinge, pillar and/or section.
door, and through the backing plate. 5. Door module panel. Refer to Door Module Replace
C. Apply sealer around hinges. ment in this section.
6. Trim panel. Refer to Trim Panel Replacement in
Tighten this section.
• Nuts to 35 N.m (26 lb ft). Adjust
Left Side: • Refer to Door Adjustment in this section.

1. Cowl side panel insulator over the lower access
hole. DOOR STRIKER BOLT
REPLACEMENT
The door striker bolts are special bolts and a washer
mounted on the door opening’s rear pillar. The bolts
pass through a hole into a threaded plate behind the
pillar. The cab door is secured in position when the lock
cam (arm) of the locking mechanism engages and
snaps around the striker bolt.
The striker bolt position is not adjustable.
Tool Required:
J 29843-9 Torx Bit (Bit Size T47)
R Rem ove o r D isconnect (Figure 21)
1. Mark the position of the striker bolt spacer on the

door pillar.
2. Striker bolts using J 29843-9 or equivalent.
1. Striker bolts into the door pillar retaining plate.

2. Align the striker bolt spacer with the previously
made mark.
Figure 19— R eplacem ent Hjnges (D oor Side)
Q Tighten
• Striker bolt'while holding spacer in position to

63 N.m (46 lb ft) using J 29843-9 or equivalent.
DOOR ADJUSTMENT
This procedure can only be used when bolt-on service
replacement hinges are installed.
Tool Required:
J 29843-9 Torx Bit (Bit Size T47) or equivalent
• Door striker bolt using J 29843-9 or equivalent

(Figure 21).
• Loosen the door hinge to the body side pillar bolts.
Figure 20—Sealer Application

DOORS 10A1-9
Adjust (Figures 21 and 22) Adjust
1. Door up or down, forward or rearward, and in or • Bolt to properly engage the door lock.
out at the door hinges.
2. Gap between the rocker panel and the door to Tighten
the specifications shown in Figure 22.
3. Gap between the door and the roof panel. . Bolt to 63 N-m (46 lb ft).
4. Gap between the rear of the door and the rear
pillar. DOOR HARDWARE
5. Gap between the door and the fender. LUBRICATION
6. D oor s u rfa c e s flu s h w ith o th e r p a n e ls The mechanical components of the door assembly
within ±1 .0 mm (0.04 inch). are lubricated during assembly. If additional lubrication
is required to any door hardware mechanism, use Lubri-
Tighten plate Spray-Lube A GM P/N 1052349, Lubriplate
Auto-Lube A GM P/N 1052196, or equivalent. Lubricate
• Hinge bolts to 35 N-m (26 lb ft). door hinge pins and rollers at normal service intervals
with 30 weight engine oil. Do not lubricate hinge roller
Install or Connect to hold-open link contacting surfaces. This may prevent
the roller from rolling properly.
• Door striker bolt.
INSIDE DOOR HANDLE
Tool Required:
J 34940 Rivet Gun
|<—►[ Remove or Disconnect (Figure 23)
1 . Trim panel. Refer to Trim Panel Replacement in

this section.
2. Water deflector. Refer to Inner Panel Water Deflec
3. Inside door handle assembly.
• Drill out the rivet head using a 5-mm (3/16-inch)
drill bit.
• Slide door Handle forward.
4. Control rods from the handle and lock lever.
1. Control rods to handle and lock lever.

2. Inside door handle.
• Insert handle assembly into slot and slide
Figure 21— Door Striker assembly to the rear.
• Handle rivet using J 34940.
Figure 22— Door Adjustm ent Specifications Figure 23— Front Door Inner Handle Assem bly
10A1-10 DOORS
3. Water deflector. 7. In n e r m o u n tin g pan e l fro m w in d o w sash
4. Trim Panel. (Figure 25).
• Slide inner mounting panel rearward to release
INNER MOUNTING PANEL regulator roller from window sash.
ASSEMBLY -►* Install or Connect (Figures 24 and 25)
■+] Remove or Disconnect (Figures 24 and 25) 1. Inner mounting panel to window sash (Figure 25).
• Slide inner mounting panel forward to release
• Lower Window regulator roller from window sash.
1 . Trim panel. Refer to Trim Panel Replacement in 2. Wiring harness.
this section. 3. Lock rods to lock handle, lock lever, and lock rod
2. Water deflector. Refer to Inner Panel Water Deflec guides (Figure 24).
tor Replacement in this section. 4. Inner panel bolts (Figure 24).
3. Speaker (if equipped) 5. Speaker (if equipped).
• Carefully pry out retainer clips. 6. Trim panel. Refer to Trim Panel Replacement in
4. Inner panel bolts (Figure 24). this section.
5. Lock rods from lock handle, lock lever, and lock rod • Carefully pry out retainer clips.
guides (Figure 25). 7. Water deflector. Refer to Inner Panel Water Deflec
6. Wiring harness. tor Replacement in this section.
LOCK ASSEMBLY

this section.
3. Inner mounting panel assembly. Refer to Inner
Mounting Panel Replacement in this section.
4. Inside door handle and lo ck c o n tro l rods
(Figure 26).
5. Lock assembly bolts.
6. O utside door handle and lock control rods
(Figure 27).
• Replace plastic retainers following disassembly.
Figure 24— Front Door Inner Mounting Panel

Assem bly
Figure 26— Inside Door Handle and Lock Control

Figure 25—Inner Mounting Panel and Window Sash Rods
DOORS 10A1-11
0 Install or Connect (Figures 26 and 27) 3. W hile holding the shutter door open, inject a small
amount of lubricant (refer to above recommenda
1. Pull outside handle out of door opening and slide tions) into cylinder.
latch outside door connector onto outside handle 4. W ork the key into the cylinder several times and
rod. Twist latch into door assembly and retain with wipe any excess lubrication residue from key.
three screws (Figure 27).
2. Inside handle (top) rod and inside lock (bottom) rod DOOR LOCK CYLINDER AND
to latch. (Figure 26) OUTSIDE HANDLE
3. Insert key in lock cylinder and adjust rod up and
down by turning key through opening. REPLACEMENT
4. Lock rod to latch through opening in front side door N ew lock cylinders are available as replacem ent
below latch. parts. If door lock cylinders require replacement for any
5. Inner mounting panel assembly. Refer to Inner reason, apply a coating of G M P/N 1 2345120 or equiva
Mounting Panel Replacement in this section. lent lubricant inside of the lock case and cylinder key
6. Water deflector. Refer to Inner Panel Water Deflec w ay prior to assembling and installing the cylinder.
tor Replacement in this section. To repair a binding lock cylinder, refer to Binding Lock
7. Trim panel. Refer to Trim Panel Replacement in Cylinders in this section. To code a new lock cylinder,
this section. refer to Lock Cylinder Coding in General Information.
BINDING LOCK CYLINDERS W -H Remove or Disconnect (Figures 27 and 28)

Binding or sticking door lock cylinders and keys that
1 . Trim panel. Refer to Trim Panel Replacem ent in
are hard to insert or remove may be corrected in many
this section.
cases by applying the proper lubrication.
The recommended materials for lubricating these 2. W ater deflector. Refer to Inner Panel W ater Deflec
components are (in order of preference): tor Replacem ent in this section.
• Lubricant GM P/N 12345120 (or equivalent). 3. Inner mounting panel assem bly. R efer to Inner
• 5 W 30 motor oil. Mounting Panel Replacem ent in this section.
• Silicone spray GM P/N 1052276 (or equivalent). 4. Outside handle rod from the rod clip (Figures 27
Penetrating lubricants (such as GM P/N 1052949 and and 28).
WD-40®) are NOT recommended because they wash 5. Lock cylinder rod from the rod clip (Figures 27
out the original lubrication and eventually evaporate, and 28).
leaving little or no lubricating material. However, if these 6 . Outside handle mounting screws (Figure 28).
materials are used to unfreeze or loosen lock cylinder 7. Door lock cylinder from the outside handle housing
components, refer to Steps 2 through 4 below for proper (Figure 28).
methods of lubrication. 8 . Handle (Figure 28).
Frozen lock cylinders due to cold weather may be +4- Install or Connect (Figures 27 and 28)
repaired using the following procedure:
1. Apply heat to cylinder with a heat gun while being 1. Handle to the vehicle (Figure 28).
careful not to damage the painted surfaces. 2. Door lock cylinder to the outside handle housing
2. Hold the door shutter open with a paper clip (or (Figure 28).
similar item) and force air into cylinders using com 3. L o c k c y lin d e r rod to th e lo c k c y lin d e r c lip
pressed air and a blow gun attachment. (Figures 27 and 28).
4. Handle rod to the handle assembly clip (Figures 27
and 28).
3110S 1380
Figure 27— Outside Door Handle and Lock

Assem bly Figure 28—Outside Door Handle Assembly
10A1-12 DOORS

this section.
4. Rivets securing the regulator to the door inner pan
el.
• Drill out front and rear rivets.
5. Regulator from inner panel.
1. Regulator to inner panel.

2. Rivets securing the regulator to the door inner pan
el using J 34940.
Figure 29— Outside Door Handle Assem bly 4. Water deflector. Refer to Inner Panel Water Deflec
(3500HD) tor Replacement in this section.
5. Outside handle mounting bolts. this section.
Tighten WINDOW REPLACEMENT

• Bolts to 4 N-m (35 lb in).
3 Remove or Disconnect (Figures 24, 31 through
Mounting Panel Replacement in this section. 33)

tor Replacement in this section. • Lower window.
8. Trim panel. Refer to Trim Panel Replacement in 1 . Trim panel. Refer to Trim Panel Replacement in
this section. this section.
WINDOW REGULATOR tor Replacement in this section.
REPLACEMENT AND MOTOR Mounting Panel Replacement in this section.
REPLACEMENT 4. Window front channel top screw.
5. Slide window out of glass channels from the bottom
The power window motor can not be serviced. It is
of door.
replaced as a unit with the regulator.
Tool Required:
J 34940 Rivet Gun
Figure 31— Front Door Inner Panel to W indow

Figure 30— Front Door W indow Regulator Assembly Glass Assem bly
DOORS 10A1-13
+4- Install or Connect (Figures 24, 31 through 33)
1. Slide window into glass channels through the bot

tom of door.
2. Window front channel top bolt. Do not tighten bolt.
3. Inner mounting panel.
A. Slide regulator rollers into glass channel.
B. Align inner panel lower front corner bolt with
hole in front glass channel assembly.
C. Tighten front channel top bolt.
D. Tighten all inner panel bolts.
Tighten
• Run channel and inner panel bolts to 2 N.m

(18 lb in).
this section. Figure 32— Front Door W indow Glass Run Channel
Assembly
WINDOW GLASS
WEATHERSTRIP REPLACEMENT
1. Window. Refer to Window Replacement in this

section.
2. Weatherstrip.
• Pull weatherstrip from front of glass run chan
nel, top of window frame flange, rear of glass
run channel.
1. Weatherstrip.
run channel.
section.
Figure 33— Front Door W indow W eatherstrip
FRONT GLASS RUN CHANNEL Assembly
REPLACEMENT
OUTSIDE REARVIEW MIRROR
Remove or Disconnect (Figure 32) REPLACEMENT
1. Window. Refer to Window Replacement in this Remove or Disconnect (Figure 34 and 35)
section.
2. Window glass weatherstrip. Refer to Window Glass
1 . Trim panel upper extension. Refer to Trim Panel
Weatherstrip Replacement in this section.
Upper Extension Replacement in this section.
3. Front glass run channel top bolt.
2. Access hole plugs.
4. Front glass run channel from door.
3. Nuts securing the outside rearview mirror to the
-►4-
door.
4. Outside rearview mirror from the door.
5. Electrical connector (if equipped).
1. Rear glass run channel to door.
2. Window front channel top bolt. Do not tighten bolt. -►4- Install or Connect (Figure 34 and 35)
1. Electrical connector (if equipped).
2. Outside rearview mirror to the door.
section.
10A1-14 DOORS
3. Nuts securing the outside rearview mirror to the center of the back. Pull mirror back straight out
door. of the housing with enough force to disengage
the trunnion from the motor pack.
Tighten
Inspect
• Outside rearview mirror nuts to 6 N.m (53 lb in).
4. Access hole plugs. • Motor pack top for damage to the trunnion
5. Trim panel upper extension. Refer to Trim Panel area.
Upper Extension Replacement in this section. 2. Remaining jack screws which may have remained
in the motor pack helical gear openings.
OUTSIDE REARVIEW MIRROR
Clean
LENS REPLACEMENT
• Glass from inside the mirror frame.
Install or Connect
1. Mirror from the door. Refer to Outside Rearview
Mirror Replacement in this section. • Remove the replacement mirror back and glass
A. Damaged mirror back and glass sub-assembly sub-assembly and inspect for visual damage.
from mirror housing by inserting fingers as far Insure mirror back and glass sub-assembly has
as possible behind the mirror back toward the a trunnion bar and 2 jack screws.
1. Align mirror back jack screws with helical gear
openings. Gently press the mirror back toward the
motor pack to put slight pressure on the jack
screws at helical gear openings. On a LH mirror,
electrically actuate the mirror to travel downward.
This will pull the up/down jack screw into the motor
pack. Discontinue activation when the length of the
jack screw is 50% inserted. Actuate the mirror to
travel left. This will pull the left/right jack screw into
the motor pack. Continue activation until 50% of
the length of the jack screw is inserted.
• NOTE: On a RH mirror, electrically actuate
down and right.
2. After successful insertion of jack screws into the
motor pack; visually look over the top of the mirror
back into the mirror housing. Manipulate the mirror
back to align the mirror back trunnion into the
motor pack trunnion receptor area.
Important
Figure 34— Outside Rearview Mirror • Proper alignment of trunnion during this step
will prevent damage to this area.
3. After proper alignment, place the palm of your hand
on the center of the glass and firmly press the
glass toward the motor pack to achieve proper
insertion (insertion is achieved when mirror back
trunnion is nested in the motor pack trunnion area).
9 Important
• Do not strike the glass, but uniformly apply

increasing pressure.
4. To test for completion, press the glass to manually
move in each direction. The mirror back should
stay firmly attached to the motor pack. Electrically
actuate the mirror to insure proper operation.
5. Mirror to door.
Figure 35—Outside Rearview Mirror

DOORS 10A1-15
Figure 36— Outside Vent Valve Assembly Figure 37— Inside Module Valve Assem bly
PRESSURE RELIEF VALVE Inside Module Valve Assem bly
Pressure relief valves are located in the front doors of Remove or Disconnect (Figure 37)
pickup models and behind the quarter panel stationary
glass on utility and suburban models. 1. Door trim panel. Refer to Door Trim Panel Replace
Outside Vent Valve Assem bly ment in this section.
2. Valve by drilling out the rivets.
■M- Install or Connect (Figure 37)
1. Screw retaining the assembly to the door.
2. Valve assembly by lifting it up. 1. Valve assembly to the door by riveting.
2. Door trim panel. Refer to Door Trim Panel Replace
-►4- Install or Connect (Figure 36) ment in this section.
1. Valve assembly to the door edge.
REAR SEAT ACCESS DOOR (EXTENDED

CAB)—ON-VEHICLE SERVICE
TRIM PANEL REPLACEMENT
Tool Required:
J 38778 Trim Panel Remover
1. Trim panel armrest screws (Figure 38).

2. Seat belt retractor cover.
3. Seat belt retaining D ring.
4. Trim panel from the door (Figure 39).
• Carefully pry the retainers from their seats using
J 38778.
5. Retainers from trim panel.
• Pull retainers from slot.
>4- Install or Connect (Figures 38 and 39)
1. Retainers to trim panel (Figure 39).

• Push retainer from slot.
A. Align retainers with holes in door.
B. Carefully apply pressure to seat retainers.
10A1-16 DOORS
Figure 39— Rear Seat Access Door Trim Panel Figure 40— Rear Seat Access Door Hinges
3. Seat belt retaining D ring. DOOR HINGE REPLACEMENT

4. Seat belt retractor cover.
5. Trim panel armrest screws (Figure 38).
Tighten
1. Door from body. Refer to Door Replacement in this
• Trim panel armrest screws to 5 N.m (44 lb in). section.
3. Door hinges.
DOOR REPLACEMENT• A. Scribe the location of the existing hinges on the
original hinge (Figure 38). It is critical to punch
• Apply cloth backed tape to the door and the body the center of the weld so that all of the weld is
pillar.
removed during drilling.
1. Lower hinge pin retainer.
2. Lower hinge pin using a soft-faced hammer and a welds deep enough to penetrate the hinge base
pair of locking pliers to grasp the pin and drive it
only (Figure 42).
out. D. Drill a 13 mm (1/2 inch) hole through the hinge
• Install a bolt through the lower hinges tempo
base only using the smaller hole as a pilot
rarily to hold the door in place while removing
(Figure 42).
the upper hinge pin.
E. Drive a chisel between the hinge and door
3. Upper hinge pin retainer.
pillar.
4. Upper hinge pin.
5. Bolt in lower hinge pin hole. -►4- Install or Connect (Figures 41 and 42)
6. Door from the vehicle.
1. Bolt-on hinges to pillar or door.
install or Connect (Figure 40)
2. Bolt temporarily through the lower hinge pin holes.
3. Upper hinge pin with the pointed end up.
body hinge pillar and/or door.
4. New hinge pin retainer.
C. Drill a 13 mm (1/2 inch) hinge attaching hole in
• Remove temporary bolt from the lower hinge.
three steps to ensure placing the hinge in the
5. Lower hinge pin with the pointed edge down.
proper position.
7. Lubricate bushing with engine oil.
• Coat the mating surface of the hinges with a
medium bodied sealer.
DOORS 10A1-17
DOOR ADJUSTMENT
This procedure can only be used when bolt-on service
replacement hinges are installed.
Adjust
1. Door up or down, forward or rearward, and in or

2. Gap between the rocker panel and the door.
3. Gap between the door and the roof panel.
pillar.
5. Door surfaces flush with other panels within ±
1.0 mm (0.04 inch).
Tighten
• Hinge bolts to 35 N-m (26 lb ft).
Adjust
• Lock mechanism to strikers.
DOOR HARDWARE
LUBRICATION
The mechanical components of the door assembly
are lubricated during assembly. If additional lubrication
plate Spray-Lube A GM P/N 1052349, Lubriplate
door hinge pins and rollers at normal service inteivals
with 30 weight engine oil. Do not lubricate hinge roller
to hold-open link contacting surfaces. This may prevent
the roller from rolling properly.
DOOR STRIKERS
Upper
1. Latch striker cover (Figure 43).

3. Hinges, backing plate, bolts, and nuts. 2. Striker assembly bolts (Figure 44).
A. Align the hinge and backing plate with the holes
in the hinge pillar and door. Install or Connect (Figures 43 and 44)
B. Place the bolts through the hinge, pillar and/or
door, and through the backing plate. 1. Striker assembly bolts (Figure 44).
2. Latch striker cover (Figure 43).
Tighten
Adjust
• Nuts to 35 N-m (26 lb ft).
4. Door to body. Refer to Door Replacement in this Striker assembly alignment.
section.
Tighten
0 Adiust
• Bolts to 28 N-m (21 lb ft).
• Refer to Door Adjustment in this section.
5. Apply sealer around hinges.
10A1-18 DOORS
DOOR LATCHES
Upper
1. Latch assembly bolts.
■ ► 4- Install or Connect (Figure 46)
1. Latch assembly bolts.

• Hand start front before rear to engage the net
hole locator.
m Adjust
Latch assembly alignment.
Tighten
Lower Lower
0 Rem ove or Disconnect (Figure 45) 0 Remove or Disconnect (Figure 47)
1. Mark location of assembly before removal. 1. Latch assembly bolts.

2. Striker assembly bolts. • Note: If striker has not been removed, use as
alignment guide. If striker has been removed,
"► 4- Install or Connect (Figure 45) mark location.
1. Striker assembly bolts. +4- Install or Connect (Figure 47)
0 AdiU8t 1. Latch assembly bolts.
• Striker assembly alignment. Adjust
Tighten Latch assembly alignment.
• Bolts to 10 N-m (89 lb in).• ^X Tighten

DOORS 10A1-19
CHECK STRAP DOOR HANDLE AND LINKAGE

Remove or Disconnect (Figure 48) Remove or Disconnect (Figures 49 and 50)
1. Check strap bolts. Upper Linkage

• Door in full open position.
1. Rod from handle assembly (Figure 49).
• Remove body side first, then door side.
2. Upper rod retainer (Figure 50).
• Pull from inside door to remove.
3. Upper latch assembly.
+«- • Rod slides out with latch through upper access
hole.
1. Align installation tab. Install or Connect (Figures 49 and 50)
• Install door side first.
2. Check strap bolts.
1. Upper latch assembly.
2. Upper rod retainer (Figure 49).
Tighten
3. Rod to handle assembly (Figure 50).
• Bolts to 10 N-m (89 lb in).
10A1-20 DOORS
■M- install or Connect (Figures 49 and 50)
1. Rod to lower latch assembly (Figure 49).

2. Rod to handle assembly (Figure 50).
Adjust
• Lower latch assembly.

• Linkage as required.
Door Handle
Tool Required:
J 34940 Rivet Gun
1. Rivets.
2. Control linkage.
1. Control linkage.
Adjust 2. Rivets.
• Upper latch assembly. Adjust

• Linkage as required.
Linkage as required.
Lower Linkage
1. Rod from handle assembly (Figure 40).

2. Rod from lower latch assembly (Figure 50).
DOORS 10A1-21
REAR SIDE DOORS (CREW CAB, UTILITY, AND

SUBURBAN)—ON VEHICLE SERVICE
ASHTRAY ASSEMBLY WINDOW REGULATOR HANDLE
Tool Required:
J 9886-01 Door Handle Remover
1. Ashtray
• Grasp the inside of ashtray and pull out. E3 Remove or Disconnect (Figures 53 and 54)
Install or Connect
1. Window regulator handle from vehicle.
1. Ashtray. A. Insert J 9886-01 between the handle and bear
• Push ashtray into hole in trim panel. ing plate.
B. Align the tool and push to disengage the clip.
C. Pull the handle from door.
2. Bearing plate (Figure 53).
+◄- Install or Connect (Figures 53 and 54)
1. Bearing plate to door (Figure 53).

2. Window regulator handle.
A. Raise window.
B. Install the clip onto the handle.
C. Insert handle onto window regulator shaft so the
handle is pointing toward the front of the door.
D. Push on the handle until the clip engages win
dow regulator shaft.
INSIDE HANDLE BEZEL
REPLACEMENT
Remove or Disconnect (Figure 55}
1. Handle bezel from door trim panel.

Figure 52— Rear Door Ashtray Assembly
• Insert a flat blade tool between door inside
bezel and handle assembly.
Legend
(1) Window Regulator Handle
Figure 53— W indow Regulator handle Retaining Clip Figure 54— W indow Regulator Handle and Bearing
Removal Plate
10A1-22 DOORS
Figure 55— Rear Door Inside Handle Bezel Figure 56— Rear Door Power W indow Switch
• Carefully bend retaining clips outward while

pulling out bezel. Refer to arrows shown in.
1. Handle bezel to door trim panel.

• Snap bezel into place.
POWER WINDOW SWITCH
REPLACEMENT

2. Switch mounting panel.
• Use a flat blade tool to carefully pry door power
window switch from door trim panel.
3. Power accessory electrical connectors from switch.
Figure 57— Front Door Trim Panel Courtesy Lamp
1. Power accessory electrical connectors to switch.
2. Switch to door trim panel. Install or Connect (Figure 57)
• Snap in place. 1. Lamp to trim panel.

• Snap lamp assembly into trim panel.
COURTESY LAMP • Connect wiring connector.
REPLACEMENT• 2. Trim panel. Refer to Trim Panel Replacement in
this section.
• Refer to the Engine Controls, Transmission Diagno Tool Required:
sis and Electrical Diagnosis Manual for electrical J 38778 Trim Panel Remover
diagnosis.
1. Trim panel. Refer to Trim Panel Replacement in Remove or Disconnect (Figure 58)
this section.
2. Lamp from trim panel. 1. Door handle bezel. Refer to Inside Handle Bezel
• Disconnect wiring connector. Replacement in this section.
• Carefully release lamp assembly retainers with 2. Window regulator handle (if equipped). Refer to
a flat-blade tool. Window Regulator Handle Replacement in this
section.
DOORS 10A1-23
3. Speaker grill and speaker (if equipped). Refer to
Rear Door Speaker and Grille Replacement in
Audio Systems.
4. Trim panel armrest screws.
5. Trim panel from the door.
J 38778.
• Disconnect courtesy light connector (if
equipped).
• Disconnect power window switch (if equipped).
• Disconnect speaker wiring (if equipped).
7. Courtesy lamp lens. Refer to Courtesy Lamp
Replacement in this section.
8. Power window switch (if equipped). Refer to Power
Window Switch Replacement in this section.
9. Speaker and speaker grill (if equipped). Refer to
Speaker Grille and Speaker Replacement in Audio
Systems.
Figure 59— Rear Door Water Deflectors
-► 4- Install or Connect (Figure 58)
INNER PANEL WATER
1. Retainers to trim panel.
2. Power window switch (if equipped). Refer to Power DEFLECTOR REPLACEMENT
Window Switch Replacement in this section. Waterproof deflectors are used to seal the inner panel
3. Courtesy lamp lens or reflector to trim panel. and prevent water from entering into the body. The
4. Speaker and speaker grill (if equipped). deflector is secured with adhesive between the deflector
5. Trim panel to the door. and door.
• Connect speaker and power window switch con
nectors (if equipped). FI Remove or Disconnect (Figure 59)
• Connect courtesy lamp connector.
• Align retainers with holes in door. 1. Trim panel. Refer to Trim Panel Replacement in
• Carefully apply pressure to seat retainers. this section.
6. Window regulator handle (if equipped). Refer to 2. Water deflector.
Window Regulator Handle Replacement in this A. Break the bond between the sealer and the
section. door with a flat-blade tool.
7. Trim panel armrest screws. B. Pull off.
Tighten -► 4- Install or Connect (Figure 59)
• Trim panel armrest screws to 2 N-m (18 lb in). 1. Water deflector to the door.
8. Door handle bezel. Refer to Inside Handle Bezel • Use waterproof tape, 3M® 777 adhesive, or
Replacement in this section. equivalent if needed.
WIRING HARNESS
REPLACEMENT
1. B-pillar trim panel. Refer to Trim Panel Replace

ment in Interior Trim.
2. Disconnect body harness, conduit and power door
lock connector.
this section.
5. Courtesy lamp wiring retainers.
6. Power window motor wiring connector.
Figure 58— Rear Door Trim Panel

10A1-24 DOORS
-► 4- Install or Connect (Figure 60) ALL VEHICLES:
• Apply cloth backed tape to the door and the
1. Power window motor wiring connector. body pillar.
2. Courtesy lamp wiring retainers. 1. Lower hinge pin retainer (Figure 61).
3. Water deflector. Refer to Inner Panel Water Deflec 2. Lower hinge pin using a soft-faced hammer
tor Replacement in this section. and a pair of locking pliers to grasp the pin
4. Trim panel. Refer to Trim Panel Replacement in and drive it out.
this section. • Install a bolt through the lower hinges tempo
5. Connect body harness, conduit and lock actuator. rarily to hold the door in place while removing
6. B-pillar trim panel. the upper hinge pin.
3. Upper hinge pin retainer (Figure 61).
DOOR REPLACEMENT 4. Upper hinge pin.
5. Bolt in lower hinge pin hole.
3 Rem ove or Disconnect (Figures 60 and 61) 6. Door from the vehicle.
VEH IC LES W ITH POWER DOOR COMPONENTS:
Caution in General Information. ALL VEHICLES:
2. Wiring harness connectors inside B-pillar. 2. Bolt temporarily through the lower hinge pin holes.
A. Remove B-pillar trim panel. Refer to Pillar Trim 3. Upper hinge pin with the pointed end up.
Panel Replacement in Interior Trim. 4. New hinge pin retainer.
B. Disconnect wiring harness connectors. • Remove temporary bolt from the lower hinge.
C. Disconnect wire harness conduit.
Legend
(1) Body Wiring Harness (5) Courtesy Light Wiring Connector
(2) Rear Side Door Conduit (6) Speaker
(3) Power Window Switch Connector (7) Speaker Wiring Connector
(4) Power Door Lock Connector (8) Power Window Motor Wiring Connector
Figure 60—Rear Door Wiring Harness Connectors
DOORS 10A1-25
5. Lower hinge pin with the pointed edge down.

VEHICLES WITH POWER DOOR COMPONENTS:
1. Wire harness connectors inside B-pillar. 1 /
A. Route wire harness through conduit. N l
B. Connect wiring harness connectors.
C. Install B-pillar trim panel.
2. Negative battery cable. 1
I
3. Lubricate bushing with engine oil. £ / 2
r
DOOR HINGE REPLACEMENT
EH Remove or Disconnect (Figures 62 through 64)
6 i
1. Door from body. Refer to Door Replacement in this
section.
2. B-pillar trim panel. Refer to Pillar Trim Panel
3. Excess sealer surrounding hinge. I
4. Door hinges.
A. Scribe the location of the existing hinges on the Figure 63— Drilling out Spot W elds

original hinge. It is critical to punch the center of
the weld so that all of the weld is removed
during drilling.
welds deep enough to penetrate the hinge base
only.
D. Drill a 13 mm (1/2 inch) hole through the hinge
base only using the smaller hole as a pilot.
E. Drive a chisel between the hinge and door
pillar.
[■»*■] Install or Connect (Figures 62 through 64)
1. Bolt-on hinges to pillar or door.

body hinge pillar and/or door. Figure 64— Door And Body Hinges
10A1-26 DOORS
C. Drill a 13 mm (1/2 inch) hinge attaching hole in
three steps to ensure placing the hinge in the
proper position.
• Coat the mating surface of the hinges with a
medium bodied sealer. .
3. Hinges, backing plate, bolts, and nuts.
A. Align the hinge and backing plate with the holes
in the hinge pillar and door.
B. Place the bolts through the hinge, pillar and/or
door, and through the backing plate.
Tighten
. Nuts to 35 N-m (26 lb ft).

4. Door to body. Refer to Door Replacement in this
section.
5. B-pillar trim panel.
Adjust
• Refer to Door Adjustment in this section. install or Connect (Figure 65 and 66)
1. Striker bolts into the door pillar retaining plate.
DOOR STRIKER BOLT 2. Align the striker bolt spacer with the previously
REPLACEMENT made mark.
The door striker bolts are special bolts and a washer Tighten
mounted on the door opening’s rear pillar. The bolts
pass through a hole into a threaded plate behind the • Striker bolt while holding spacer in position to
pillar. The cab door is secured in position when the lock 63 N-m (46 lb ft) using J 29843-9 or equivalent.
cam (arm) of the locking mechanism engages and • Striker bolts while holding spacer in position to
snaps around the striker bolt. 28 N-m (21 lb ft) using J 29843-9 or equivalent.
The striker bolt position is not adjustable. (Utility Only)
Tool Required:
DOOR ADJUSTMENT
B Rem ove or Disconnect (Figure 65 and 66) Tool Required:
1. Mark the position of the striker bolt spacer on the This procedure can only be used when bolt-on service
door pillar. replacement hinges are installed.
2. Striker bolts using J 29843-9 or equivalent.
• Door striker bolt using J 29843-9 or equivalent.

Adjust (Figure 67)
1. Door up or down, forward or rearward, and in or

2. Gap between the rocker panel and the door.
3. Gap between the door and the roof panel.
pillar.
5. Gap between the door and the fender.
6. Door surfaces flush with other panels within ±
1.0 mm (0.04 inch).
Tighten
• Hinge bolts to 35 N-m (26 lb ft).
Figure 65— Door Striker

DOORS 10A1-27
Figure 68— Rear Door Inner Handle Assembly

Figure 67— Door Adjustment
1. Door striker bolt.
|^ l Adjust
• Bolt to properly engage the door lock.
Tighten
. Bolt to 28 N-m (21 lb ft).
DOOR HARDWARE
LUBRICATION
The mechanical components of the door assembly
are lubricated during assembly. If additional lubrication
plate Spray-Lube A GM P/N 1052349, Lubriplate
Figure 69— Rear Door Inner Handle Control Rods
door hinge pins and rollers at normal service intervals
with 30 weight engine oil. Do not lubricate hinge roller Install or Connect (Figures 68 and 69)
to hold-open link contacting surfaces. This may prevent
the roller from rolling properly. 1. Inside handle control rod from the handle and lock
lever assembly.
INSIDE DOOR HANDLE 2. Inside lock control rod from the handle and lock
ASSEMBLY REPLACEMENT lever assembly.
Tool Required: 3. Inside door handle.
J 34940 Rivet Gun • Insert handle assembly into slot and slide
assembly to the rear.
B Remove or Disconnect (Figures 68 and 69) • Handle rivets using J 34940.
4. Water deflector.
1 . Trim panel. Refer to Trim Panel Replacement in 5. Trim Panel.
this section.
2. Water deflector. Refer to Inner Panel Water Deflec INSIDE DOOR HANDLE
tor Replacement in this section. BRACKET REPLACEMENT
3. Inside door handle assembly (Figure 68). Tool Required:
• Drill out the rivet heads. J 34940 Rivet Gun
• Slide door handle forward.
4. Inside handle control rod from the handle and lock Remove or Disconnect (Figure 70)
lever assembly (Figure 69).
5. Inside lock control rod from the handle and lock 1. Inside door handle assembly. Refer to Inside Door
lever assembly (Figure 69). Handle Assembly Replacement in this section.
10A1-28 DOORS
3. Armrest bracket from door.
• Drill out rivets.
• Disconnect control rods from retainers.
4. Retainers and U-nuts from bracket.
1. Retainers and U-nuts to bracket.

2. Armrest bracket to door.
• Connect control rods from retainers.
• Bracket rivets using J 34940.
this section.
LOCK ASSEMBLY
Figure 70— Rear Door Inner Handle Assem bly
Bracket
2. Inside door handle bracket from door. this section.
• Drill out rivets. 2. Water deflector. Refer to Inner Panel Water Deflec
0 Install or Connect (Figure 70) 3. Inside door handle and lock co n tro l rods
(Figure 72).
1. Inside door handle bracket to door. 4. Outside door handle (Suburban, Crew Cab-thread
• Bracket rivets using J 34940. ed clip requires unsnap) (YukorvTahoe 4 door-push
2. Inside door handle assembly. Refer to Inside Door in clip) (Figure 73).
Handle Assembly Replacement in this section. 5. Power door lock connector.
7. Lock assembly from vehicle.
ARMREST BRACKET • Child security lock from lock assembly. (Utility
REPLACEMENT Only)
Tool Required:
J 34940 Rivet Gun Install or Connect (Figures 72 and 73)
0 Rem ove or Disconnect (Figure 71) 1. Lock assembly to vehicle.

• Child security lock to lock assembly. (Utility
1 . Trim panel. Refer to Trim Panel Replacement in Only)
this section. 2. Lock assembly bolts.
Figure 72— Inside Rear Side Door Handle and Lock

Figure 71— Armrest Bracket Control Rods
DOORS 10A1-29
Figure 73— Outside Rear Side Door Handle and Figure 74— Outside Handle
Lock Assem bly
3. Outside handle mounting bolts.
3. Power door lock connector.
4. Outside door handle (Suburban, Crew Cab-thread Tighten
ed clip requires snap) (Yukon/Tahoe 4 door-push in
clip) (Figure 72). • Bolts to 4 N.m (35 lb in).
5. Inside door handle and lock control rods (Figure 4. Water deflector. Refer to Inner Panel Water Deflec
72). tor Replacement in this section.
6. Water deflector. Refer to Inner Panel Water Deflec 5. Trim panel. Refer to Trim Panel Replacement in
tor Replacement in this section. this section.
this section. WINDOW REPLACEMENT
OUTSIDE HANDLE Remove or Disconnect (Figures 75 and 76)
REPLACEMENT
• Lower window.
New lock cylinders are available as replacement
parts. If door lock cylinders require replacement for any
this section.
reason, apply a coating of GM P/N 12345120 or equiva
lent lubricant inside of the lock case and cylinder key
way prior to assembling and installing the cylinder.
3. Window sash channel bolts.
R Remove or Disconnect (Figure 74)
4. Glass weatherstrip (Figure 76).
• Pull weatherstrip out of window frame and front
run channel.
this section.
4. Outside handle from door.
• Remove handle control rod from clip retainer.
1. Handle control rod to handle clip retainer.

2. Handle to the vehicle.
A. Hold handle assembly upside down.
B. Insert handle control rod into hole in lock.
C. Flip handle assembly right side up.
Figure 75— Rear Door Window S a sh Channel

10A1-30 DOORS
WINDOW FRONT GLASS RUN
CHANNEL

section.
3. Front glass run channel top bolt.
4. Front glass run channel from door.
1. Rear glass run channel to door.

2. Window front channel top bolt. Do not tighten bolt.
Figure 76— Rear Door W indow W eatherstrip 4. Window. Refer to Window Replacement in this
section.
5. Lift window out of the top of door.
1. Slide window into glass channels through the top of

door.
2. Glass weatherstrip (Figure 76).
3. Window sash channel bolts.
Tighten
• Window sash channel bolts to 2 N m (18 lb in).

this section.
WINDOW GLASS
Figure 77— Rear W indow Front Glass Run Channel
WEATHERSTRIP REPLACEMENT Bolts
1. Window. Refer to Window Replacement in this sec

tion.
2. Weatherstrip.•
run channel.
1. Weatherstrip.
run channel.
section.
Figure 78— Rear Side Door Control Assem bly
DOORS 10A1-31
WINDOW REGULATOR
REPLACEMENT AND MOTOR
REPLACEMENT
Tool Required:
J 34940 Rivet Gun
The power window motor can not be serviced. It
is replaced as a unit with the regulator.
I Remove or Disconnect (Figure 79)

this section.
3. Window glass. Refer to Window Replacement in
this section.
4. Window sash.
5. Glass weatherstrip.
6. Regulator assembly from door.
A. Drill rivets securing the regulator to door inner
panel. (1) Bolt
B. Guide regulator assembly though rear lower (2) Regulator
hole. Figure 79— Rear Side Door W indow Regulator
Assem bly
4. Window glass. Refer to Window Replacement in
1. Regulator assembly to door. this section.
A. Guide regulator assembly though rear lower 5. Water deflector. Refer to Inner Panel Water Deflec
hole. tor Replacement in this section.
B. Install rivets securing the regulator to the door 6. Trim panel. Refer to Trim Panel Replacement in
inner panel using J 34940. this section.
2. Glass weatherstrip.
3. Window sash.
REAR CARGO DOORS (U TILITY AND

SUBURBAN)—ON-VEHICLE SERVICE
Tool Required:
1. Trim panel from the door.

J 38778.
2. Remove retainers from trim panel.
■►4- Install or Connect (Figure 80)
1. Retainers to trim panel.

• Align retainers with holes in door.
• Carefully apply pressure to seat retainers.
Figure 80— Rear Cargo Door Trim Panel

10A1-32 DOORS
WINDOW GARNISH MOLDINGS

this section.
2. Garnish molding screws.
3. Garnish molding retainers.
4. Garnish molding from door.
1. Garnish molding to door.

2. Garnish molding retainers.
3. Garnish molding screws.
this section.
Moldings
INNER PANEL WATER
DEFLECTOR REPLACEMENT
Waterproof deflectors are used to seal the inner panel
and prevent water from entering into the body. The
deflector is secured with adhesive between the deflector
and door.
Rem ove or Disconnect

this section.
2. Water deflector.
A. Break the bond between the sealer and the
door with a flat-blade tool.
B. Pull off.
Install or Connect
Figure 82— Rear Cargo Door Access Hole Covers
1. Water deflector to the door.
WIRING HARNESS
• Use waterproof tape or 3M® 777 adhesive if
needed.
REPLACEMENT
2. Trim panel to the door. 0 Remove or Disconnect (Figure 83)
ACCESS HOLE COVERS (BASE 1. Negative battery cable. Refer to Battery Disconnect
MODELS ONLY) 2. Trim panel. Refer to Trim Panel Replacement in
this section.
3. Wiring.
Rem ove or Disconnect (Figure 82) A. Door wiring contact screws.
B. Door wiring contact connector.
1. Access hole cover screws. C. Window defogger wiring connectors.
2. Access hole covers. D. Power door lock actuator connector.
E. Wiring harness retainers.
0 Install or Connect (Figure 82) 4. Wiring harness from the door.
1. Access hole covers.

2. Access hole cover screws.
DOORS 10A1-33
Legend
(1) Door Opening Contacts (4) Rear Cargo Door Contacts
(2) Window Defogger Wiring Connector (5) Power Door Lock Actuator
(3) Grommet (6) Power Door Lock Actuator Wiring Connector
Figure 83— Door W iring Harness Locations
■M- Install or Connect (Figure 83) CARGO DOOR REPLACEMENT

1. Wiring harness to door. Remove or Disconnect (Figure 84)
2. Wiring.
A. Wiring harness retainers. 1. Negative battery cable (vehicles with power compo
B. Power door lock actuator connector. nents only). Refer to Battery Disconnect Caution in
C. Window defogger wiring connectors. General Information.
D. Door wiring contact connector. • Apply cloth backed tape to the door, and body
E. Door wiring contact screws. pillar.
3. Trim panel. Refer to Trim Panel Replacement in 2. Check assembly hinge pin using soft-faced ham
this section. mer and locking pliers.
10A1-34 DOORS
Figure 85— Hinge Check Assem bly
3. Lower hinge pin using a soft-faced hammer and CARGO DOOR HINGE
locking pliers.
• Temporarily install a bolt through the lower hing REPLACEMENT
es to hold the door in place while removing the
upper hinge pin. Remove or Disconnect
4. Upper hinge pin.
5. Bolt in lower hinge pin hole. 1. Door from body. Refer to Cargo Door Replacement
6. Door from vehicle. in this section.
Install or Connect (Figure 84) 3. Remove two bolts per hinge from door pillar.
4. Hinges from door.
1. Door to the vehicle. A. Scribe the location of the existing hinges on the
2. Bolt through the lower hinge pin holes. body pillar and door.
3. Upper hinge pin with the pointed end down using a B. Center punch each of the weld marks on the
soft-faced hammer and a pair of locking pliers to original hinge. It is critical to punch the center of
grasp the pin. the weld so that all of the weld is removed
• Remove the temporary bolt in the lower hinge. during drilling.
4. Lower hinge pin with the pointed end down. C. Drill a 3 mm (1/8 inch) pilot hole through the
• Remove cloth backed tape from the door, and welds deep enough to penetrate the hinge base
the body pillar. only.
5. Check assembly pin with the pointed end down. D. Drill a 13 mm (1/2 inch) hole through the hinge
6. Negative battery cable. base only using the smaller hole as a pilot.
E. Drive a chisel between the hinge and the door.
CARGO DOOR HINGE CHECK
Install or Connect
|*"»| Rem ove or Disconnect (Figure 85) 1. Bolt-on hinges to door.
1. Apply cloth backed tape to the door and body pillar. within the scribe marks made on the body hinge
2. Pin retainer. pillar and the door at the time of removal.
3. Hinge pin using a soft-faced hammer and locking B. Center punch each bolt hole location on the
pliers. body hinge pillar and/or door.
4. Spring. C. Drill a 13 mm (1/2 inch) hinge attaching hole in
5. Check assembly. three steps to ensure placing the hinge in the
proper position.
+4r Install or Connect (Figure 85) 2. Prepare the surface for the replacement hinges
1. Check assembly. • Coat the mating surface of the hinges with a
2. Spring. medium bodied sealer. .
3. Hinge pin using a soft-faced hammer and locking 3. Hinges, backing plate, bolts, and nuts to door and
pliers. pillar.
4. New pin retainer. A. Align the hinge and backing plate with the holes
• Remove cloth backed tape from the door and in the hinge pillar and door.
the body pillar.
DOORS 10A1-35
B. Place the bolts through the hinge, pillar and/or Install or Connect (Figure 86)
door, and through the backing plate.
1. Striker to the vehicle.
Tighten 2. Striker screw.
3. Align the striker and screw with the previously
• Nuts to 35 N-m (26 lb ft). made mark.
4. Door to body. Refer to Cargo Door Replacement in
this section. Tighten
• Screw to 8 N-m (75 lb in).
REAR CARGO DOOR BODY
MOUNTED STRIKERS REAR CARGO DOOR
PROTECTORS
1. Mark the position of the upper and/or lower striker.
2. Striker screw. 1. Protector bolts.
3. Striker. 2. Protector.
1. Protector.
2. Protector bolts.
CARGO DOOR LOCK ASSEMBLY

REPLACEMENT (RIGHT DOOR)
1. Door trim panel (if equipped). Refer to Door Trim

Panel Replacement in this section.
2. Access hole cover (if equipped). Refer to Access
Hole Covers in this section.
3. Lock rod from lock assembly rod clip.
5. Lock assembly from door.
Figure 86— Cargo Upper and Lower Strikers +«■ Install o r Connect (Figure 88)
1. Lock assembly to door.

Legend
(1) Bolt
(2) Protector
Figure 87—Rear Cargo Door Protectors Lock Control Rods
10A1-36 DOORS
3. Lock rod from lock assembly rod clip. Install or Connect (Figures 89 and 90)
Hole Covers in this section. 1. Actuator to door.
• Use J 34940 to install actuator rivets.
LOCK ACTUATOR 2. Actuator lock control rod (Figure 89).
Tool Required: 3. Actuator wiring connector.
J 34940 Rivet Gun 4. Water deflector (if equipped). Refer to Inner Panel
Water Deflector Replacement in this section.
3 Remove or Disconnect (Figures 89 and 90) 5. Trim panel (if equipped). Refer to Trim Panel
1 . Trim panel (if equipped). Refer to Trim Panel 6. Access hole cover (if equipped). Refer to Access
Replacement in this section. Hole Covers in this section.
2. Water deflector (if equipped). Refer to Inner Panel
Water Deflector Replacement in this section. DOOR LOCK CYLINDER, ROD,
3. Access hole cover (if equipped). Refer to Access AND OUTSIDE HANDLE
4. Actuator lock control rod (Figure 89). REPLACEMENT (RIGHT DOOR)
5. Actuator wiring connector. New lock cylinders are available as replacement
6. Actuator from door parts. If door lock cylinders require replacement for any
• Drill out rivets. reason, apply a coating of GM P/N 12345120 lubricant
or equivalent inside of the lock case and cylinder key
way prior to assembling and installing the cylinder.
To repair a binding lock cylinder, refer to Binding lock
cylinders. To code a new lock cylinder, refer to Lock
Cylinder Coding in General Information.
|+-»| Remove or Disconnect (Figure 91)

4. Lock cylinder rod from the rod clip.
5. Outside handle rod from the rod clip.
7. Handle assembly.
8. Door lock cylinder from the outside handle housing.
Figure 89— Rear Side Door Lock Actuator Wiring

Connector and rivets
3110S1412
Figure 90— Rear Side Door Lock Actuator Control Figure 91— Rear Cargo Door Outside Handle and
Rod Lock Assem bly
DOORS 10A1-37
+«■ Install or Connect (Figure 91) 5. Access hole cover (if equipped). Refer to Access
1. Door lock cylinder to the outside handle housing. 6. Water deflector (if equipped). Refer to Inner Panel
2. Handle assembly. Water Deflector Replacement in this section.
3. Outside handle mounting bolts. 7. Door trim panel (if equipped). Refer to Door Trim
Tighten
LEFT DOOR MOUNTED STRIKER
• Bolts to 4 N.m (35 lb in). Tool Required:
4. Outside handle rod from the rod clip (Figure 91). J 29843-9 Torx Bit (Bit Size T47)
5. Lock cylinder rod from the rod clip (Figure 91). The door striker bolt is a special bolt and washer
6. Access hole cover (if equipped). Refer to Access mounted on the left door opening. The bolt passes
Hole Covers in this section. through a hole into a threaded plate inside of the door.
7. Water deflector (if equipped). Refer to Inner Panel Cargo doors are secured in position when the lock cam
Water Deflector Replacement in this section. (arm) of the locking mechanism in the right door engag
8. Door trim panel (if equipped). Refer to Door Trim es and snaps around the striker bolt.
LEFT DOOR LATCH CONTROL
HANDLE 1. Door trim panel (if equipped). Refer to Door Trim
Remove or Disconnect (Figures 92 and 93) 2. Water deflector (if equipped). Refer to Inner Panel
1. Door trim panel (if equipped). Refer to Door Trim 3. Access hole cover (if equipped). Refer to Access
Panel Replacement in this section. Hole Covers in this section.
2. Water deflector (if equipped). Refer to Inner Panel 4. Mark the position of the striker bolt spacer on the
Water Deflector Replacement in this section. door pillar.
3. Access hole cover (if equipped). Refer to Access 5. Striker bolt using J 29843-9 or equivalent.
4. Lower latch control rod from control handle clip Install or Connect (Figure 93)
(Figure 92).
5. Upper latch control rod from control handle clip 1. Striker bolt into the door pillar retaining plate.
(Figure 92). 2. Align the striker bolt spacer with the previously
6. Latch control handle nuts (Figure 93). made mark.
7. Latch control handle (Figure 93).
Tighten
• Striker bolt while holding spacer in position to
1. Latch control handle (Figure 93). 63 N-m (46 lb ft) using J 29843-9 or equivalent.
2. Latch control handle nuts (Figure 93). 3. Access hole cover (if equipped). Refer to Access
3. Upper latch control rod from control handle clip Hole Covers in this section.
(Figure 92). 4. Water deflector (if equipped). Refer to Inner Panel
4. Lower latch control rod from control handle clip Water Deflector Replacement in this section.
(Figure 92).
Figure 93— Rear Cargo Door Lock Striker and Latch

Control Handle (Mounted to Left Door)
10A1-38 DOORS
LOWER LATCH REPLACEMENT


4. Control rod from latch (Figure 94).
5. Control latch bolts and spacer (Figure 95).
6. Control latch from door (Figure 95).
Figure 94— Lower Latch Control Rod

1. Control latch to door (Figure 95).
2. Control latch spacer and bolts (Figure 95).
3. Control rod to latch (Figure 94).
DOOR BUMPER ASSEMBLY

REPLACEMENT
B Rem ove or Disconnect (Figure 95)
1. Bumper bolts.
2. Bumper assembly.
++ install or Connect (Figure 95)
1. Bumper assembly. Figure 95— Lower Latch and Bumper

2. Bumper bolts.
UPPER LATCH REPLACEMENT 1. Latch to door (Figure 97).
2. Latch bolts (Figure 97).
3 Rem ove or Disconnect (Figures 96 and 97)
3. Control rod to latch (Figure 96).
1. Door trim panel (if equipped). Refer to Door Trim Hole Covers in this section.
Panel Replacement in this section. 5. Water deflector (if equipped). Refer to Inner Panel
2. Water deflector (if equipped). Refer to Inner Panel Water Deflector Replacement in this section.
Water Deflector Replacement in this section. 6. Door trim panel (if equipped). Refer to Door Trim
3. Access hole cover (if equipped). Refer to Access Panel Replacement in this section.
4. Control rod from latch (Figure 96).
5. Latch cover.
• Remove cover screw.
6. Latch bolts (Figure 97).
7. Latch from door (Figure 97).
DOORS 10A1-39
SIDE DOOR WINDOW SEALING ■M-j Install or Connect (Figures 98 and 99)
STRIP REPLACEMENT 1. Outer sealing strip to the door channel.

The outer belt sealing strip is used to seal between • Press it into place.
the inner and outer door panels and the window at the 2. Trim panel. Refer to Trim Panel Replacement in
belt line. The outer sealing strip can be replaced. Do this section.
not remove the inner sealing strip since the strip is 3. Close door.
stapled to the trim panel.
SIDE DOOR OPENING
1. Open door.
2. Trim panel. Refer to Trim Panel Replacement in Remove or Disconnect (Figure 100)
this section.
3. Outer sealing strip from the door channel. 1. Open door.
2. Pull the weatherstrip from the door pinchweld
flange.
Figure 98— Front Door Outer Belt Door W indow Figure 99— Rear Door Outer Belt Door Window
Outer Seal Outer Seal
10A1-40 DOORS
-4 4 - Install or Connect (Figure 100) ■ 44- Install or Connect (Figure 101)
1. Door weatherstrip to the door pinchweld flange. 1. Roof drip molding.

• Push the molding over the pinchweld.
A. Position the preformed corner of the weather 2. Close door.
strip in the upper rear corner of the door
opening. SIDE DOOR AUXILIARY
B. Push the weatherstrip onto the flange, starting
at the preformed corner, and working around
the entire edge of the door opening. Tool Required:
2. Close door.
SIDE DOOR ROOF DRIP
1. Open door.
WEATHERSTRIP REPLACEMENT 2. Weatherstrip from mounting surface using J 38778.
-4 4 - Install or Connect (Figure 102)

1. Weatherstrip to mounting surface.
1. Open door. • Press retainers in place.
2. Pull the roof drip molding from the pinchweld and 2. Close door.
windshield molding flange.
Figure 100— Door Opening W eatherstrip Installation Figure 102— Rocker Auxiliary W eatherstrip
Figure 101—Roof Drip Molding Figure 103—Cargo Door Opening Weatherstrip

DOORS 10A1-41
REAR CARGO DOOR OPENING
WEATHERSTRIP
1. Open door.
2. Pull the w eath erstrip from the door pinchw eld
flange.
•M- Install or Connect (Figure 103)
1. Door weatherstrip to the door pinchweld flange.

A. Align white mark on weatherstrip with the left
edge of upper striker.
B. Push weatherstrip on to flange while working
o utw ard to left and right corne rs of door
opening.
C. Push weatherstrip down both sides of outer
flanges to lower corners. Figure 104— Cargo Door Upper W eatherstrip
D. Locate the center of the lower portion of weath
erstrip and push onto lower flange.
E. Push excess loops of weatherstrip from the
center to outward to corners.
2. Push w eatherstrip securely around the outside
perimeter of door opening flange.
3. Close door.
REAR CARGO DOOR UPPER

WEATHERSTRIP
1. Open cargo door.

2. Pull the w eath erstrip from the door pinchw eld
flange.
1. Center weatherstrip assembly. Figure 105— Cargo Door Corner W eatherstrip

2. Push firmly to the center of upper roof flange.
3. Peel off backing paper while pressing weatherstrip
firmly to flange.
4. Close door. 1. Weatherstrip to mounting surface.
• Peel off backing paper.
REAR CARGO DOOR CORNER • Press retainers in place.
2. Close door.
WEATHERSTRIP
Tool Required:
J 38778 Trim Panel Rem over
1. Open door.
2. Weatherstrip from mounting surface using J 38778.
10A1-42 DOORS
SPECIFICATIONS

A p plicatio n N-m Lb ft Lb in
Armrest Mounting Screws 5 — 44
Check Strap Bolts 10 — 89
Door Hinge Bolts 35 26
Door Hinge Nuts 35 26 —
Door Lock and Actuator Assembly Mounting Bolts 9 — 80

Door Striker Bolt 28 21 —
Door Striker Screw 8 — 75

Mini W edge Door Striker Bolt 63 46 —
W indow Run Channel Screws 2 — 18

W indow Sash Channel Bolts 6 — 53
Outside Door Handle Mounting Bolts 4 — 35
Outside R earview Mirror Retaining Nuts 6 — 53
Side Access Door Lower Striker Bolt 10 — 89
Side Access Door Latch Bolts 24 18 —
Trim Panel Armrest Screws 2 — 18
SPECIAL TOOLS
SEATS 10A2-1
SECTION 10A2
SEATS
DIAGNOSIS OF MANUAL SEAT ADJUSTER
Adjuster Will Not 1. W ire assembly too tight. 1. Loosen the wire assembly by moving
Lock the hooked end to the forward hole of
the lock bar.
2. Lock bar spring disconnected or broken. 2 . Connect the spring or install a new
3. Lock bar sticking or binding. spring.
3. Lubricate the lock bar pivot. If the bar is
binding, eliminate the cause of binding
or replace the adjuster.
Adjuster Will Not 1. W ir e a s s e m b ly to o lo o s e o1.r Eliminate the slack in the wire assembly
Unlock disconnected. by m oving th e h o o k e d end to the
rearward hole of the lock bar.
2. Lock bar sticking or binding. 2. Lubricate the lock bar pivot. If the bar is
binding, eliminate the cause of binding
or replace the adjuster.
Seat Hard To Move 1. Adjusters new, not seated. 1. O perate the seat to the full forward and
Forward Or full rearward positions several times to
Rearward w ork th e new tig h tn e s s out of the
channels.
2. Adjuster(s) improperly lubricated. 2. Lubricate the adjuster channels with
Lubriplate Auto-Lube A or equivalent.
3. A d ju s te r(s ) binding d u e to b en t or 3. Replace the adjuster.
dam aged channels.
Easy Entry C able from the seat back to the adjuster is Pull back the covering on the seat back and
Passenger Seat In disconnected. seat. M ake sure the cable is still connected
Extended Cab Does and taut from the seat back through the seat
Not Slide Forward to the adjuster.
When The Seat Is
Tilted Forward
D 0217
DIAGNOSIS OF SIX-WAY POWER ADJUSTER

CONDITION POSSIBLE CAUSE CORRECTION
Horizontal operation 1. Improper lubrication of the seat adjuster 1. Lubricate carriages and seat adjuster
of the seat is not carriages and seat adjuster slides. slides with a lithium base grease.
smooth. Apparent 2. T ra n s m is sio n a s s e m b ly is loose or 2. Inspect transmission assembly. Tighten
hard operation. binding. mounting screws or replace assembly if
necessary.
Horizontal chuck or 1. Seat adjuster carriages out of alignment 1. In s p e c t tra n s m is s io n a s s e m b ly and

looseness. or worn. replace if necessary.
10A2-2 SEATS
DIAGNOSIS OF SIX-WAY POWER ADJUSTER (cont’d)

CONDITION POSSIBLE CAUSE CORRECTION
Adjuster will not 1. No power to the adjuster assembly. 1. R efer to Driveability, Emissions, and
operate horizontally. Electrical D iagnosis M anual for this
vehicle.
2 . Seat adjuster drive cable damaged. 2. In p e c t d riv e c a b le a n d re p la c e if
necessary.
3. Seat adjuster motor is not working. 3. Inspect adjuster motor assembly and
replace if necessary.
One or both 1. No power to the adjuster assembly. 1. R efer to Driveability, Emissions, and
adjusters will not Electrical D iagnosis M anual for this
operate vertically. vehicle.
2. Seat adjuster drive cables dam aged. 2. Inspect drive cab le s and rep lace if
necessary.
3. Seat adjuster motor is not working. 3. Inspect adjuster motor assem bly and
replace if necessary.
D0311
ON-VEHICLE SERVICE
FRONT SEATS
FRONT BUCKET SEAT Tighten
REPLACEMENT • Bolts to 55 N.m (41 lb ft).
3. Seat trim cover.

1. Seat trim cover. Refer to Front Seat Trim Cover

FRONT SEAT TRIM COVER
Replacem ent in this section. REPLACEMENT
2. Seat retaining bolts.
3. Seat from the vehicle.
1. Rem ove screws.
1. Seat to the vehicle. 2. Remove trim cover from seat.
Figure 2— Front Bucket Seat Trim Cover

Figure 1— Front Bucket Seat Mounting (Right Side Only)
SEATS 10A2-3
Figure 3— Front Bucket Seat Trim Cover and Figure 4— Front Bucket Seat Trim Cover with
Components (Right Side inner Only) Lumbar Switch)
Install or Connect (Figures 2 through 5) Install or Connect (Figures 5 and 6)
1. Install trim cover to seat. 1. The seat adjuster to the seat.

2. Install screws. 2. The bolts to retain the seat adjuster to the seat.
FRONT SEAT RISER Tighten
Remove or Disconnect (Figure 5) • The bolts to retain the seat adjuster to the seat
to 25 N.m (18 lb ft).
1. Th e front seat assembly from the vehicle. Refer to
3. The front seat and the seat adjuster to the seat
Front Seat Assembly in this section.
riser.
2 . T h e nuts retaining the s e a t riser to th e s ea t
4. The nuts to retain the seat adjuster to the seat
adjuster.
riser.
3. The front seat riser from the seat adjuster.
■ M- install or Connect (Figure 5) Tighten
1. The front seat riser to the seat adjuster. • The nuts to retain the seat adjuster to the seat
2. T h e nuts to retain th e s e a t riser to the s ea t riser to 45 N-m (33 lb ft).
adjuster.
Power Seat Adjuster Switch
Tighten
• The nuts to retain the seat riser to the seat
adjuster to 45 N-m (33 lb ft). 1 . T h e screws retaining the pow er seat adjuster
3. The front seat assembly to the vehicle. Refer to switch to the seat cushion.
Front Seat Assembly in this section. 2. Th e power seat adjuster switch from the seat
cushion.
FRONT SEAT ADJUSTER 3. T h e e lectrical connector from the pow er seat
adjuster switch.
Manual Seat Adjuster Switch 4. The power seat adjuster switch from the vehicle.
-►4- install or Connect (Figure 5)

1. The nuts retaining the seat adjuster to the seat 1. The power seat adjuster switch to the vehicle.
riser. 2. The electrical connector to the power seat adjuster
2. The front seat and the seat adjuster from the seat switch.
riser. 3. The power seat adjuster switch to the seat cushion.
3. The bolts retaining the seat adjuster to the seat. 4. The screws to retain the power seat adjuster switch
4. The seat adjuster from the seat. to the seat cushion.
10A2-4 SEATS
HEAD RESTRAINT FRONT SEAT BACK RECLINER
REPLACEMENT HANDLE
1 . T h e re c lin e r h a n d le c o v e r from the re c lin e r

1. Raise head restraint to its full up position. mechanism.
2. Insert a paper clip or a similar tool in the hole at 2. Th e screw retaining the recliner handle to the
the forward edge of the head restraint retainer. recliner mechanism.
3. Press in on the tool to release the retainer clips 3. The recliner handle from the recliner mechanism.
and lift the head restraint from the retainers.
+4- Install or Connect
1. The recliner handle to the recliner mechanism.
2. T h e screw retaining the recliner handle to the
1. The head restraint into the retainers.
recliner mechanism.
2. Push the head restraint to its full down position and
3. T h e r e c lin e r h a n d le c o v e r to th e r e c lin e r
pull up to ensure it is engaged with the head
mechanism.
restraint retainers.
HEAD RESTRAINT GUIDE FRONT SEAT BACK

HINGE/RECLINER MECHANISM
REPLACEMENT
The front seat back recliner mechanism is mounted to
the inboard side of the seat. The outboard hinge bolts to
Remove or Disconnect (Figure 9) the seat back and the seat bottom.

1. Seat Back trim cover and pad. Refer to Seat Back
Trim Cover and Pad Replacement in this section.
1. The front seat from the vehicle. Refer to Front Seat
2. Head restraint guide(s) from the seat back frame by
Assembly in this section.
squeezing the retaining tabs together at the base of
2. Release the seat cushion cover to access the bolts
the guide (Figure 9) and lifting up.
retaining the hinge or recliner mechanism to the
seat cushion frame. Refer to Front Seat Cushion
Install or Connect (Figure 9) Cover in this section.
3. Release the seat back cover and lift it enough to
1. Head restraint guide(s) by pressing into the seat access the bolts retaining the hinge or recliner
back fram e until the retaining tabs snap into place mechanism to the seat back. Refer to Front Seat
at the bottom of the fram e opening (Figure 9). Back Cover in this section.
2. Seat Back trim cover and pad. Refer to Seat Back 4. The bolts retaining the hinge/recliner mechanism to
Trim Cover and Pad Replacem ent in this section. the seat back frame.
5. The bolts retaining the hinge/recliner mechanism to
the seat cushion frame.
FRONT SEAT ARMREST 6 . T h e h in g e /re c lin e r m e c h a n ism from th e s eat
assembly.
Remove or Disconnect (Figures 8, 10 and 11) -► 4- Install or Connect (Figures 5 and 8)
1. R elease the bottom edge of the seat back cover. 1 . T h e h in g e /r e c lin e r m e c h a n is m to th e s e a t

Refer to Front Seat Back Cover in this section. assembly.
2. Using a small bladed tool, release the clip retaining 2 . The bolts to retain the hinge/recliner mechanism to
the arm rest to the seat back. the seat back frame.
3. Pull the arm rest from the seat back.
Tighten
Install or Connect (Figures 8, 10 and 11)
• The bolts to retain the hinge/recliner mechanism
to the front seat back frame to 35 N-m (26 lb ft).
1. The retaining clip to the seat back, ensure that the
retaining clip is fully seated. 3. The bolts to retain the hinge/recliner mechanism to
2. Th e armrest to the seat back. the seat cushion frame.
3. Press on the armrest to engage the armrest with
Tighten
the retaining clip in the seat back.
4. Secure the bottom edge of the seat back cover.
Refer to Front Seat Back Cover in this section.
to the seat cushion fram e to 35 N-m (26 lb ft).
SEATS 10A2-5
Legend
(1) Seat Cushion Cover (13) Power Seat Control Switch
(2) Seat Cushion Pad (14) Power Seat Control Switch Cover
(3) Seat Cushion Frame (15) Bolt
(4) Seat Cushion Pad Support W ire Spring (16) Lumbar Switch
(5) Seat Recliner (17) Bolt
(6) Bolt (18) Seat Cushion Finish Panel
(7) S eat Back Release Handle (19) Seat Riser Cover
(8) Seat Cushion to Recliner Fill Pad (20) Seat Riser
(9) Seat Recliner Bolt (21) Power Seat Adjuster Wiring Harness
(10) Bolt (22) Hog Ring
(11) Seat Recliner Handle (23) Lumbar Pump
(12) Seat Recliner Handle Bolt (24) Hog Ring
Figure 5— Seat Cushion Assembly (Front Bucket Seat)
4. The front seat back cover. Refer to Front Seat Back 4. Release the hook and loop strips retaining the seat
Cover in this section. back cover to the seat back foam pad.
5. The front seat cushion cover. Refer to Front Seat 5. To e as e rem oval, place a piece of cardboard
Cushion Cover in this section. between the seat back cover and the foam pad.
6 . The front seat to the vehicle. Refer to Front Seat 6. Working from side to side, carefully lift the seat
Assembly in this section. back cover from the foam pad.

FRONT SEAT BACK COVER
1. Working from side to side, carefully install the seat
Remove or Disconnect (Figure 12) back cover over the foam pad.
2 . Remove the cardboard from between the seat back
cover and the foam pad.
The armrest. Refer to Front Seat Armrest in this
3. Engage the hook and loop strips retaining the seat
section.
back cover to the seat back foam pad.
2. Head restraint and guides. Refer to Head Restraint
5. Head restraint and guides.
3. Release the bottom edge of the seat back cover.
6 . The armrest to the seat back.
10A2-6 SEATS
FRONT SEAT CUSHION COVER
1 . T h e recliner handle. R efer to Front S eat Back

Recliner Handle in this section.
2. The power seat adjuster switch (if equipped). Refer
to Power Seat Adjuster Switch in this section.
3. Release the seat cushion cover retainers from the
seat frame.
4. Release the hook and loop strips retaining the seat
cushion cover to the seat cushion foam pad.
5. The seat cushion cover from the foam pad.
1. The seat cushion cover to the foam pad.

3. T h e s eat cushion cover retainers to the seat
cushion frame.
(1) Adjusting Latch Spring 4. The power seat adjuster switch (if equipped). Refer
(2) W ire Assembly to Power Seat Adjuster Switch in this section.
(3) Return Spring 5. T h e recliner handle. R efer to Front S e a t Back
(4) Adjusting Latch Spring Recliner Handle in this section.
(5) Bolt
(6) Riser FRONT SEAT BACK FRAME
(7) Adjusting Lever
(8) Screw REPLACEMENT
Figure 6— Manual Seat Adjuster (Bucket Seat)
I . S e a t from riser. R e fe r to Front B u ck et S e a t

Legend
(1) Armrest (8) Bolt
(2) Armrest Clip (9) Seat Cushion Strap
(3) S eat Back Cover (10) Seat Air Supply Hose
(4) Seat Back Pad (11) Seat Back Pivot Bushing
(5) Seat Head Restraint (12) Seat Back Frame
(6) Seat Back Cushion Panel (13) Seat Head Restraint Guide
(7) Lumbar Support Bladder
Figure 7— Seat Back Assem bly (Front Bucket Seat)
SEATS 10A2-7
Legend
(1) Head Restraint (1) Armrest Retaining Clip
(2) Head Restraint Retainer (2) Front Seat Back
(3) Head Restraint Retainer (3) Front Seat Back Armrest
Figure 8— Bucket Seat Head Restraint Figure 10— Arm rest
Figure 11— Removing the Arm rest Retaining Clip
2. Head restraint and guides. Refer to Head Restraint | ^ l Important

3. S eat back pad. Refer to Bucket Seat Back Trim • N o te th e position and length of the bolts
Cover and Pad Replacem ent in this section. removed.
4. Two bolts retaining the seat back hinge to the seat
back frame. | j | Important
important • Complete the following steps O NLY if the seat

is equipped with a lumbar support.
• N o te th e p o sition and len gth of th e bolts — S e a t cushion pad. R efer to Bucket S eat
removed. Cushion Trim Cover and Pad Replacement
in this section.
5. Two bolts retaining the seat back recliner to the
seat back frame. — Tw o screw s retaining th e lu m b ar cable
assembly to the seat cushion frame.
— Turn the threaded black end of the assembly
10A2-8 SEATS
— Insert the lumbar adjuster cable into the slot
in the assembly. Turn the threaded black
end of the assembly until the slot retaining
the cable is concealed.
— Two screw s retaining the lum bar cab le
— S e at cushion pad. R efer to Bucket S eat
Cushion Trim Cover and Pad Replacement
in this section.
seat back frame.
Important
• Install the bolts in their original locations, as

noted during disassembly.
Tighten

(1) Front Seat Back Foam Pad back frame.
(2) Front S eat Back Cover
Important
Figure 12— Front Seat Back Cover

Tighten

4. Seat back pad.
6 . Seat to the riser.
FRONT SEAT CUSHION FRAME

REPLACEMENT
4 -+ Remove or Disconnect (Figure 5)
I . S e a t from riser. R e fe r to Fro n t B u ck et S e a t

Legend
(1) Seat Cushion Foam Pad
(2) Seat Cushion Frame
(3) S eat Cushion Cover
Figure 13— Front Seat Cushion Cover
to expose the retaining slot for the cable.

Rem ove the cable from the assembly.
6 . Seat Back fram e from the seat assembly.
1. Seat Back fram e to the seat assembly.
Important
• Com plete the following steps ONLY if the seat Figure 14— Lumbar Switch W ith Power Seats
is equipped with a lumbar support. (Switch Without Power Seats Similar)
SEATS 10A2-9
2. Head restraint and guides. Refer to Head Restraint Tighten
3. Seat cushion pad. Refer to Bucket Seat Cushion . Bolts to 30 N.m (22 lb ft).
Trim Cover and Pad Replacem ent in this section.
4. Seat cushion pad.
cushion frame.
Important
POWER SEAT LUMBAR SWITCH
• N o te th e position and length of th e bolts REPLACEMENT
removed.

seat cushion frame.
1. Screws attaching switch to side of seat cushion.
Important • Pull switch partially out from seat cushion.
2. Switch from switch bezel.
• N o te th e position and length of th e bolts
3. Switch wiring harness in-line connector.
removed.
4. Rubber hoses.
5. Switch, wiring harness and hoses from side of seat
| ^ 1 Important
cushion.
• Complete the following steps ONLY if the seat
— Two screw s retaining the lum bar cab le • Route switch wiring harness and hoses through
assembly to the seat cushion frame. opening in side of seat cushion and through open
— Turn the threaded black end of the assembly ing in seat frame.
Remove the cable from the assembly. 1. Rubber hoses.
2. Switch wiring harness to vehicle wiring harness.
6 . Seat cushion frame from the seat assembly. 3. Switch wiring harness in-line connector.
4. Switch in switch bezel.
• Position switch bezel in seat cushion opening
and install screws.
1. Seat cushion fram e to the seat assembly.
Important MANUAL SEAT LUMBAR

SWITCH REPLACEMENT
is equipped with a lumbar support. Remove or Disconnect
in the assembly. Turn the threaded black 1. Seat from vehicle. Refer to Front Split Bench Seat
end of the assembly until the slot retaining Replacement or Front Bucket Seat Replacement in
the cable is concealed. this section.
— Two screw s retaining the lum bar cable 2 . Screws that attach switch to side of seat cushion.
assembly to the seat cushion frame. • Pull switch out from opening in side of seat
2. Two bolts retaining the seat back recliner to the cushion.
seat cushion frame. 3. Switch wiring harness in-line connector.
4. Rubber hoses.
Important 5. Switch, wiring harness and hoses from side of seat
cushion.
noted during disassembly. Install or Connect
Tighten
• Route switch wiring harness and hoses through
opening in side of seat cushion.
1. Rubber hoses.
3. Two bolts retaining the seat back hinge to the seat 2 . Switch wiring harness to vehicle wiring harness.
cushion frame.
• Position switch in seat cushion opening and
9 Important install screws.
3. S eat assem bly in vehicle. Refer to Front Split

• Install the bolts in their original locations, as Bench Seat Replacem ent or Front Bucket Seat
noted during disassembly. Replacement in this section.
10A2-10 SEATS
LUMBAR BLADDER 3. Lower screws from seat back trim panel.
• Push down and pull out at top of seat back trim
REPLACEMENT panel and remove.
(Non-Removable Seat 4. Left and right seat trim J-hooks from seat frame.
5. Rubber hose from bladder assembly.
Back Panel) 6 . Bladder mounting bars from around hooks on frame
(one located on each side). Refer to Figure 8.
7. Slide bladder upwards, off mounting bars.
1. Seat from vehicle. Refer to Front Split Bench Seat
8 . Bladder from seat back.
Replacem ent or Front Bucket Seat Replacement in
this section.
• Tilt seat back forward and place seat assembly
1. Bladder to seat back by sliding over bladder mount
upside-down.
ing bars. Refer to Figure 15.
2. Seat back panel lower retainer from seat frame.
2. Rubber hose to bladder.
3. Rubber hose between bladder and pump.
3. Bladder mounting bars around hooks on frame (one
• P la c e h a n d d o w n in s id e s e a t b a c k and
located on each side). Refer to Figure 8.
disconnect bladder mounting bars from round
4. Left and right seat trim J-hooks onto seat frame.
hooks on frame (one on each side).
5. Lower seat back panel bracket to lower seat back.
4. Slide bladder downwards and off mounting bars.
5. Bladder from seat back. • Push down and in at top of seat back panel to
secure.
Install or Connect 6 . Seat back panel screws.
7. Seat trim close-out strip to seat back trim panel.
• Position bladder inside seat back on mounting bars 8 . Slide seat back into original position.
and slide upwards.
1. Rubber hose between bladder and pump. LUMBAR BLADDER
2. Bladder mounting bars to round hooks on frame
(one on each side).
REPLACEMENT
3. Seat back panel lower retainer to seat frame. (Seats w ithout Removable
4. S e a t assem bly in vehicle. R efer to Front Split
Bench or Front Bucket Seat Replacement in this
Seat Back Panel)
section.
LUMBAR BLADDER 1. Seat from vehicle. Refer to Front Split Bench Seat
REPLACEMENT Replacement or Front Bucket Seat Replacem ent in
(Seats w ith Removable Seat this section.
2. Seat trim close-out strip at bottom of seat back.
Back Panel) 3. Rubber hose from bladder assembly.
4. Bladder mounting bars from around hooks on frame
(one located on each side). Refer to Figure 8.
1. Slide seat forward. 5. Slide bladder upwards, off mounting bars.
2. Seat trim close-out strip from seat back trim panel. 6 . Bladder from seat back.
1. Bladder to seat back by sliding over bladder mount

ing bars. Refer to Figure 15.
2. Rubber hose to bladder.
3. Bladder mounting bars around hooks on frame (one
located on each side). Refer to Figure 8.
4. Seat trim close-out strip at bottom of seat back.
5. Seat.
LUMBAR PUMP REPLACEMENT


Replacement or Front Bucket Seat Replacement in
this section.
2. Pump wiring harness in-line connector.
3. Rubber hose from switch to pump.
4. Retaining rings which secure pump and pump
cover assembly to seat.
SEATS 10A2-11
5. Pump and pump cover assembly from seat. 2. The nuts retaining the seat riser to the seat adjust
er.
+4- Install or Connect (Figure 15) 3. The front seat riser from the seat adjuster.
1. Pum p and pum p cover assem b ly in seat and ++ Install or Connect (Figures 17 and 18)
secure with retaining rings.
2. Rubber hose from switch to pump. 1. The front seat riser to the seat adjuster.
3. Pump wiring harness in-line connector. 2. T h e nuts to retain th e s e a t riser to th e seat
4. S eat assem bly in vehicle. R efer to Front Split adjuster.
Bench S eat R eplacem ent or Front Bucket Seat
Replacem ent in this section. Tighten
FRONT SPLIT BENCH • The nuts to retain the seat riser to the seat
SEAT REPLACEMENT adjuster to 45 N.m (33 lb ft).
3. The front seat assembly to the vehicle. Refer to
E3 Remove or Disconnect (Figure 16) Front Seat Assembly in this section.
1. Seat trim cover. Refer to Front Seat Trim Cover FRONT SEAT ADJUSTER
2 . Seat retaining bolts. Remove or Disconnect (Figure 19)
3. Seat and seat belt from the vehicle.
1. The nuts retaining the seat adjuster to the seat
-M - Install or Connect (Figure 16) riser.
2. The front seat and the seat adjuster from the seat
1. Seat to the vehicle. riser.
2 . Seat retaining bolts. 3. The bolts retaining the seat adjuster to the seat.
4. The seat adjuster from the seat.
Tighten
3. Bolts retaining the seat belt to the floor. 1. The seat adjuster to the seat.
2. The bolts to retain the seat adjuster to the seat.
Tighten
Tighten
• Bolts to 55 N.m (41 lb ft).
4. Seat trim cover to seat. Refer to Front Seat Trim • The bolts to retain the seat adjuster to the seat
Cover Replacement in this section. to 25 N-m (18 lb ft).
FRONT SEAT RISER riser.
Remove or Disconnect (Figures 17 and 18) riser.
1. The front seat assembly from the vehicle. Refer to Tighten

Front Seat Assembly in this section.
• The nuts to retain the seat adjuster to the seat
riser to 45 N-m (33 lb ft).
HEAD RESTRAINT
REPLACEMENT
4 -+ Remove or Disconnect (Figures 20 and 21)
1. Raise head restraint to its full up position.

2. Insert a paper clip or a similar tool in the hole at
the forward edge of the head restraint retainer.
3. Press in on the tool to release the retainer clips
+4- Install or Connect (Figures 20 and 21)

Figure 16— Front Split Bench Seat Mounting restraint retainers.
10A2-12 SEATS
Legend
(1) Seat Cushion Cover (13) Power Seat Control Switch
(2) Seat Cushion Pad (14) Power Seat Control Switch Cover
(3) Seat Cushion Fram e (15) Bolt
(4) Seat Cushion Pad Support W ire Spring (16) Lumbar Switch
(5) Seat Recliner (17) Bolt
(6) Bolt (18) Seat Cushion Finish Panel
(7) Seat Back Release Handle (19) Seat Riser Cover
(8) Seat Cushion to Recliner Fill Pad (20) Seat Riser
(9) Seat Recliner Bolt (21) Power Seat Adjuster Wiring Harness
(11) Seat Recliner Handle (23) Lumbar Pump
(12) Seat Recliner Handle Bolt (24) Hog Ring
Figure 17— Seat Cushion Assembly (Front Split Bench Passenger Side)
HEAD RESTRAINT GUIDE 2. Seat back trim cover and pad. Refer to Seat Back
REPLACEMENT
FRONT SEAT ARMREST
Remove or Disconnect (Figures 20, 23 and 24)
2. Using a small bladed tool, release the clip retaining
the armrest to the seat back.
3. Pull the armrest from the seat back.
|-M-| Install or Connect (Figure 22) Install or Connect (Figures 20, 23, and 24)
1. Head restraint guide(s) by pressing into the seat 1. The retaining clip to the seat back, ensure that the
back fram e until the retaining tabs snap into place retaining clip is fully seated.
at the bottom of the fram e opening (Figure 22). 2. The armrest to the seat back.
SEATS 10A2-13
Legend
(1) Armrest Inner Pivot Bracket Cover (16) Hog Ring
(2) Seat Cushion Frame (17) Seat Cushion Air Pump
(3) Seat Cushion Pad Support W ire Spring (18) Seat Cushion Pad
(4) Seat Recliner (19) Hog Ring
(5) Bolt (20) Seat Cushion Cover
(6) Seat Back Release Handle (21) Lower Seat Armrest Outer Cover
(7) Bolt (22) Upper Seat Armrest Outer Cover
(8) Seat Cushion to Recliner Fill Pad (23) Seat Armrest Latch
(9) Seat Recliner Handle (24) Seat Armrest/Center Console
(10) Power Seat Adjuster Switch (25) Cushion Seat Belt Reinforcement
(11) Power Seat Adjuster Switch Cover (26) Seat Belt Opening Bezel Retainer
(12) Lumbar Switch (27) Armrest Pivot Bushing
(13) Seat Cushion Finish Panel (28) Armrest Detent Rivet
(14) Power S eat Adjuster Wiring Harness (29) Armrest Detent
(15) Seat Riser
Figure 18— Seat Cushion Assembly (Front Spilt Bench Driver Side)
3. Press on the armrest to engage the armrest with 2. Th e screw retaining the recliner handle to the
the retaining clip in the seat back. recliner mechanism.
4. Secure the bottom edge of the seat back cover. 3. The recliner handle from the recliner mechanism.
+ 4- Install or Connect (Figures 17 and 18)
FRONT SEAT BACK RECLINER
HANDLE 1. The recliner handle to the recliner mechanism.
2. The screw retaining the recliner handle to the
recliner mechanism.
3. T h e r e c lin e r h a n d le c o v e r to th e r e c lin e r
mechanism.
I . T h e re c lin e r h a n d le c o v e r from th e re c lin e r
mechanism.
10A2-14 SEATS
FRONT SEAT BACK
HINGE/RECLINER MECHANISM
The front seat back recliner mechanism is mounted to
the inboard side of the seat. Th e outboard hinge bolts to
the seat back and the seat bottom.

Assembly in this section.
2. Release the seat cushion cover to access the bolts
retaining the hinge or recliner mechanism to the
seat cushion frame. Refer to Front Seat Cushion
Cover in this section.
3. Release the seat back cover and lift it enough to
access the bolts retaining the hinge or recliner
mechanism to the seat back. Refer to Front Seat
Back Cover in this section.
(1) Return Spring
the seat back frame.
(2) W ire Assembly
(3) Riser
(4) Bolt
6 . T h e h in g e /re c lin e r m e c h a n is m from th e s ea t
(5) Bolt
(6) Riser assembly.
Figure 19— Manual Seat Adjuster (Split Bench Seat)
Legend
(4) Seat Back Pad (11) Seat Back Pivot Bushing
(5) Seat Head Restraint (12) Seat Back Frame
(6) S eat Back Cushion Panel (13) Seat Head Restraint Guide
Figure 20— Seat Back Assembly (Front Split Bench)
SEATS 10A2-15
Legend Legend
(1) Head Restraint (1) Armrest Retaining Clip
(2) Head Restraint Retainer (2) Front Seat Back
(3) Head Restraint Retainer (3) Front Seat Back Armrest
Figure 21— Head Restraint Figure 23— Arm rest
Figure 24— Removing the Arm rest Retaining Clip
[~H~| Install or Connect (Figures 17 and 18) Tighten
1 . T h e h in g e /r e c lin e r m e c h a n is m to th e s e a t • The bolts to retain the hinge/recliner mechanism

assembly. to the front seat back frame to 35 N-m (26 lb ft).
2. The bolts to retain the hinge/recliner mechanism to 3. The bolts to retain the hinge/recliner mechanism to
the seat back frame. the seat cushion frame.
10A2-16 SEATS
Tighten FRONT SEAT BACK FRAME
• The bolts to retain the hinge/recliner mechanism REPLACEMENT
to the seat cushion frame to 35 N-m (26 lb ft).
4. The front seat back cover. Refer to Front Seat Back
Cover in this section.
1. S e a t from riser. R e fe r to Front B u cket S e a t
5. The front seat cushion cover. Refer to Front Seat
Cushion Cover in this section.
2. Head restraint and guides. Refer to Head Restraint
6 . The front seat to the vehicle. Refer to Front Seat Replacement in this section.
Assembly in this section. 3. Seat back pad. Refer to Bucket Seat Back Trim
Cover and Pad Replacement in this section.
FRONT SEAT BACK COVER 4. Two bolts retaining the seat back hinge to the seat
back frame.
Important
1. The armrest. Refer to Front Seat Armrest in this
section. • N o te the position and length of th e bolts
2. Head restraint and guides. Refer to Head Restraint removed.
Replacem ent in this section. 5. Two bolts retaining the seat back recliner to the
3. R elease the bottom edge of the seat back cover. seat back frame.
4. R elease the hook and loop strips retaining the seat
back cover to the seat back foam pad. Important
5. To e as e rem oval, place a piece of cardboard
between the seat back cover and the foam pad. • N o te the position and length of th e bolts
6 . Working from side to side, carefully lift the seat removed.
back cover from the foam pad.
Important
1. Working from side to side, carefully install the seat is equipped with a lumbar support.
back cover over the foam pad. — S e at cushion pad. R efer to Bucket S eat
2. Rem ove the cardboard from between the seat back Cushion Trim Cover and Pad Replacement
cover and the foam pad. in this section.
3. Engage the hook and loop strips retaining the seat — Two screw s retaining the lum bar cab le
back cover to the seat back foam pad. assembly to the seat cushion frame.
4. Secure the bottom edge of the seat back cover. — Turn the threaded black end of the assembly
5. Head restraint and guides. to expose the retaining slot for the cable.
6 . The armrest to the seat back. Remove the cable from the assembly.
6 . Seat Back frame from the seat assembly.
FRONT SEAT CUSHION COVER
1. Seat Back frame to the seat assembly.
1 . T h e recliner handle. R efer to Front S e a t Back
Recliner Handle in this section. | j | Important
to Power Seat Adjuster Switch in this section. • Complete the following steps ONLY if the seat
3. Release the seat cushion cover retainers from the is equipped with a lumbar support.
seat frame. — Insert the lumbar adjuster cable into the slot
4. R elease the hook and loop strips retaining the seat in the assembly. Turn the threaded black
cushion cover to the seat cushion foam pad. end of the assembly until the slot retaining
5. T h e seat cushion cover from the foam pad. the cable is concealed.
— Two screw s retaining the lu m b ar cab le
Install or Connect (Figures 17 and 18) assembly to the seat cushion frame.
— S e at cushion pad. R efer to Bucket S eat
1. The seat cushion cover to the foam pad. Cushion Trim Cover and Pad Replacement
2. Engage the hook and loop strips retaining the seat in this section.
cushion cover to the seat cushion foam pad. 2. Two bolts retaining the seat back recliner to the
3. T h e s ea t cushion cover retainers to the seat seat back frame.
cushion frame.
4. The power seat adjuster switch (if equipped). Refer Important
to Power Seat Adjuster Switch in this section.
5. T h e recliner handle. R efer to Front S eat Back • Install the bolts in their original locations, as
Recliner Handle in this section. noted during disassembly.
SEATS 10A2-17
Tighten — Two screw s retaining the lum bar cable
. Bolts to 30 N.m (22 lb ft). 2. Two bolts retaining the seat back recliner to the
3. Two bolts retaining the seat back hinge to the seat seat cushion frame.
back frame.
m Important
Important
Tighten
Tighten
4. Seat back pad. 3. Two bolts retaining the seat back hinge to the seat
5. Head restraint and guides. cushion frame.
▼ Important
FRONT SEAT CUSHION FRAME
REPLACEMENT • Install the bolts in their original locations, as
Tighten
I . S e a t from riser. R e fe r to Front B u cket S e a t
• Bolts to 30 N.m (22 lb ft).
2. Seat cushion pad. Refer to Bucket Seat Cushion 4. Seat cushion pad. Refer to Bucket Seat Cushion
Trim Cover and Pad Replacem ent in this section. Trim Cover and Pad Replacement in this section.
3. Two bolts retaining the seat back hinge to the seat 5. S e a t to the riser. R efer to Front Bucket S eat
cushion frame. Replacement in this section.
Important POWER SEAT LUMBAR SWITCH

• N o te th e position and length of th e bolts REPLACEMENT
removed.
4. Two bolts retaining the seat back recliner to the Remove or Disconnect (Figure 25)
seat cushion frame.
Important
• Pull switch partially out from seat cushion.
• N o te the position and length of the bolts 2. Switch from switch bezel.
removed. 3. Switch wiring harness in-line connector.
4. Rubber hoses.
I j I Important 5. Switch, wiring harness and hoses from side of seat
cushion.
— Two screw s retaining the lum bar cable
Remove the cable from the assembly.
5. Seat cushion frame from the seat assembly.
1. Seat cushion frame to the seat assembly.•
Important

the cable is concealed. Figure 25— Lumbar Switch
10A2-18 SEATS
1
o p ening in side of s ea t cushion and through
opening in seat frame.
1. Rubber hoses.
and install screws.
MANUAL SEAT LUMBAR

SWITCH REPLACEMENT
1. S eat from vehicle. Refer to Front Split Bench Seat

Replacem ent or Front Bucket Seat Replacem ent in
this section. Figure— 26 Bladder Assem bly
2. Screws that attach switch to side of seat cushion.
• Pull switch out from opening in side of seat 2. Bladder mounting bars to round hooks on frame
cushion. (one on each side).
3. Switch wiring harness in-line connector. 3. Seat back panel lower retainer to seat frame.
4. Rubber hoses. 4. S e at assem bly in vehicle. R efer to Front Split
5. Switch, wiring harness and hoses from side of seat Bench or Front Bucket Seat Replacem ent in this
cushion. section.

LUMBAR PUMP REPLACEMENT
1. Rubber hoses.
2. Switch wiring harness to vehicle wiring harness. 1. Seat from vehicle. Refer to Front Split Bench Seat
Replacement or Front Bucket Seat Replacement in
• Position switch in seat cushion opening and
install screws. this section.
3. S e at assem bly in vehicle. R efer to Front Split
Bench S eat R eplacem ent or Front Bucket Seat 3. Rubber hose from switch to pump.
Replacem ent in this section. 4. Retaining rings which secure pump and pump
cover assembly to seat.
LUMBAR BLADDER 5. Pump and pump cover assembly from seat.
REPLACEMENT +4- Install or Connect (Figure 26)

1. Pum p and pump cover assem b ly in s eat and
secure with retaining rings.
4. S e a t assem bly in vehicle. R efer to Front Split
upside-down.
Bench S e at R eplacem ent or Front Bucket S eat
2 . S eat back panel lower retainer from seat frame. Replacem ent in this section.
3. Rubber hose between bladder and pump.
• P la c e h a n d d o w n in s id e s e a t b a c k and
disconnect bladder mounting bars from round
FRONT BENCH SEAT
hooks on frame (one on each side). REPLACEMENT
4. Slide bladder downwards and off mounting bars.
5. Bladder from seat back.
1. Seat trim cover. Refer to Front Seat Trim Cover
• Position bladder inside seat back on mounting bars Replacem ent in this section.
and slide upwards. 2. Seat retaining bolts.
1. Rubber hose between bladder and pump. 3. Seat from the vehicle.
SEATS 10A2-19
-M - Install or Connect (Figure 29)
1. The seat adjuster to the seat.

2. The bolts to retain the seat adjuster to the seat.
Tighten
• The bolts to retain the seat adjuster to the seat

to 25 N.m (18 lb ft).
riser.
riser.
Tighten
• The nuts to retain the seat adjuster to the seat

riser to 45 N.m (33 lb ft).
HEAD RESTRAINT
REPLACEMENT
4 -4 Remove or Disconnect (Figures 30 and 31)
1. Seat to the vehicle.
2. Seat retaining bolts. 1. Raise head restraint to its full up position.
Tighten the forward edge of the head restraint retainer.
• Bolts to 55 N.m (41 lb ft). and lift the head restraint from the retainers.
3. Seat trim cover to seat. Refer to Front Seat Trim
Cover Replacement in this section. Install or Connect (Figures 30 and 31)
FRONT SEAT RISER 1. The head restraint into the retainers.

Remove or Disconnect (Figure 28) pull up to ensure it is engaged with the head
1. The front seat assembly from the vehicle. Refer to
Front Seat Assembly in this section. HEAD RESTRAINT GUIDE
2. T h e nuts retaining the s e a t riser to the seat REPLACEMENT
adjuster.
3. The front seat riser from the seat adjuster. Remove or Disconnect (Figure 32)
-► 4- Install or Connect (Figure 28) 1. Seat back trim cover and pad. Refer to Seat Back
1. The front seat riser to the seat adjuster. 2. Head restraint guide(s) from the seat back frame by
2. T h e nuts to retain the s e a t riser to the s ea t squeezing the retaining tabs together at the base of
adjuster. the guide (Figure 32) and lifting up.
Tighten -► 4- Install or Connect (Figure 32)
• The nuts to retain the seat riser to the seat 1. Head restraint guide(s) by pressing into the seat
adjuster to 45 N.m (33 lb ft). back frame until the retaining tabs snap into place
3. The front seat assembly to the vehicle. Refer to at the bottom of the frame opening (Figure 32).
Front Seat Assembly in this section. 2 . Seat back trim cover and pad. Refer to Seat Back
FRONT SEAT ADJUSTER
FRONT SEAT ARMREST
4 --4 Remove or Disconnect (Figure 29)
4 --4 Remove or Disconnect (Figure 30, 33 and 34)
1. The nuts retaining the seat adjuster to the seat
riser. 1. Release the bottom edge of the seat back cover.
2 . The front seat and the seat adjuster from the seat Refer to Front Seat Back Cover in this section.
riser. 2. Using a small bladed tool, release the clip retaining
3. The bolts retaining the seat adjuster to the seat. the armrest to the seat back.
4. The seat adjuster from the seat. 3. Pull the armrest from the seat back.
10A2-20 SEATS
Legend
(1) Armrest Detent Rivet (16) Bench Seat Cushion Pad
(2) Armrest Detent (17) Seat Cushion Air Pump
(3) Armrest Inner Pivot Bracket Cover (18) Hog Ring
(4) S eat Cushion Frame (19) Seat Adjuster W ire Assembly
(5) S eat Cushion Pad Support W ire Spring (20) Reinforcement
(6) S eat Recliner (21) Clip
(7) Bolt (22) Seat Riser
(8) S eat Back R elease Handle (23) Seat Cushion Strap
(10) S eat Cushion to Recliner Fill Pad (25) Bench Seat Cushion Cover
(11) Lumbar Switch (26) Lower Armrest Outer Cover
(12) S eat Cushion Finish Panel (27) Upper Armrest Outer Cover
(13) Seat Adjuster Retainer Spring (28) Armrest Latch
(14) S eat Adjuster Retainer Spring Insulator (29) Armrest/Center Console
(15) S eat Riser (30) Armrest Pivot Bushing
(31) Cushion Seat Belt Reinforcement
(32) Seat Belt Opening Bezel Retainer
Figure 28— Seat Cushion Assembly (Bench Seat)
Install or Connect (Figure 30, 33 and 34) FRONT SEAT BACK RECLINER
1. T h e retaining clip to the seat back, ensure that the
HANDLE
retaining clip is fully seated.
2. T h e armrest to the seat back. Remove or Disconnect (Figure 28)
3. Press on the armrest to engage the armrest with
the retaining clip in the seat back. 1 . T h e re c lin e r h a n d le c o v e r from th e re c lin e r
4. Secure the bottom edge of the seat back cover. mechanism.
Refer to Front Seat Back Cover in this section. 2. Th e screw retaining the recliner handle to the
recliner mechanism.
3. The recliner handle from the recliner mechanism.
SEATS 10A2-21
6 . T h e h in g e /re c lin e r m e c h a n ism from th e s eat
assembly.
1 . T h e h in g e /r e c lin e r m e c h a n is m to th e s e a t
assembly.
2. The bolts to retain the hinge/recliner mechanism to
Tighten

to the front seat back fram e to 35 N.m (26 lb ft).
3. The bolts to retain the hinge/recliner mechanism to

Legend
(1) Return Spring Tighten
(2) Return Spring
(3) Adjusting Latch Spring • The bolts to retain the hinge/recliner mechanism
(4) Bolt to the seat cushion frame to 35 N-m (26 lb ft).
(5) Riser
(6) Bolt 4. The front seat back cover. Refer to Front Seat Back
(7) Reinforcement Cover in this section.
(8) Adjusting Lever 5. The front seat cushion cover. Refer to Front Seat
(9) W ire Assembly Cushion Cover in this section.
(10) Bolt 6 . The front seat to the vehicle. Refer to Front Seat
(11) Riser Assembly in this section.
(12) Adjusting Latch Spring
Figure 29— Manual Seat Adjuster (Bench Seat) FRONT SEAT BACK COVER
+«■ Install or Connect (Figure 28)
4 -+ Remove or Disconnect (Figure 30)
1. The recliner handle to the recliner mechanism.
2. Th e screw retaining the recliner handle to the 1. The armrest. Refer to Front Seat Armrest in this
recliner mechanism. section.
3. T h e r e c lin e r h a n d le c o v e r to th e r e c lin e r 2. Head restraint and guides. Refer to Head Restraint
mechanism. Replacement in this section.
FRONT SEAT BACK 4. Release the hook and loop strips retaining the seat
HINGE/RECLINER MECHANISM back cover to the seat back foam pad.
5. To ease rem oval, place a piece of cardboard
The front seat back recliner mechanism is mounted to between the seat back cover and the foam pad.
the inboard side of the seat. The outboard hinge bolts to 6 . Working from side to side, carefully lift the seat
the seat back and the seat bottom.
back cover from the foam pad.

Assembly in this section. 1. Working from side to side, carefully install the seat
2 . Release the seat cushion cover to access the bolts back cover over the foam pad.
retaining the hinge or recliner mechanism to the 2. Remove the cardboard from between the seat back
seat cushion frame. Refer to Front Seat Cushion cover and the foam pad.
Cover in this section. 3. Engage the hook and loop strips retaining the seat
3. Release the seat back cover and lift it enough to back cover to the seat back foam pad.
access the bolts retaining the hinge or recliner 4. Secure the bottom edge of the seat back cover.
mechanism to the seat back. Refer to Front Seat 5. Head restraint and guides.
Back Cover in this section.
6 . The armrest to the seat back. Refer to Front Seat
Armrest in this section.
10A2-22 SEATS
Legend
(4) S eat Back Pad (11) Seat Back Pivot Bushing
(5) S eat Head Restraint (12) Seat Back Frame
(6) S eat Back Cushion Panel (13) Seat Head Restraint Guide
Figure 30— Seat Back Assem bly (Bench Seat)
(1) H ead Restraint

(2) H ead Restraint Retainer
(3) H ead'R estraint Retainer to Power Seat Adjuster Switch in this section.
3. Release the seat cushion cover retainers from the
Figure 31— Head Restraint
seat frame.
FRONT SEAT CUSHION COVER cushion cover to the seat cushion foam pad.
5. Th e seat cushion cover from the foam pad.
I*"*! Remove or Disconnect (Figure 28)
1. T h e recliner handle. R efer to Front S e a t Back
Recliner Handle in this section. 1. The seat cushion cover to the foam pad.
SEATS 10A2-23
Legend Figure 34— Removing the Arm rest Retaining Clip

(1) Armrest Retaining Clip
I l Important
(2) Front Seat Back
(3) Front Seat Back Armrest
Figure 33— Armrest is equipped with a lumbar support.
— S e at cushion pad. R efer to Bucket Seat
in this section.
3. The seat cushion cover retainers to the seat cush
— Two screw s retaining the lum bar cable
ion frame.
4. Th e power seat adjuster switch (if equipped). Refer — Turn the threaded black end of the assembly
to Power Seat Adjuster Switch in this section. to expose the retaining slot for the cable.
5. The recliner handle. R efer to Front S e at Back Remove the cable from the assembly.
Recliner Handle in this section. 5. Seat Back fram e from the seat assembly.
FRONT SEAT BACK FRAME Install or Connect (Figure 30)
REPLACEMENT 1. Seat Back frame to the seat assembly.
9 Important
I . S e a t from riser. R e fe r to Front B u cket S e a t is equipped with a lumbar support.
Replacement in this section. — Insert the lumbar adjuster cable into the slot
2. Seat Back pad. Refer to Bucket Seat Back Trim in the assembly. Turn the threaded black
Cover and Pad Replacem ent in this section. end of the assembly until the slot retaining
3. Two bolts retaining the seat back hinge to the seat the cable is concealed.
back frame. — Tw o screw s retaining th e lu m b ar cable
9 Important — S e at cushion pad. R efer to Bucket Seat
in this section.
• N o te the position and length of th e bolts
removed. seat back frame.
Important
seat back frame.
9 Important noted during disassembly.
Tighten
• N o te th e p o sition and len g th of th e bolts
removed.
back frame.
10A2-24 SEATS
Im p o r ta n t Im p o rta n t
• Install the bolts in their original locations, as • Complete the following steps ONLY if the seat
noted during disassembly. is equipped with a lumbar support.
T ig h te n
the cable is concealed.
. Bolts to 30 N.m (22 lb ft). — Two screws retaining the lumbar cable
4. Seat Back pad. Refer to Bucket Seat Back Trim 2. Two bolts retaining the seat back recliner to the
Cover and Pad Replacement in this section. seat cushion frame.
5. Seat to the riser. Refer to Front Bucket Seat
Replacement in this section. Im p o rta n t
FRONT SEAT CUSHION FRAME • Install the bolts in their original locations, as
REPLACEMENT
T ig h te n
R e m o v e o r D is c o n n e c t (F ig u r e 2 8 )
I.S e a t from riser. Refer to Front Bucket Seat cushion frame.
2. Seat cushion pad. Refer to Bucket Seat Cushion Im p o rta n t
3. Two bolts retaining the seat back hinge to the seat • Install the bolts in their original locations, as
cushion frame. noted during disassembly.
T ig h te n
Im p o rta n t
• Note the position and length of the bolts 4. Seat cushion pad. Refer to Bucket Seat Cushion
removed. Trim Cover and Pad Replacement in this section.
5. Seat to the riser. Refer to Front Bucket Seat
4. Two bolts retaining the seat back recliner to the Replacement in this section.
seat cushion frame.
POWER SEAT LUMBAR SWITCH
Im p o rta n t REPLACEMENT
• Note the position and length of the bolts R e m o v e o r D is c o n n e c t (F ig u r e 3 5 )
removed.
• Pull switch partially out from seat cushion.
Im p o rta n t 2. Switch from switch bezel.

— Two screws retaining the lumbar cable
Remove the cable from the assembly.
5. Seat cushion frame from the seat assembly.
In s ta ll o r C o n n e c t (F ig u r e 2 9 )
1. Seat cushion frame to the seat assembly.
Figure 35—Lumbar Switch

SEATS 10A2-25
4. Rubber hoses.
5. Switch, wiring harness and hoses from side of seat
cushion.
+◄ - In s ta ll o r C o n n e c t (F ig u r e 3 5 )

opening in side of seat cushion and through
opening in seat frame.
1. Rubber hoses.
and install screws.
MANUAL SEAT LUMBAR

SWITCH REPLACEMENT
R e m o v e o r D is c o n n e c t

Replacement or Front Bucket Seat Replacement in |-M -| In s ta ll o r C o n n e c t (F ig u re 3 6 )
this section.
2. Screws that attach switch to side of seat cushion. • Position bladder inside seat back on mounting bars
• Pull switch out from opening in side of seat and slide upwards.
cushion.
3. Switch wiring harness in-line connector. 1. Rubber hose between bladder and pump.
4. Rubber hoses. 2. Bladder mounting bars to round hooks on frame
5. Switch, wiring harness and hoses from side of seat (one on each side).
cushion. 3. Seat Back panel lower retainer to seat frame.
4. Seat assembly in vehicle. Refer to Front Split
In s ta ll o r C o n n e c t
Bench or Front Bucket Seat Replacement in this
• Route switch wiring harness and hoses through section.
1. Rubber hoses. LUMBAR PUMP REPLACEMENT
• Position switch in seat cushion opening and R e m o v e o r D is c o n n e c t (F ig u r e 3 6 )
install screws.
3. Seat assembly in vehicle. Refer to Front Split
Bench Seat Replacement or Front Bucket Seat 1. Seat from vehicle. Refer to Front Split Bench Seat
Replacement in this section. Replacement or Front Bucket Seat Replacement in
this section.
LUMBAR BLADDER 2. Pump wiring harness in-line connector.
REPLACEMENT 4. Retaining rings which secure pump and pump cov
R e m o v e o r D is c o n n e c t (F ig u r e 3 6 ) er assembly to seat.
5. Pump and pump cover assembly from seat.
0 In s ta ll o r C o n n e c t (F ig u r e 3 6 )
upside-down.
2. Seat Back panel lower retainer from seat frame. 1. Pump and pump cover assembly in seat and
3. Rubber hose between bladder and pump. secure with retaining rings.
• Place hand down inside seat back and discon 2. Rubber hose from switch to pump.
nect bladder mounting bars from round hooks 3. Pump wiring harness in-line connector.
on frame (one on each side). 4. Seat assembly in vehicle. Refer to Front Split
4. Slide bladder downwards and off mounting bars. Bench Seat Replacement or Front Bucket Seat
5. Bladder from seat back. Replacement in this section.
10A2-26 SEATS
REAR PASSENGER SEATS

REAR SEAT REPLACEMENT REAR SEAT RISER
R e m o v e o r D is c o n n e c t (F ig u re s 3 7 th ro u g h 4 4 )
R e m o v e o r D is c o n n e c t (F ig u re s 4 5 th ro u g h 4 9 )
1. Front and rear leg trim covers.
2. Seat retaining bolts. 1. The rear passenger seat from the vehicle. Refer to
3. Seat from the vehicle. Rear Passenger Seats in this section.
+4*1 In s ta ll o r C o n n e c t (F ig u r e s 3 7 th r o u g h 4 4 )
2. The nuts and bolts retaining the seat riser to the
seat cushion frame.
1. Seat into the vehicle. 3. The seat riser from the seat cushion frame.
+ 4- In s ta ll o r C o n n e c t (F ig u r e s 4 5 th o u g h 4 9 )
T ig h te n
1. The seat riser to the seat cushion frame.
• Bolts to 55 N-m (41 lb ft). 2. The nuts and bolts to retain the seat riser to the
3. Front and rear leg trim covers. seat cushion frame.
F ig u re 3 7 — In s ta ll R e a r S e a t (S u b u rb a n )
Figure 40—Folding Rear Seat Mounting

SEATS 10A2-27
F ig u re 4 1 — F o ld in g R e a r S e a t T rim C o v e r s (U tility ) F ig u re 4 2 — S e a t R e ta in in g B o lts a n d C o m p o n e n ts

(U tility )
T ig h te n
• The nuts and bolts to retain the seat riser to the

seat cushion frame to 55 N-m (41 lb ft).
3. The rear passenger seat to the vehicle. Refer to
Rear Passenger Seats in this section.
REAR SEAT HEAD RESTRAINT

R e m o v e o r D is c o n n e c t (F ig u r e 51 th r o u g h 5 5 )
1. Raise head restraint to its full up position.

In s ta ll o r C o n n e c t (F ig u r e s 51 th r o u g h 5 5 )

HEAD RESTRAINT GUIDE

REPLACEMENT
R e m o v e o r D is c o n n e c t (F ig u r e 5 0 )

-M - In s ta ll o r C o n n e c t (F ig u r e 5 0 )
1. Head restraint guide(s) by pressing into the seat

back frame until the retaining tabs snap into place
at the bottom of the frame opening (Figure 51).
2. Seat Back trim cover and pad. Refer to Seat Back Figure 44— Rear Seat Mounting (Crew Cab)
10A2-28 SEATS
(1) Seat Cushion Cover (6) Bolt

(2) Seat Cushion Pad (7) Bolt
(3) Hog Ring (8) Washer
(4) Seat Cushion Frame (9) Seat Cushion Frame Support Wire Spring
(5) Seat Cushion Frame Support
F ig u re 4 5 — R e a r F o ld in g B e n c h S e a t C u s h io n (U tility )
Legend
(1) Seat Cushion Cover (6) Bolt
(2) Seat Cushion Pad (7) Bolt
(3) Hog Ring (8) Washer
(4) Seat Cushion Frame (9) Seat Cushion Frame Support Wire Spring
F ig u re 4 6 — R e a r F o ld in g B e n c h S e a t C u s h io n (E x te n d e d C a b )
REAR SEAT BACK 2. The armrest. Refer to Rear Passenger Seat

Armrest in this section.
3. Open the access flaps at the lower rear corners of
R e m o v e o r D is c o n n e c t (F ig u re s 51 th ro u g h 5 5 ) the seat back, to allow for access to the seat back
to the frame retaining bolts.
1. The seat from the vehicle. Refer to Rear Passenger 4. The bolts from the seat back frame.
Seat Assembly in this section. 5. Seat Back frame from the seat back cushion frame.
SEATS 10A2-29
Legend
(1) Bolt (16) Adjuster Spring Insulator
(2) Hinge (17) Adjuster Spring
(3) Hinge Pivot (18) Riser
(4) Support (19) Bolt
(5) Washer (20) Bench Seat Cushion Frame Support
(6) Bracket (21) Bench Seat Cushion Pad
(7) Bushing (22) Bolt
(8) Reinforcement (23) Reinforcement
(9) Bracket (24) Adjuster Wire Assembly
(11) Washer (26) Hog Ring
(12) Bench Seat Cushion Frame (27) Riser
(13) Rod (28) Bolt
(14) Seat Cushion Pad Support Wire Spring (29) Bench Seat Cushion Cover
(15) Cushion Recliner Filler Pad (30) Cushion Seat Belt Reinforcement
F ig u re 4 7 — R e a r F o ld in g B e n c h S e a t C u s h io n (C r e w C a b )
+4* In s ta ll o r C o n n e c t (F ig u r e s 51 th r o u g h 5 5 ) 5. The seat to the vehicle. Refer to Rear Passenger

Seat Assembly in this section.
1. The seat back frame to the seat cushion frame.
2. The bolts to retain the seat back frame to the seat REAR SEAT CUSHION COVER
cushion frame.
0 R e m o v e o r D is c o n n e c t (F ig u re s 4 5 th ro u g h 4 9 )
a T ig h te n
• The bolts to retain the seat back frame to the 1. The rear passenger seat from the vehicle. Refer to
seat cushion frame to 35 N-m (26 lb ft). Rear Passenger Seat in this section.
3. Secure the access flaps at the lower rear corners 2. The rear passenger seat riser. Refer to Rear
of the seat back. Passenger Seat Riser Assembly in this section.
4. The armrest to the seat back. Refer to Rear 3. The seat back from the seat cushion. Refer to Rear
Passenger Seat Armrest in this section. Passenger Seat Back in this section.
10A2-30 SEATS
(1) Seat Belt Strap

(2) Bolt
(3) Bolt
(4) Seat Cushion Frame
(6) Seat Cushion Frame Support Wire Spring
(7) Seat Cushion Pad
(8) Seat Cushion Cover
F ig u re 4 8 — R e a r F o ld in g S e a t C u s h io n 4 0 %
(S u b u r b a n )
4. The hog rings from the rear edge of the seat (3) Seat Belt Opening Bezel Retainer
cushion cover. (4) Seat Cushion Cover
5. The seat belt buckles. Refer to Rear Passenger
(6) Seat Belt Wire
Seat Belt Buckles in this section.
(7) Seat Cushion Strap
6. All remaining hog rings retaining the seat cushion (8) Seat Cushion Frame
cover to the seat cushion frame. (9) Seat Cushion Frame Support
7. Release the hook and loop strips retaining the seat (10) Seat Cushion Frame Support Wire Spring
cushion cover to the foam pad. (11) Seat Cushion Frame Support
8. The seat cushion cover from the foam pad. (12) Washer
(13) Seat Belt Cable End
-M - In s ta ll o r C o n n e c t (F ig u r e s 4 5 th r o u g h 4 9 ) (14) Bolt
(15) Seat Belt
1. The seat cushion cover to the foam pad. (16) Bolt
2. Engage the hook and loop strips retaining the seat (17) Cushion Seat Belt Reinforcement
cushion cover to the foam pad. F ig u r e 4 9 — R e a r F o ld in g S e a t C u s h io n 6 0 %
3. The seat belt buckles. Refer to Rear Passenger (S u b u rb a n )
Seat Belt Buckles in this section.
4. The hog rings to retain the seat cushion cover to REAR SEAT BACK COVER
5. The seat back to the seat cushion. Refer to Rear R e m o v e o r D is c o n n e c t (F ig u re s 51 th ro u g h 5 5 )
Passenger Seat Back in this section.
6. The rear passenger seat risers. Refer to Rear 1. The armrest from the seat back. Refer to Rear
Passenger Seat Riser Assembly in this section. Passenger Seat Armrest in this section.
7. The rear passenger seat to the vehicle. Refer to 2. The head restraints from the seat back. Refer to
Rear Passenger Seat in this section. Rear Passenger Seat Head restraint in this section.
SEATS 10A2-31
3. Engage the hook and loop strips that retain the
seat back cover to the seat back foam pad.
5. The head restraints to the seat back. Refer to Rear
Passenger Seat Head restraint in this section.
6. The armrest to the seat back. Refer to Rear
Passenger Seat Armrest in this section.
REAR BENCH SEAT BACK

FRAME REPLACEMENT
3 Rem ove or D isconnect (Figures 51 through
55)
1. Seat Back trim cover and pad. Refer to Rear and

Second Rear Bench Seat Back Trim Cover and
Pad Replacement in this section.
2. Latch release cable. Refer to Rear and Second
Rear Bench Seat Latch Release Cable Replace
ment in this section.
back cover to the seat back foam pad.
5. To ease removal, place a piece of cardboard ■ M- Install or Connect (Figures 51 through 55)
between the seat back cover and the foam pad.
6. Working from side to side, carefully lift the seat 1. Latch release cable. Refer to Rear and Second
back cover from the foam pad. R ear B en ch S e a t L a tch R e le a s e C a b le
Install or Connect (Figures 51 through 55) 2. Seat Back trim cover and pad. Refer to Rear and
back cover over the foam pad.
2. Remove the cardboard from between the seat back
cover and the foam pad.
Legend
(1) Seat Back Cushion Pad (6) Bolt
(2) Seat Back Cushion Cover (7) Seat Back Finish Panel
(3) Seat Belt Comfort Guide (8) Seat Back Frame
(4) Bolt (9) Head Restraint Guide
(5) Strap (10) Head Restraint
Figure 51—-Rear Folding Bench Seat Back (Utility)
10A2-32 SEATS
Legend
(1) Seat Back Cushion Cover (10) Bolt
(2) Seat Belt Comfort Guide (11) Washer
(3) Bolt (12) Filler Block
(4) Seat Cushion Hinge (13) Bolt
(5) Bolt (14) Seat Back Hinge
(6) Bolt (15) Seat Back Frame
(7) Seat Support (16) Head Restraint Guide
(8) Spacer (17) Head Restraint
(9) Bolt (18) Seat Back Cushion Pad
Figure 52— Rear Folding Bench Seat Back (Extended Cab)
Legend
(1) Seat Back Cushion Cover (6) Rivet
(2) Seat Back Cushion Pad (7) Seat Back Hinge
(3) Head Restraint (8) Hog Ring
(4) Head Restraint Guide (9) Seat Belt Comfort Guide
(5) Seat Back Frame
Figure 53— Rear Folding Bench Seat Back (Crew Cab)
SEATS 10A2-33
(1) Seat Back Cushion Cover

(2) Head Restraint
(3) Head Restraint Guide
(5) Seat Back Cushion Finish Panel
(6) Bolt
(7) Seat Back Cushion Pad
(8) Seat Belt Comfort Guide
Figure 54— Rear Folding Seat Back 40% (Suburban) Legend
(1) Head Restraint
REAR BENCH SEAT CUSHION (2) Seat Back Cushion Cover
FRAME REPLACEMENT (3) Cupholder
(4) Center Armrest/Console
E3 Rem ove or D isconnect (Figures 45 through
(5)
(6)
Washer
Bolt
49) (7) Cover
(8) Bolt
I.S e a t cushion trim cover and pad. Refer to Rear (9) Bolt
and Second Rear Bench Seat Cushion Trim Cover (10) Seat Back Cushion Finish Panel
and Pad Replacement in this section. (11) Seat Back Cushion Frame
2. Seat cushion frame. (12) Seat Back Cushion Pad
Install or C onnect (Figures 45 through 49) Figure 55— Rear Folding Seat Back 60% (Suburban)
1. Seat cushion frame.

2. Seat cushion trim cover and pad. Refer to Rear
REAR SEAT SUPPORT
and Second Rear Bench Seat Cushion Trim Cover REPLACEMENT (EXTENDED
and Pad Replacement in this section. CAB) W ITH REAR ACCESS
REAR FOLDING SEAT PANEL DOOR-RIGHT SIDE ONLY
REPLACEMENT

1 . Jack cover and contents. Refer to Jack and
1. Remove bolts. Stowage Replacement in Interior Trim.
2. Remove rear folding seat panel. 2. Jack bottom box.
3. Pivot trim covers.
[•»<-{ Install or C onnect (Figure 56) 4. Rear seat mounting bolts.
5. Lift and support seat end.
1. Install rear folding seat panel. 6. Support retaining bolts.
2. Install bolts. 7. Support assembly from the vehicle.
10A2-34 SEATS
5. Pivot trim covers.
6. Jack bottom box.
7. Jack cover and contents.
REAR SEAT SUPPORT

REPLACEMENT (EXTENDED
CAB) LEFT SIDE-ALL MODELS &
RIGHT SIDE W ITHOUT REAR
ACCESS DOOR
4- + Rem ove or Disconnect (Figure 57)
1. Jack cover and contents (right side only).

2. Jack bottom box (right side only).
3. Rear seat with pivot covers.
4. Rear seat from vehicle.
Figure 56— Rear Folding Seat Panel (U tility) 5. Front seat belt retractors.
6. Front shoulder pivots.
Install or Connect (Figure 57) 7. Armrest.
8. Lower rear quarter trim panel.
1. Support assembly to the vehicle. 9. Lower center trim panel under rear glass.
2. Support retaining bolts. 10. Upper rear quarter trim panel.
3. Lower seat to pivot assembly. 11. Support retaining bolts.
4. Seat mounting bolts. 12. Support assembly from the vehicle.

Tighten
1. Support assembly to the vehicle.

• Bolts to 55 N-m (41 lb ft). 2. Support retaining bolts.
Figure 57—Rear Folding Seat Support (Extended Cab)

SEATS 10A2-35
Tighten
• Bolts to 55 N m (41 lb ft).

3. Upper rear quarter trim panel.
4. Lower center trim panel under rear glass.
5. Lower rear quarter trim panel.
6. Armrest.
7. Front shoulder pivots.
8. Front seat belt retractors.
9. Rear seat into vehicle and position.
10. Rear seat and pivot covers.
11. Jack bottom box (right side only).
12. Jack cover and contents (right side only).
SECOND REAR SEAT ASSEMBLY

1. The quick release latch plates for the lap/shoulder Figure 58— Rear Seat M ounting (Suburban)
belts by pressing a drift punch or similar tool into
the release hole of the seat belt buckle while floor rail.
pulling on the safety belt. 4. Roll the seat back and down to secure into place.
2. Pull up on the handle at the rear of the seat. 5. The quick release latch plate for the lap/shoulder
3. Roll seat forward and lift up and out of the floor belt by inserting the latch plate into the seat belt
rails. buckle and pushing to engage the latch plate with
4. The seat from the vehicle. the seat belt buckle.
REAR SEAT HEAD RESTRAINT
1. The seat to the vehicle.
2. Align the seat attaching points with the slots in the Rem ove or Disconnect (Figure 59)
floor rail.
3. Push the seat forward in the rail to lock the front of 1. Raise head restraint to its full up position.
the seat risers onto the pins on the inside of the 2. Insert a paper clip or a similar tool in the hole at
(1) Seat Back Cushion Cover (7) Bolt

(2) Seat Back Cushion Pad ( 8) Bolt
(3) Head Restraint (9) Seat Belt
(4) Head Restraint Guide ( 10) Bolt
(5) Seat Back Frame ( 11) Seat Belt Contort Guide
(6) Seat Back Hinge
Figure 59— Rear Seat #2 Seat Back (Suburban)
10A2-36 SEATS
44 - Install or Connect (Figure 59)
1. The seat back frame to the seat cushion frame.

2. The bolts to retain the seat back frame to the seat
cushion frame.
Tighten
• The bolts to retain the seat back frame to the

seat cushion frame to 35 N.m (26 lb ft).
3. Secure the access flaps at the lower rear corners
of the seat back.
4. The armrest to the seat back. Refer to Rear
Passenger Seat Armrest in this section.
5. The seat to the vehicle. Refer to Rear Passenger
REAR SEAT CUSHIOM COVER

and lift the head restraint from the retainers. 1. The rear passenger seat from the vehicle. Refer to
Rear Passenger Seat in this section.
44 Install or C onnect (Figure 59) 2. The rear passenger seat riser. Refer to Rear Pas
senger Seat Riser Assembly in this section.
1. The head restraint into the retainers. 3. The seat back from the seat cushion. Refer to Rear
2. Push the head restraint to its full down position and Passenger Seat Back in this section.
pull up to ensure it is engaged with the head 4. The hog rings from the rear edge of the seat cush
restraint retainers. ion cover.
REAR SEAT HEAD RESTRAINT Seat Belt Buckles in this section.
GUIDE REPLACEMENT 6. All remaining hog rings retaining the seat cushion
cover to the seat cushion frame.
Rem ove or D isconnect (Figure 60) 7. Release the hook and loop strips retaining the seat
cushion cover to the foam pad.
1. Seat Back trim cover and pad. Refer to Seat Back 8. The seat cushion cover from the foam pad.
2. Head restraint guide(s) from the seat back frame by 44- Install or C onnect (Figure 61)
the guide (Figure 60) and lifting up. 1. The seat cushion cover to the foam pad.
4 4 Install or C onnect (Figure 60) cushion cover to the foam pad.
1. Head restraint guide(s) by pressing into the seat Seat Belt Buckles in this section.
back frame until the retaining tabs snap into place 4. The hog rings to retain the seat cushion cover to
at the bottom of the frame opening (Figure 60). the seat cushion frame.
2. Seat Back trim cover and pad. Refer to Seat Back 5. The seat back to the seat cushion. Refer to Rear
Trim Cover and Pad Replacement in this section. Passenger Seat Back in this section.
6. The rear passenger seat risers. Refer to Rear
REAR SEAT BACK Passenger Seat Riser Assembly in this section.
7. The rear passenger seat to the vehicle. Refer to
Rem ove o r D isconnect (Figure 59) Rear Passenger Seat in this section.
1. The seat from the vehicle. Refer to Rear Passenger

REAR SEAT BACK COVER
2. The armrest. Refer to Rear Passenger Seat
Armrest in this section. Hjj Rem ove or D isconnect (Figure 59)
3. Open the access flaps at the lower rear corners of
the seat back, to allow for access to the seat back 1. The armrest from the seat back. Refer to Rear
to the frame retaining bolts. Passenger Seat Armrest in this section.
4. The bolts from the seat back frame. 2. The head restraints from the seat back. Refer to
5. Seat Back frame from the seat back cushion frame. Rear Passenger Seat Head restraint in this section.
SEATS 10A2-37
(1) Seat Back Hinge (6) Seat Cushion Cover

(3) Recliner Filler Block (8) Bolt
(4) Seat Cushion Frame (9) Seat Belt
Figure 61— Rear Seat #2 Seat Cushion (Suburban)
3. Release the bottom edge of the seat back cover. Install o r Connect (Figure 59)
back cover to the seat back foam pad. 1. Latch release cable. Refer to Rear and Second
5. To ease removal, place a piece of cardboard Rear Bench Seat Latch Release Cable Replace
between the seat back cover and the foam pad. ment in this section.
6. Working from side to side, carefully lift the seat 2. Seat Back trim cover and pad. Refer to Rear and
back cover from the foam pad. Second Rear Bench Seat Back Trim Cover and
-M - Install or C onnect (Figure 59)
REAR SEAT CUSHION FRAME
back cover over the foam pad. REPLACEMENT
2. Remove the cardboard from between the seat back
cover and the foam pad. I++1 Rem ove or D isconnect (Figure 61)
3. Engage the hook and loop strips that retain the
seat back cover to the seat back foam pad. 1. Seat cushion trim cover and pad. Refer to Rear
4. Secure the bottom edge of the seat back cover. and Second Rear Bench Seat Cushion Trim Cover
5. The head restraints to the seat back. Refer to Rear and Pad Replacement in this section.
Passenger Seat Head restraint in this section. 2. Seat cushion frame.
6. The armrest to the seat back. Refer to Rear Pas
senger Seat Armrest in this section. I**" ! Install or C onnect (Figure 61)
REAR SEAT BACK FRAME 1. Seat cushion frame.

REPLACEMENT 2. Seat cushion trim cover and pad. Refer to Rear
and Second Rear Bench Seat Cushion Trim Cover
and Pad Replacement in this section.
1. Seat Back trim cover and pad. Refer to Rear and

2. Latch release cable. Refer to Rear and Second
Rear Bench Seat Latch Release Cable Replace
10A2-38 SEATS
SPECIFICATIONS

Front Seat Retaining Bolts 55 41 —
Hinge/Recliner Mechanism to the Seat Back Frame and Seat Cushion 35 26 —
Frame Bolts
Rear Seat Retaining Bolts 17 13 —
Rear Seat Support Bolts 55 41 —
Seat Adjuster to the Seat Bolts 25 18 —
Seat Adjuster to the Seat Riser Nuts 45 33 —
Seat Back Recliner to Seat Back Frame Bolts 30 22 —

Seat Riser to Seat Cushion Frame Bolts 55 41 —
SPECIAL TOOLS
1. TRIM PAO C UP REMOVER

WINDOWS 10A3-1
SECTION 10A3
WINDOWS
GENERAL INFORMATION
The information contained in this section provides ser Im portant
vice procedures that apply to stationary windows
retained with urethane adhesive and related reveal • If corrosion of the pinchweld flange is present, or if
moldings. sheet metal repairs or replacements are required,
the pinchweld flange must be refinished to present
STATIONARY WINDOWS a clean Primer Only surface.
Most stationary windows (specifically windshields) are • If paint repairs are required, mask the flange bond
retained to the body with urethane adhesive which ing area (prior to applying the color coat) to provide
when totally cured, adheres the window to the body a clean Primer Only surface.
increasing structural integrity. The reinstallation of win • Appropriate materials for these primer applications
dows with urethane adhesive requires either partial or are typically two component catalyzed products
complete replacement of the urethane adhesive bead: such as BASF DE17, DUPONT 2610, PPG DP90
• The Short Method (also known as short cut or (or equivalent) applied by following the manufactur
close cut) is the partial replacement. ers directions for mix, application and dry times.
• The Extended Method (also known as long • After repairing the opening as indicated, shake
method, full strip or full cut) is the complete pinchweld primer #3 (black) well, and using a new
replacement. dauber, apply to the primed surface of the flange in
the bonding area. Allow to dry for 10 minutes.
Short Method
• Use the extended method of replacement and
The short method can be used where the original appropriate bead size when installing the window.
urethane adhesive bead left on the window opening
pinchweld flange (after window removal) can serve as a 9 Im portant
base for the new window. This method uses a small
bead of urethane adhesive to adhere the window in the
opening to the original urethane adhesive bead. • The urethane adhesive bead profile for extended
This method is best used when the following apply: method will vary depending on the style of vehicle
When the original bead of urethane adhesive left on the being repaired.
body after window removal is;
A. intact without portions of bead missing, ADHESIVE SERVICE KIT
B. solidly adhered to the pinchweld flange and no Urethane Adhesive Caulking Kit GM P/N 12346284
corrosion is present on the flange, contains four different primers, urethane adhesive with
C. uniform in shape, smooth, without multiple cuts nozzle, daubers and instructions with warnings. This
or loose material present, urethane adhesive caulking kit is designed to be used
D. when repainting of the opening or collision when replacing any urethane adhesive-installed window
repair/sheet metal replacement is NOT required,
using the short method, or any urethane adhesive-in
E. or when urethane adhesive deterioration is not
stalled window using the extended method. An equiva
evident (no powdery residue).
lent urethane adhesive system may be used as long as
Extended Method the system meets GM Specification GM3651M. Always
The extended method is to be used when the original follow the system manufacturer’s application, handling
urethane adhesive bead left on the window opening and curing instructions.
pinchweld flange (after window removal) CANNOT serve
as a base for the new window, OR, in any case where ELECTROCHROMIC INSIDE
the use of the Short Method is in doubt.
This method includes the replacement of a majority of REARVIEW MIRROR
the urethane adhesive bead, where a thin film of the W ITH COMPASS
original bead remains and applying pinchweld primer to
any exposed painted areas on the pinchweld flange. If equipped, this mirror automatically dims to a level
There should not be any mounds or loose pieces of required to minimize glare while still maintaining maxi
urethane adhesive remaining on the pinchweld flange. It mum rear vision when Auto Mirror is enabled. The com
is not necessary to remove all traces of urethane pass is an eight point compass readout that calibrates
adhesive. automatically as the vehicle is driven.
10A3-2 WINDOWS
There are two buttons on the bottom of the mirror. into the compass Magnetic North to True North. The
Depending on how the vehicle is equipped the mirror mirror is preset to Zone 8. Vehicles sold in Japan are
will have a COMP position which turns on/off the com preset to Zone 9.
pass, and either a MIRROR which turns on/off the Auto To set compass variance do the following:
Mirror feature (Figure 2), or a TEMP which displays the 1. With the display turned on, push in the COMP but
outside temperature reading. ton for 3 seconds, until the Zone selection comes
To operate the mirror and compass do the following: up (a number will be displayed in the mirror com
1. Turn vehicle ignition switch to ON. pass window.
2. Push in MIRROR/TEMP side of switch to turn Auto 2. Toggle until correct zone is found and release
Mirror on/off. Auto Mirror is enabled when Auto switch.
LED is on. 3. The display will show all segments, and return to
3. Push in MIRROR/TEMP side of switch and hold 3 the normal compass mode within 10 seconds of no
seconds. Mirror will darken and remain dark until switch activity.
switch is released. Upon release, Auto Mirror is C alibration of Com pass
enabled. 1. Turn vehicle ignition switch ON. The letter C should
4. Push in COMP button to turn compass on/off. Com be displayed in the mirror compass window. If not,
pass is enabled when a direction is displayed in the hold the COMP switch (bottom of the mirror) for
mirror compass window. 6 seconds until the letter C is displayed in the
5. If a different Zone selection is desired, refer to mirror compass window.
Compass Calibration in this section. 2. To check calibration quickly, drive vehicle in a
Compass should display a direction, or a C. Go to 360-degree circle in an area free of large metal and
mirror function checkout. If the compass display charac metallic objects (AT LESS THAN 5 MPH) until the
ters are not on, check that the compass is enabled display reads a compass direction. If compass
(push in COMP button on the bottom of mirror); recheck
does not calibrate after three 360 degree circles
ignition is ON. and the compass still displays C, replace mirror
If compass display characters are not displayed check assembly. If compass displays C to begin with and
the following: then after two minutes displays all segments refer
• For Electrical Diagnosis of the mirror refer to the to Magnetic Field in this section.
Engine Controls, Transmission Diagnosis, and 3. Normal calibration is achieved automatically by
Electrical Diagnosis Manual. simply driving the vehicle.
1. Remove connector from rear of housing.
2. Check for ignition switched battery voltage at the M agnetic Field
connector with a digital volt meter. 1. If there is a strong magnetic field in the area near
3. Ignition switched battery voltage should be in the the mirror, the compass circuit cannot compensate
range of 11.0 to 15 volts. for it. Check for magnetic antenna mount, magnetic
4. If correct voltage is present between terminals, notepad holder, and any similar magnetized items
replace mirror assembly. in area of mirror. Remove magnetic item and turn
5. If zero volts is between terminals, check fuse and mirror off for 30 seconds and then back on again. If
wiring harness from mirror to fuse box and chassis mirror comes back on displaying direction or C,
ground. inform vehicle owner of offending magnetic part
and refer to Compass Calibration in this section.
N ight V ision M irror Function Check 2. If mirror still displays all segments, replace mirror
There may be a time that the night vision mirror or assembly.
compass does not operate properly. System function
checks and procedures for correcting the operation of
the night vision mirror are listed below.
1. Compass reads direction but is not accurate. Refer
to Compass Variance in this section.
2. Compass displays a C. Refer to Compass Calibra
tion in this section.
3. Compass displays all segments. Refer to Magnetic
Field in this section.
4. Mirror does not automatically dim when glare is
present in mirror at night time. Refer to Mirror Auto-
dim in this section.
Com pass V ariance Set-U p
Compass variance is the difference between Magnetic
North and Geographic North. The difference between
Magnetic and Geographic North can be great enough to
cause the compass to give false readings.
Compass variance is compensated by calibrating the
compass. To do this successfully refer to the map in
Figure 1 to determine the zone number to be entered
Figure 1— Com pass Variance Zone Map
WINDOWS 10A3-3
Perform the following steps to check auto mirror func
tion:
1. Position the vehicle in a well lit area.
2. Locate the forward facing sensor on the back side
of the mirror housing.
3. Cover the forward facing sensor with a dark cloth
(black preferred). After the dark cloth has been
over the sensor for 10 seconds to one minute, the
glass should start to darken.
4. Remove the cloth, and the glass will begin to return
to the clear reflective stage.
5. Repeat above steps several times to make sure the
mirror is operating correctly.
6. If glass will not darken after cloth over forward fac
ing sensor has been in place for two minutes and
vehicle is positioned in brightly lit area and com
pass display is showing a direction, replace mirror
assembly.
7. If compass display is not on, check to see if ignition
is on and push in the COMP position and perform
Figure 2— N ight Vision Rearview M irror w ith test again.
Com pass
M irror Clean-Up
M irror Autodim Once the Compass Variance adjustment and the com
A forward-facing sensor in the back of the mirror case pass is displaying correct direction, the mirror glass
measures the ambient light just as your eyes do. When should be cleaned with a paper towel dampened with
the rear-facing sensor in the mirror glass senses glare glass cleaner. Spraying glass cleaner directly on mirror
such as headlights from a following vehicle, it energizes is not recommended.
the chemical layer in the glass, causing it to darken only
to the precise level required to eliminate glare while
maximizing rear vision. As glare is reduced the mirrored
glass returns to its normal clear state.
ON-VEHICLE SERVICE
REAR VIEW MIRROR MOUNT 3. Immediately apply the button to the windshield,
ensuring it is the right way up, and hold firmly for a
BUTTON REPLACEMENT minute. Allow to set for fifteen minutes (Figure 6).
Tools Required: 4. Mirror to mirror mount button.
Inside Mirror Adhesive Kit GM P/N 1052369 or
equivalent.
Rem ove or D isconnect (Figures 4 and 5)
1. M irror mounting button from m irror bracket

(Figure 3).
A. Mark outside of windshield with crayon to iden
tify old location of rear view mirror button
(Figure 5).
B. Thoroughly scrape inside windshield glass and
mirror button with a safety razor or utility knife
to remove all old adhesive. Wipe clean with
clean cloth saturated with alcohol.
■M- Install o r C onnect (Figures 6 and 7)
1. Apply a generous amount of activator to the mount

ing surface of the mirror button and windshield
where the button is to be positioned. Allow the acti
vator to dry for five minutes. DO NOT TOUCH the
mounting surface of the button or the glass
(Figure 5).
2. Apply one drop of adhesive to the center of the Figure 3— N ight Vision R earview M irror w ith
button. Com pass and Tem perature
10A3-4 WINDOWS
WINDSHIELD SERVICE (Use a piece of chalk and mark the point on the cab,
next to the reveal molding). Later, when examining the
When replacing a cracked windshield, it is important flange of the opening for a cause of the crack start at
that the cause of the crack be determined and the con the point marked.
dition corrected before a new window is installed. The Before removing the window cover the instrument
cause of the crack may be an obstruction or high spot panel and the surrounding sheet metal with protective
somewhere around the flange of the opening. Cracking coverings.
may not occur until pressure from the high spot or
obstruction becomes particularly high due to winds,
extremes of temperature, or rough terrain. Suggestions
WINDSHIELD REPLACEMENT
of what to look for are described later in this section Tools Required;
under Inspection. J 24402-A Window Sealant Removal Knife.
If a windshield is broken, the glass may already have J 39032-A Stationary Window Removal Tool.
fallen or been removed from the adhesive. Often, how Solvent for cleaning edge of window (use GM
ever, it is necessary to remove a cracked or otherwise Glass Cleaner #1050427 or isopropyl alcohol).
imperfect windshield that is still intact. In this case, it is Household cartridge-type caulking gun.
a good practice to crisscross the window with strips of Commercial-type razor knife (for cutting around
duct tape before removing it; this will help hold the edge of window).
window together. Rubber suction grips.
If a crack extends to the edge of the window, mark
the point where the crack meets the reveal molding.
Figure 5— M arking the Location Figure 7— M ounting the Button

WINDOWS 10A3-5
C A U TIO N : F ailu re to co ver d e fro s te r o u tlets,
w hen replacing w in d o w s, can cause broken
g lass to be exp elled w hen d efro s te r is op erat
ed, resu ltin g in perso n al in ju ry.
Rem ove or D isconnect (Figures 8 through 10)
• Place protective coverings around the window

removal area.
1. Windshield wiper arms. Refer to Wiper Arm
Removal in Windshield Wiper Washer System.
2. Radio antenna mast. Refer to Fixed Antenna
Replacement in Audio Systems.
3. Cowl vent grille. Refer to Cowl Vent Grille Replace
ment in Sheet Metal.
4. Windshield stop screws.
5. Rear view mirror. Refer to Mirror Removal in this

section.
• Be sure to disconnect electrical lead for vehi
cles equipped with night vision rearview mirror.
6. Door opening seals, windshield garnish moldings,
and speaker covers.
• Cut the molding from the window with a
razor-type knife taking care not to damage the
paint.
• Work from the outside.
7. Windshield from the flange.
A. Use J 24402-A or J 39032 to cut the window
from the urethane adhesive (Figures 4 and 5).
Keep the cutting edge of the knife against the
window, and cut the urethane adhesive from the
windshield.
B. With the aid of an assistant, remove the wind
shield.
F 3 Clean
Figure 8— Cold Knife Rem oval
• Loosened adhesive from the pinchweld flange
by wiping with a dry cloth.
• Do not attempt to scrape away old adhesive still
attached. The paint could be damaged.
Inspection
An inspection of the flange of the windshield opening,
reveal molding, and glass may reveal the cause of a
broken windshield. This can help prevent future
breakage.
Look for high weld or solder spots, hardened spot
weld sealer, or any other obstruction or irregularity in
the flange. Also, check the cowl vent grille for contact
with the windshield.
Check the fit of the rearview adhesive mounting pad.
Replace the mounting pad if needed. Refer to Figure 12
for proper location of the mounting pad.
J 39032
Figure 9— W indow Rem oval using the S tationary

W indow Rem oval Tool
10A3-6 WINDOWS
Install or Connect (Figures 11 through 15)
1. Spacers and V.I.N. plate filler strip.

2. With the aid of a helper, dry fit the window in the
opening to determine the correct position by;
A. Positioning the window in the opening,
B. Using masking tape, mark the location of the
window in the opening,
C. Slit the masking tape at the window edge,
D. Remove window from opening an place it inside
up on a clean protected surface.
3. If performing an extended method installation,
shake pinchweld primer # 3 (black) well, and apply
to any exposed painted surfaces (or scratches to
bare metal) on the pinchweld flange. Allow to dry
for 10 minutes. If short method is being used, DO
NOT prime the existing bead of urethane adhesive
on the body.
m Im portant Figure 12— R earview M irror Adhesive Pad Location
• If corrosion of the pinchweld flange is present,

or if sheet metal repairs or replacements are
required, the pinchweld flange must be refin
ished to present a clean primer only surface.
• If paint repairs are required, mask the flange
bonding area (prior to applying the color coat) to
provide a clean primer only surface.
• After repairing the opening as indicated, shake
pinchweld primer #3 (black) well, and using a
new dauber, apply to the primed surface of the
flange in the bonding area. Allow to dry for
10 minutes.
4. If the original window is being reused, remove any
existing urethane adhesive from the window edge
and surface, using a razor knife or equivalent.
5. If the original reveal molding (or new production
type reveal molding) is being used, install molding
to the edge of the window.
6. Install new acoustic strip on w indshield, if
Figure 13— W indshield Prim er Locations
necessary.
7. If the extended method is being used, apply a dam
material, such as Norton Windshield Dam Replace
ment or equivalent, approximately 12mm to 18mm
(1/2 inch to 5/8 inch) from the outer edge of the
window, around the perimeter of the window to con
trol urethane squeeze out.
| j | Im portant
• Care should be taken to prevent window prep

#1 (clear) from running into the vision area of
the window. This primer dries almost instantly,
but may stain the viewing area of the window if
not applied evenly.
8. Using a new dauber, apply glass prep #1 (clear) for
approximately 10mm to 16mm (3/8 inch to 5/8 inch)
around the entire perimeter of the inner surface and
any exposed edges of the window. Wipe dry with a
clean cloth.
9. Shake window primer #2 (black) well, and using a
new dauber, apply primer to the same areas that
window prep #1 (clear) were applied to. Allow to
dry for approximately 6 to 10 minutes.
WINDOWS 10A3-7
14. Watertest the window immediately using a soft
spray. Warm or hot water is preferred to accelerate
the cure of the adhesive. DO NOT direct a hard
stream of high pressure water at fresh urethane
adhesive.
A. Refer to Waterleak Tests.
B. If leaks are found, apply extra urethane adhe
sive at the leak point using a plastic paddle.
15. Windshield stop screws.
16. Rear view mirror.
17. Windshield pillar trim and door weatherstrip.
18. Speaker grilles.
20. Windshield wiper arms.
21. Radio antenna mast.
22. Windshield garnish moldings.
Im portant
Figure 14— W indshield Prim er Dim ensions • Allow the vehicle to remain at room temperature
(22 degrees Celsius/72 degrees Fahrenheit at 30%
relative humidity) for a minimum of six hours.
• Partially lower a door window to prevent pressure
build ups when closing doors prior to urethane
adhesive cure.
• DO NOT DRIVE VEHICLE until urethane adhesive
is cured (minimum of six hours at room tempera
ture).
. DO NOT USE COMPRESSED AIR to dry urethane
adhesive.
STATIONARY BODY SIDE

WINDOW REPLACEMENT
Tool Required:
J 24402-A Glass Sealant Remover Knife.
1. Quarter trim panel from around the window frame.

Refer to Quarter Panel Trim Replacement in Interi
or Trim.
10. If short method is being used, cut the tip of the
application nozzle to provide a bead of 6 mm
(1/4 inch) in diameter. If extended method is being
used, the applicator nozzle should be cut to provide
a bead of approximately 14.5 mm (0.57 inch)
11. Using a cartridge type caulking gun, apply a
smooth continuos bead of urethane adhesive;
A. to the existing bead of urethane adhesive on
the body when using the short method, OR
B. using the edge of the window (or inside edge of
the reveal molding in certain cases) as a guide
for the nozzle, apply urethane adhesive to the
inner surface of the window, when using the
extended method.
12. Using rubber suction cups, and with the aid of a
helper, install the window in the opening;
A. Place the window on the lower supports.
B. Align the tape lines on the window and the body
pillar.
13. Press the window firmly in place. Tape the window
to the body to minimize movement and clean up
any urethane squeeze out from the body. Figure 16— Extended Cab Stationary Body Side
Glass
10A3-8 WINDOWS
Figure 19— W indow Fram e Pinchw eld fo r Body

Prim er
2. Molding from the glass with a razor knife.
3. Window glass assembly using J 24402-A.
• Wipe away loose adhesive from the frame with
a dry cloth.
Install or Connect (Figures 18 through 20)
1. Body primer on the pinchweld flange in areas

where the paint has come off.
• Use the GM repair kit P/N 12346284 or equiva
lent, which contains the proper primers and
adhesive.
• Allow the primer to dry.
2. Clear primer to the window covering an area of
18 mm (3/4 inch) from the edge of the glass
(Figures 18 and 19).
• Wipe primer dry Immediately.
3. Black primer to the same area as the clear primer.
4. Urethane adhesive bead to the body to fill in any
gaps in the old adhesive. Figure 20— W indow Fram e
• Apply a light hand pressure to the glass to

wet-out the adhesive and to bond the glass to
the pinchweld (Figure 20).
5. Quarter trim panel.
• Allow the adhesive to dry for several hours and
then test the window for water leaks. Refer to
Water Leak Test in this section.
BODY SIDE LATCHED

WINDOW REPLACEMENT
The latched side window is a one-piece assembly that
includes the window, molding, hinges, and latch
assembly.
M Rem ove o r D isconnect (Figures 21)
1. Latch rivets.
2. Hinge rivets.
3. Window assembly.
• Do not replace the weatherstrip unless it is
damaged.
Figure 18— Prim er and A dhesive A pplication Points
WINDOWS 10A3-9
Figure 21— Body Side Latched W indow Figure 23— Rear Sliding Glass W indow A ssem bly
Com ponents (Pickup)
Install or Connect (Figures 21)
1. Window assembly.
2. Hinge rivets.
3. Latch rivets.
REAR WINDOW REPLACEMENT

• On a window with a defogger, unclip the connector

at the left and right side of the window from the
inside of the cab.
• Remove all trim panels necessary to gain access
for rear window removal. Refer to Interior Trim for
the trim panel removal procedures.
1. Molding from the glass with a razor knife.
Figure 24— P rim er and A dhesive A pplication Points
Figure 25— Rear W indow Assem bly (Suburban and

Figure 22— Rear W indow A ssem bly (Pickup M odel) U tility)
10A3-10 WINDOWS
2. Glass assembly from the window frame using
J 24402-A.
• With a helper standing outside the cab, push
the window out from the inside.
3. Wipe away the loose adhesive from the frame with
a dry cloth.
■M- install or C onnect (Figures 22 through 28)
1. Body primer to the pinchweld flange in areas where

the paint has come off.
• Use the repair kit GM P/N 12346284 or equiva
lent that contains the proper primers and
adhesive.
2. Clear primer to the window covering an area of
18 mm (3/4 inch) from the edge of the glass
(Figure 27).
• Wipe off immediately.
Figure 26— Rear W indow Prim er W idth (Suburban 3. Black primer to the same area as the clear primer.
and U tility) • Allow the primer to dry.
4. Urethane adhesive bead to the body to fill in any
gaps in the old adhesive.
5. Window.
• On windows with defoggers, connect the clips
on each side of the window on the inside to the
body connectors.
• Install all trim panels that were removed to gain
access for rear window removal
• On sliding windows, be sure the two tabs on the
bottom of the window are positioned in the slots
on the body before installing the window.
REAR WINDOW DEFOGGER

SYSTEM
The optional defogger consists of a heating element
bonded to the inside surface of the rear glass. This unit
uses an instrument panel mounted switch with an inte
gral indicator lamp and will operate for 5 to 10 minutes
and will then turn off by automatic timer. The system
Figure 27— Rear W indow Prim er Locations can be turned off during this operating period by manu
(Suburban and U tility) ally shutting off the defogger switch or turning off the
ignition switch. When activated, an indicator light is illu
minated. A 12-volt current flows through the relay and
out to the resistive heating elements on the rear win
dow. The current enters the grid from the left side of the
window and leaves the grid heater from the right side of
the window. The ground circuit is on the right side of
the cab.
The length of time required to remove interior fog
varies under such conditions as vehicle speed, outside
glass temperature, atmospheric pressure, and number
of passengers.
The rear window harness plugs into a connector at
the fuse panel and leads to the instrument panel mount
ed switch. The harness then continues from the switch
routed along the left rocker panel area to the rear of the
cab. At this point it is routed up to where it meets the
grid connector at the back glass.
Figure 28— Rear Door W indow Seal Installation

(Suburban and U tility)
WINDOWS 10A3-11
DIAGNOSIS OF THE REAR WINDOW DEFOGGER

SYSTEM
System W on’t Heat 1. Blown fuse. 1. Replace the fuse with a fuse of the cor
The W indow rect rating.
2. Broken switch. 2. Test the switch for conduction. Replace
the switch if necessary.
3. Circuit is open. 3. Test for voltage at the left connection of
the window. If voltage is present, check
the ground circuit. If voltage is not
present, test the relay for operation and
voltage. If the relay voltage is present,
find the open in the harness between
the relay and the heater.
System W on’t Turn 1. Blown rear window defogger fuse. 1. Replace the fuse with a fuse of the cor
On. The Indicator rect rating.
Lam p Is O ff. 2. Relay is faulty. 2. Make sure the relay is firmly seated in
its socket. Jump the ORN/BLK wire to
the LT BLU wire. The relay should click.
If the relay clicks, find the open
between the switch and the relay if the
relay doesn’t click, replace the relay.
3. Switch is faulty. 3. Test the switch with a test lamp.
Replace the switch with a test lamp.
Replace the switch if it’s proven faulty.
D0102
• Move the lamp from the feed wire side to the

grounded side of each grid. The lamp should be
TESTING REAR WINDOW fully bright then gradually dim as it is moved
across the grid. Be sure to check each grid line
DEFOGGER in at least two places to avoid the possibility of
GRID LINES bridging a gap (Figure 29).
1. Start the engine and turn on the defogger system. 3. If the test lamp shows full brilliance at both ends of
2. Ground an unpowered test lamp and lightly touch the grid line, check for a loose ground wire connec
the prod tip to each grid line. tion to the sheet metal.
4. If the lamp suddenly goes out as it is moved across
the grid, a break has been located.
GRID LINE REPAIR

Tools Required:
R ear W indow D e fog g er R e p a ir K it GM
P/N 12345345, or equivalent.
Heat Gun - capable of reaching 260 * C (500 * F)
Rem ove or D isconnect

Inspect
• Rear window defogger lines. (Mark the grid line

breaks on the outside of the window with a
grease pencil).
Figure 29— Test Lam p B rilliance Zones -Norm al

O perating Rear W indow
10A3-12 WINDOWS
Clean Inspect
• The grid line area to repaired. Buff with steel A. Grid line repair area. If the repair appears dis
wool and wipe clean using a cloth dampened colored, apply a coat of tincture of iodine to the
with alcohol. Buff and clean about 6 mm repair area using a pipe cleaner or a fine brush.
(0.25 in.) beyond each side of the break in the Allow iodine to dry for about 30 seconds and
grid line. Be sure the glass is at room carefully wipe off the excess with a lint-free
temperature. cloth.
B. Test the defogger operation to verify grid line
[■M"! Install or Connect repair.
C. Leave the grid area untouched for 24 hours.
1. Grid line repair template or two strips of tape posi
tioned above and below the repair area. Repair BRAIDED LEAD WIRE REPAIR
template or tape M UST be used to control the 1. The rear defogger bus bar lead wire or terminal can
width of the repair area. If the template is used, be be reattached by soldering using a solder contain
sure the die cut metering slot is the same width as ing 3 percent silver and a rosin flux paste.
the grid line. 2. Before soldering the bus bar, the repair area should
be buffed with fine steel wool. This removes the
C A U TIO N : To A vo id P ersonal injury: oxide coating formed during the glass manufacture.
• Do n o t a llo w th e re p a ir m a te ria l to 3. Apply the paste-type rosin flux in small quantities to
com e in contact w ith skin o r eyes and the wire lead and bus bar repair area using a
avoid breathing vapor. brush.
• Do not use near sparks or open flam e. 4. The soldering iron tip should be coated with solder
beforehand. Use only enough heat to melt the sol
2. The grid repair material at room temperature to the der and only enough solder to ensure a complete
repair area using a small brush (Figure 31). repair.
3. Remove the template or tape carefully. 5. Do not overheat the wire when resoldering it to the
bus bar.
N O TIC E : The g rid line repair m aterial m ust
be cured with heat. To avoid heat damage to WINDOW POLISHING
the in te rio r trim , p ro te ct the trim near the
repair where heat is applied. M inor Scratch and A brasion Rem oval
Minor scratches and abrasions can be removed or
4. Holding the heat gun 25 to 50 mm (1 to 2 inches) reduced by following the procedure outlined below. Pre
from the repair area, apply heat at 260 * to 370 * C cautions must be taken to prevent distortions of vision.
(500* to 700* F) for 2 to 3 minutes (Figure 30). If a Double vision may result if an attempt is made to
heat gun is not available, allow the repair to air dry remove deep scratches. Deep scratches should not be
at an ambient temperature of 20 * to 39 * C (70 * to removed from an area in the driver’s line of vision; in
90 * F) for 24 hours. such cases, the glass should be replaced.
5. Negative battery cable(s). The procedure that follows was developed using a
cerium oxide compound. Follow manufacturer’s direc
tions if other materials are used.
Recom m ended Equipm ent
1. A low speed (600-1300 RPM) rotary polisher.
2. A wool felt, rotary polishing pad 7 mm (3 inches) in
diameter and 51 mm (2 inches) thick.
3. Powdered cerium oxide mixed with water. This is
the abrasive compound.
4. A wide mouth container to hold the abrasive com
pound.
Polishing Procedure (Figure 32)
1. Mix at least 44 ml (1.5 oz) of cerium oxide with
enough water to obtain a creamy consistency. If the
mixture is too thick it will cake on the felt pad more
quickly. If it is too runny, more polishing time will be
needed.
2. Draw a circle around the scratches on the opposite
side of the glass with a marking crayon or
equivalent.
3. Draw a line directly behind the scratch(es) to serve
as a guide for locating the scratch while polishing.
Figure 30— Apply G rid M aterial to a Broken Grid
Line
WINDOWS 10A3-13
6. Polish the scratched area, but note the following:
• Agitate the mixture as often as needed to main
tain the creamy consistency of the compound.
• Use moderate but steady pressure.
• Hold the pad flat against the glass.
• Use a feathering-out motion.
• Dip the pad into the mixture every 15 seconds
to ensure that the wheel and the glass are
always wet during the polishing operation. A dry
pad causes excessive heat to develop.
• Keep the pad free of dirt and other foreign sub
stances.
WATER LEAK TESTS

Various methods can be used to check for water
leaks after the window adhesive has been allowed to
dry. Use the first test method whenever possible for
generalized testing since it provides a large volume of
water to a general area without exceeding the sealing
Legend limitations of the glass. Once the leak area has been
(1) Repair Area found, locate the exact entry point by using the water
(2) 25-50mm (1-2 inches) hose or air hose test.
Figure 31— A pplying Heat to the Grid Line R epair Checking With Watertest Stands
To assemble watertest stands, refer to Figure 33. Use
them as follows.
1. Position the stands as shown in Figures 34 and 35.
Water spray from the stands should overlap on the
vehicle.
2. Run the water at a volume of 14 liters (3.7 gallons)
per m inute and at a pressure of 155 kPa
(22 psi) (measured at the nozzle) for at least
4 minutes.
3. Have someone inside the cab during the test to
check for the location of any leaks.
4. To check the windshield, the water spray should be
aimed 30 degrees down and 45 degrees toward the
rear. Aim at the corner of the w indshield
(Figure 34).
5. To check the side windows, the water spray should
be aimed 30 degrees down and 45 degrees toward
the rear. Aim at the center of the rear quarter.
6. To check the back window, aim the water spray
30 degrees down and 30 degrees toward the front.
Legend Water Hose Test
(1) Guidelines Run water through a hose without the nozzle
(2) Hold Pad Flat Against Glass attached. Begin testing at the base of the window or
Figure 32— W indow Polishing windshield and slowly move the hose upward and
across the top (Figure 36). Have someone in the
4. Cover the surrounding area with masking paper to vehicle watch for leaks.
catch the drippings or spattered polish.
Air Hose/Bubble Solution Test
5. Dip the felt pad attached to the polisher into the
mixture. Do not submerge the pad or allow the pad
to stay in the mixture as it may loosen the bond NOTICE: The a ir hose test should only be
between the pad and the metal plate. used on fu lly cured urethane. O therwise,
damage to the urethane bead could result in
N O TIC E: Never hold the tool in one spot or additional leaks.
operate the tool on the glass any longer than
30 to 45 seconds. If the glass becomes hot to
touch, le t it a ir cool before proceeding fur
ther. Cooling with cold water may crack heat
ed glass. A void excessive pressure. It may
cause overheating o f the glass.
10A3-14 WINDOWS
Put liquid detergent diluted with water in a squirt bot
tle. Have a helper inside the cab with an air hose.
Beginning at the bottom of the window and gradually
moving up the window edges and across the top (Figure
37), squirt soap solution on the window moldings and
glass on the outside of the vehicle. Have a helper aim
the compressed air at the same locations from the
inside of the vehicle. Air pressure from the hose should
not exceed 205 kPa (30 psi). Bubbles will form in the
soap solution at the location of the leak.
REPAIRING WATERLEAKS
Depending on where the leak is located, it may be
necessary to remove the trim molding or headliner to
repair the leak. Refer to Interior Trim.
1. Cut out a portion of the adhesive in the leak area
from inside or outside the vehicle (Figure 38 or 41).
2. Clean and remove all loose particles from the area.
3. Caulk in adhesive between the window and the
pinchweld flange where the old adhesive has been
cut away and feather it out several inches to each
side of the leak area. Use urethane adhesive from
GM P/N 12346284 or equivalent.
4. Mist the newly applied adhesive with water to cure
the adhesive and check for leaks.
5. Install molding.
6. Allow the adhesive to dry for several hours, then
check for water leaks.
WINDNOISE DIAGNOSIS AND

REPAIR
To analyze a reported windnoise condition, a test
drive in the vehicle is necessary due to the many vari
ables that could singularly or collectively be attributed to
creating the objectionable noise condition.
C A U TIO N : For s afety reaso n s an a s s is ta n t
sh ould d rive th e veh icle w h ile th e tech n ician
ch ecks fo r th e lo catio n of th e rep o rted co n d i
Legend
tio n .
(1) 0.5 inch Coupling
(2) F ull Je t S pray N ozzle No. 1/2G G -25 or A regular route for the road test should already have
Equivalent been chosen. The road should include smooth and
(3) 60 degrees straight streets that run in all four directions (North,
(4) 0.5 inch x 36 inch Pipe South, East and West). It should be an area where
(5) 0.5 inch by 0.5 inch by 0.25 inch Reducing Tee there is little traffic or noise that would interfere with the
(Right Stand Only) test.
(6) 0.5 inch Coupling (Left Stand Only) The vehicle should be driven at the speed in which
(7) Water Pressure Gauge (Right Stand Only) the noise was noticed or until it is heard. Safe and legal
(8) 0.5 inch by 60 inch Pipe speeds should never be exceeded.
(9) 0.5 inch Pipe to Hose Nipple im portant
(10) Hose Quick Connect
(11) 12 foot (5/8 inch Diameter) Cross Hose • Often there is one primary leak source and one or
(12) 5/8 inch Female Hose Coupling more secondary leaks that contribute to the noise
(13) 0.5 inch Cap condition. Repairing only one of the contributing
(14) 0.5 inch by 12 inch Nipple leak sources may not completely repair the total
(15) 0.5 inch Cross with Weld-On 0.5 in Cap condition, but only reduce it.
(16) 0.5 inch Close Nipple Many of the waterleak diagnosis tests are also used
(17) Input Hose 2.0 foot (5/8 inch Diameter) (Right for windnoise diagnosis.
Stand Only) Most windnoise is caused by either leaking seals or
(18) 5/8 inch Female Hose Coupling misaligned body surfaces. There are three basic types
(19) 0.5 inch Pipe to Hose Nipple (Right Stand Only) of windnoise:
(20) 0.5 inch Tee (Left Stand Only) • Whistle
(21) 0.5 inch Cross (Right Stand Only) • Roar
Figure 33— W atertest Stand Assembly • Rush
WINDOWS 10A3-15
Figure 34— W ater Leak Test Stands
Legend
(1) 45 degrees (4) Windshield and Front Body
(2) 45 degrees (5) Side
(3) 30 degrees (6) Back Glass
Figure 35— W ater Leak Test w ith Test Stands
When moving at highway speeds, air pressure inside Diagnose wind whistle or roar as follows:
the vehicle becomes significantly greater than air pres 1. Note details about the wind noise:
sure outside. If there is a leak, the escaping air causes • Perceived location.
a hiss or whistle. • Location where loudest.
Wind roar is caused by air passing over or through an • When it occurs.
opening between two body surfaces. Adjustments in • Vehicle speed.
alignment to the body surfaces can correct wind roar. • Interior fan speed.
Wind rush is caused by air pressing over the vehicle’s • Position of windows.
body and is related to the aerodynamics of the vehicle. • What it sounds like.
Both wind whistle and wind roar which are serviceable 2. Inspect vehicle for possible cause of windnoise.
should be ruled out before concluding a wind noise is 3. Test drive vehicle and determine if windnoise is
due to wind rush. external or internal.
10A3-16 WINDOWS
Figure 36— W ater Hose Test Figure 38— Rem oving A dhesive from Inside the
Vehicle
Figure 37— A ir Hose and B ubble S olution Test

Figure 39— Rem oving A dhesive from O utside the
4. Perform a visual inspection of the following: Vehicle
• Loose fasteners.
• Torn weatherstrips. 1. While driving, determine location by lowering one
• Broken weld joints. window at a time. If location appears to correspond
• Sealer and/or adhesive skips. with condition noticed in Step 2 above, pull over
and make a temporary repair with 51 mm (2 inch)
Exterior Windnoise wide masking tape.
Exterior windnoise will be louder when the vehicle is 2. Tape over gaps and moldings one at a time, test
driven with one or more windows down. It is caused by driving in between. When the area causing the
air passing over body panels, seams or openings. windnoise is taped over, the wind noise should no
The following items should be used by the technician longer occur.
during the test drive to aid in leak detection: Temporarily repair the condition with masking tape.
• Mechanic’s stethoscope or heater hose. Adjust tape as required. Continue testing to determine if
• Masking tape-51 mm (2 inches) in width. noise has been eliminated or other leak areas exist.
• Strip caulk. When all reported leak conditions have been located,
• China marking pencil. make permanent repairs utilizing proper alignment tech
niques and sealing materials as required.
N O TIC E : If m asking the g rille and headlamp
bezel areas, care m ust be taken not to re strict
a irflo w and cause vehicle overheating.
WINDOWS 10A3-17
3. Pull over and make temporary repairs using mask
ing tape. If still unable to determine source of interi
or windnoise, perform one or more of the following
three diagnostic tests.
Tracing Pow der or C halk Test
Clean
• Weatherstrips and contact surfaces with clean

ing solvent.
A. Apply powder or chalk in an unbroken line to
the contact surface of weatherstrip around
perimeter of suspected areas. Surrounding
areas must be free of chalk or powder.
B. Close panel completely without slamming.
This presses the weatherstrip firmly against
the mating surfaces.
Inspect
• Applied line on weatherstrip will be marred

Vehicle where contact is good. A corresponding
imprint will be on mating .surfaces.
• Gaps or irregularities in powder or chalk line
on mating surfaces indicate areas with poor
seal.
A ir Pressure Test
A. Mask off both pressure relief valves.
B. Turn on vehicle’s ventilation fan.
C. Close all windows and doors.
D. With stethoscope or length of heater hose, lis
ten for escaping air along door and window
seals.
Soap Solution or B ubble Test
A. Mask off pressure relief valve(s).
B. Turn on vehicle’s ventilation fan.
C. Close all windows and doors.
D. Apply soap solution to potential leak areas.
E. Look for bubbles revealing escaping air.
An air hose can be used instead of pressurizing the
vehicle’s interior. Do not exceed 207 kPa (30 psi) when
Figure 41— 'Trim m ing the A dhesive from O utside an air hose is used.
th e Vehicle Windnoise leak repairs are very similar to waterleak
repairs. The actual procedure depends on the type of
Interior Windnoise seal being repaired.
Leaks around door opening weatherstrips do not
Interior windnoise will not be heard with a window
always indicate a faulty weatherstrip. A door or door
lowered. It is caused by air leaving the inside of the
window adjustment may resolve the problem.
vehicle through a seal or seam.
1. Tape over relief valves to cause added air pressure
within the vehicle.
2. Test drive the vehicle and listen for windnoise or
whistle.
10A3-18 WINDOWS
SPECIAL TOOLS
J 34946
1. J 2 4 4 0 2 -A GLASS SEALANT REMOVER (COLD KNIFE)

2. J 24709 -0 1 GLASS SEALANT REMOVER (HOT KNIFE)
3. J 24811 - A URETHANE ADHESIVE DISPENSING GUN
4. J 34940 RIVET GUN
5. J 36863 GLASS REMOVAL KIT
6. J 39032 STATIONARY GLASS REMOVAL TOOL
7. J 34946 W INDOW ROLL PIN REMOVER
INTERIOR TRIM 10A4-1
SECTION 10A4
INTERIOR TRIM
ON-VEHICLE SERVICE
HANDLING ELECTROSTATIC 4. Never jump, ground, or use test equipment probes
on any components or connectors unless specified
DISCHARGE (ESD) SENSITIVE in diagnosis. When using test equipment, always
PARTS connect the ground lead first.
5. Do not remove the solid state component from its
Many solid state electrical components, such as those protective packaging until you are ready to install
found in the instrument panel and the radio, can be the part.
damaged by Electrostatic Discharge (ESD). Some will 6. Always touch the solid state component’s package
display a label, but many will not (Figure 1). to a ground before opening. Solid state compo
nents can also be damaged if:
N O TIC E:In order to avoid possibly damag • They are bumped or dropped.
ing any components, observe the following: • They are laid on any metal work benches or
components that operate electrically, such as a
1. Body movement produces an electrostatic charge. TV, radio, or oscilloscope.
ground point (metal) on the vehicle. This should be SUNSHADE REPLACEMENT
done any time you:
• Slide across the seat.

• Do any walking. 1. Screws.

2. Do not touch exposed electric terminals on compo 2. Electrical connector (if equipped).
nents with your finger or any tools. Remember, the 3. Sunshade.
connector that you are checking might be tied into
a circuit that could be damaged by electrostatic
discharge.
3. When using a screwdriver or similar tool to discon 1. Electrical connector (if equipped).
nect a connector, never let the tool come in contact 2. Sunshade.
with or come between the exposed terminals. 3. Screws.
NOTICE
A
itA
C O N T E N T S S E N S IT IV E
TO
S T A T IC E L E C T R IC IT Y c h n o o io a
Figure 1— E lectrostatic D ischarge Parts Label

1QA4*2 INTERIOR TRIM
ASSIST HANDLE REPLACEMENT
R em ove o r D isconnect (Figures 3 through 7)
1. Handle screw covers.

2. Screws.
3. Handle.
0 In stall o r C onnect (Figures 3 through 7)
1. Handle.
2. Screws.
3. Handle screw covers.
COAT HOOK REPLACEMENT

1. Screw.
2. Coat hook.
Figure 3— A ssist Handle Replacem ent (R ear)

Figure 6—-Assist H andle Replacem ent (Extended
Cab 3rd Door)
++ Install o r C onnect (Figure 8)
1. Coat hook.
2. Screw.
KNEE BOLSTER REPLACEMENT

[fr+ l Rem ove o r D isconnect (Figure 9)
1. Knee bolster screws.

2. Unsnap knee bolster.
3. Twist brake release cable to disengage.
4. Lap cooler hose.
1. Lap cooler hose.

2. Brake release cable.
3. Snap knee bolster into instrument panel assembly.
Figure 4— Assist Handle Replacement (Front) 4. Knee bolster screws.
Figure 7— A ssist Handle R eplacem ent (R ear Side

Door) Figure 9— Knee B olster
FLOOR STORAGE
COMPARTMENT REPLACEMENT
1. Front tray from the compartment.

2. Storage bin.
3. Two bolts.
4. Storage compartment.
|-M -j Install or Connect (Figure 10)

(1) Floor Storage Compartment Assembly
1. Storage compartment. (2) Bolt
2. Two bolts. (3) Sealer
(4) Floor Storage Compartment Tray
j^ l Tighten Figure 10— Floor S torage Com partm ent
• Storage compartment bolts to 6 N-m (53 lb in).

3. Storage bin.
4. Front tray.
10A4-4 INTERIOR TRIM
UPPER W INDSHIELD GARNISH WINDSHIELD GARNISH
MOLDING REPLACEMENT MOLDING REPLACEMENT

1. Hinge pillar trim panel. Refer to Hinge Pillar Trim

1. Upper windshield trim. Panel Replacement in this section.
2. Windshield garnish molding.
2. Roof side door trim.
• Pull molding straight out to release retainers.
3. Windshield pillar trim.
0 In stall o r C onnect (Figure 11)

I+4-I Install or C onnect (Figure 12)
1. Windshield garnish molding.

1. Windshield pillar trim. • insert molding retainers into slots and press.
2. Roof side door trim. 2. Hinge pillar trim panel. Refer to Hinge Pillar Trim
3. Upper windshield trim. Panel Replacement in this section.
REAR SIDE DOOR UPPER

GARNISH MOLDING
REPLACEMENT
1. Molding by pulling straight down,
install or C onnect (Figure 13)
1. Molding by inserting retainers into slots and press

ing into place.
HEADLINER REPLACEMENT
Pickup, Extended Cab, and Crew Cab
Rem ove or Disconnect (Figures 14 through 16)
1. Sunshades. Refer to Sunshade Replacement in

this section.
2. Assist handles (if equipped). Refer to Assist Handle
3. Rear window lower molding. Refer to Rear Window
Lower Garnish Molding Replacement in this
Figure 11— U pper W indshield G arnish M olding section.
Figure 12— 'W indshield G arnish M olding Figure 13— Rear Side Door Upper G arnish M olding
Replacem ent R eplacem ent
INTERIOR TRIM 10A4 p5
4. Quarter panel trim. Refer to Quarter Panel Trim
5. Rear window upper molding. Refer to Rear Window
Upper Garnish Molding Replacement in this
section.
6. Upper windshield garnish molding. Refer to Upper
Windshield Garnish Molding Replacement in this
section.
7. Headliner.
A. Grasp the panel on the left and right sides near
the front of the cab.
B. Disengage the front of the panel from the roof.
1. Retainers to the trim panel.

2. Headliner to the vehicle.
• Insert the retainers into the windshield frame.
3. Upper windshield garnish molding. Refer to Upper
Windshield Garnish Molding Replacement in this
section.
4. Rear window upper molding. Refer to Rear Window
Upper Garnish Molding Replacement in this
section.
5. Quarter panel trim. Refer to Quarter Panel Trim
6. Rear window lower molding. Refer to Rear Window
Lower Garnish Molding Replacement in this
section.
7. Assist handle (if equipped). Refer to Assist Handle
this section.
Suburban and U tility
0 Remove or Disconnect (Figures 17 through 19)
1. Assist handles (if equipped). Refer to Assist Handle

this section.
3. Windshield garnish moldings. Refer to Windshield
Garnish Molding Replacement in this section.
Figure 17—Rear Headliner (Suburban w/o Rear A/C)

4. Coat hooks. Refer to Coat Hook Replacement in 6. Upper windshield garnish moldings.
this section. 7. HVAC control assembly (if equipped).
5. Dome lamps. 8. Dome lamps.
6. HVAC control assembly (if equipped). Refer to 9. Coat hooks.
Heater, Ventilation, and Air Conditioning. 10. Windshield garnish moldings.
7. Upper windshield garnish moldings. Refer to Upper 11. Sunshades.
Windshield Garnish Molding Replacement in this 12. Assist handles (if equipped).
section.
8. Rear seat belt upper trim covers. OVERHEAD CONSOLE
9. Side door lock pillar molding. Refer to Pillar Mold REPLACEMENT
ing Replacement in this section.
10. Upper center trim panel.
11. Cargo door lock pillar molding panel. Refer to Pillar
E3 Rem ove o r D isconnect (Figure 20)
Molding Replacement in this section. 1. Console from the roof screw.

12. Overhead console. Refer to Overhead Console 2. Electrical connectors.
Replacement in this section. 3. Console.
-►4- Install o r C onnect (Figures 17 through 19)
1. Overhead console.
2. Cargo door lock pillar molding panel. 1. Console to the roof.
3. Upper center trim panel. 2. Electrical connectors.
4. Side door lock pillar molding. 3. Console to the roof screw.
5. Rear seat belt upper trim covers.
Tighten
• Overhead Console Screws to 2 N-m (18 lb in).
REAR WINDOW UPPER

GARNISH MOLDING
REPLACEMENT
E3 Rem ove o r D isconnect (Figures 21 and 24)
1. Retainer screws (if equipped).

2. Molding from roof panel; slide nylon slipstick or
equivalent between roof panel and garnish molding
near clips while carefully pulling garnish molding
downward.
(1) Standard Overhead Console

(2) Overhead Console with Rear A/C
Figure 19—Headliner (Ttoo-Door Utility) Figure 20—Overhead Console
Figure 21— Rear W indow G arnish M olding Figure 23— Rear W indow U pper G arnish M olding
Assem bly (Pickup, Extended Cab, and Crew Cab) (Extended Cab)
(Suburban and U tility)

(P ickup, and C rew Cab)
REAR WINDOW LOWER
|-M -) Install o r C onnect (Figures 21 and 24) GARNISH MOLDING
1. Molding to the rear body panel. REPLACEMENT
2. Retainer screws (if equipped).
S Tighten
1. Lightly pull lower edge of molding to release the
• Upper Garnish Molding Screws to 2 N.m four clips.
(18 lb in). 2. Lift molding up and away from glass to release
upper retainers.
Figure 25— Rear W indow Low er G arnish M olding
■M" install o r C onnect (Figure 25)
1. Align molding clips with holes in body panel along

back glass.
2. Snap molding into place by applying light pressure
along top of molding at glass.
3. Align lower row of molding clips, then snap lower
portion of molding into place.
QUARTER PANEL TRIM

REPLACEMENT
Pickup, Extended Cab,
and C rew Cab
Rem ove o r D isconnect (Figures 26 and 28)
1. Coat hook. Refer to Coat Hook Replacement in this

section.
2. Seat belt guide. Refer to Seat Belts in Restraints.
3. S eat b e lt re tra cto r. R efer to S eat B elts in
Restraints. Cab)
4. Jack cover, jack, and jack tray (right side).

5. Rear window lower garnish molding. Refer to Rear
Window Lower Garnish Molding Replacement in
this section.
6. Quarter panel trim screws (Pickup and Crew Cab
only).
7. Rear screw from the s ill trim plate (Pickup and
Crew Cab only).
8. Quarter panel.
■►4- Install or C onnect (Figures 26 and 28)
1. Quarter panel.
2. Panel screws (Pickup and Crew Cab only).
Tighten
• Quarter panel trim screws to 2 N.m (18 lb in).

3. Rear screw into the sill trim plate.
4. Rear window lower garnish molding.
5. Jack tray, jack, and cover (right side).
6. Seat belt retractor.
7. Seat belt guide.
8. Coat hook. Refer to Coat Hook Replacement in this
section.
Suburban and U tility
R ight Side
0 Remove o r Disconnect (Figures 29 through 42)
1. Rear seat. Refer to Rear Seat Replacement in

Seats.
2. Armrest to side panel screws. (Suburban only)
3. Armrest from the quarter panel trim.
4. Rear blower motor trim cover.
5. Cargo door pillar molding. Refer to Pillar Molding
6. Rear door lock pillar molding (Suburban only).
Refer to Pillar Molding Replacement in this section.
Figure 29— R ight Body Side Trim Panel (Suburban
7. Front door lock pillar molding (Utility). Refer to Pil
w /R ear A /C )
lar Molding Replacement in this section.
8. Quarter panel trim screws.
9. Quarter panel trim from the vehicle.
• Lift panel to release from vehicle.
0 Install o r C onnect (Figures 29 through 42)
1. Quarter panel trim to the vehicle.

2. Quarter panel trim screws.
Tighten
• Quarter Panel Trim Screws to 2 N-m (18 lb in).

3. Rear door lock pillar molding to pillar (Suburban
only).
4. Front door lock pillar molding to pillar (Utility only).
Refer to Hinge Pillar Molding Replacement in this
section.
5. Cargo door pillar molding to pillar. Refer to Hinge
Pillar Trim Panel Replacement in this section.
6. Rear blower motor trim cover. Figure 30— R ight Body S ide Trim Panel and U pper
7. Armrest to quarter panel trim. A rm rest (Suburban w /R ear A /C )
8. Armrest to the quarter panel trim screws.
Tighten
• Quarter Panel Trim Armrest Screws to 2 N-m

(18 lb in).
9. Rear seat.
Left Side
|» + | Remove or Disconnect (Figures 29 through 42)
1. Rear seat. Refer to Rear Seat Replacement in

Seats.
2. Spare tire cover.
3. Spare tire and jack (Utility).
4. Spare tire rest trim covers.
5. Spare tire rest bolts.
6. Spare tire rest from the vehicle.
7. Spare tire holder from the floor.
8. Spare tire l-bolt from the vehicle.
9. Armrest. D oor)
Figure 32— Left Body Side Trim Panel (Four Door

U tility)
Figure 35— Left Body Side Trim Panel (U pper

Arm rest-Suburban w /o Rear A /C )
Figure 33— R ight Body Side Trim Panel (Four Door
3. Rear door lock pillar trim panel (Suburban only).
U tility)
Front door lock pillar (Utility only). Refer to Hinge
10. Cargo door pillar moldings. Refer to Hinge Pillar Pillar Trim Panel Replacement in this section.
Trim Panel Replacement in this section. 4. Intermediate seat belt anchor to floor bolt. Refer to
11. Intermediate seat belt to rear door pillar bolt. Refer Seat Belts in Restraints.
to Seat Belts in Restraints. 5. Intermediate seat belt to rear door pillar bolt. Refer
12. Intermediate seat belt anchor to the floor bolt. Refer to Seat Belts in Restraints.
to Seat Belts in Restraints. 6. Cargo door pillar trim panels to pillar. Refer to
13. Rear door lock pillar molding. Refer to Hinge Pillar Hinge Pillar Trim Panel Replacement in this sec
Trim Panel Replacement in this section. tion.
14. Quarter panel trim screws. 7. Armrest.
15. Quarter panel trim from the vehicle. 8. Spare tire l-bolt to vehicle.
9. Spare tire holder to floor.
0 In stall or C onnect (Figures 29 through 42) 10. Spare tire rest to vehicle.
11. Spare tire rest bolts.
1. Quarter panel trim to vehicle. 12. Spare tire rest covers and jack (Utility).
2. Quarter panel trim screws. 13. Spare tire.
14. Spare tire cover.
Tighten 15. Rear seat. Refer to Rear Seat Replacement in
Seats.
• Q uarter Panel Trim Screws to 2 N.m (18 lb in).
Figure 36— Left Body Side Trim Panel

(Low er-Suburban w /o Rear A /C ) Figure 39— R ear W indow G arnish M olding (U tility
w /o Convenience Package)
Figure 37— R ear W indow G arnish M olding

(Suburban w /o C onvenience Package)
door U tility w /o C onvenience Package)
LOWER REAR
QUARTER TRIM PANEL
REPLACEMENT
Pickup and Extended Cab
B Remove o r Disconnect (Figures 43 through 46)
1. Armrest (if equipped).

2. Pocket from the lower panel (if equipped).
3. Lower panel screws.
4. Panel from the vehicle.
|-M -| Install o r C onnect (Figures 43 through 46)
1. Panel to the vehicle.

Figure 3 6 —R ear W indow G arnish M olding
2. Lower panel screws.
Figure 44— Side Rear Low er Panel (Extended Cab

w /R ear S eat)
Figure 45— Side Rear Low er Panel (Extended C ab)

Suburban)
3. Pocket to the lower panel (if equipped).
4. Armrest (if equipped).
REAR PANEL CARPET

REPLACEMENT
Pickup, Extended Cab, and C rew Cab
[*-» | Rem ove or D isconnect (Figure 47)

this section.
2. Side rear trim panel.
3. Side rear lower panel.
4. Carpet retainers.
5. Carpet panel.
6. Carpet.
Figure 46— Side Rear Low er Panel (Extended Cab

install o r C onnect (Figure 48)
w /o Rear S eat)
1. Trim panel to the retainers.

2. Retainer screw.
DOOR SILL TRIM PLATE

REPLACEMENT
|4»+| Rem ove or D isconnect (Figure 49)
1. Screws.
2. Sill trim plate.
+4- Install o r C onnect (Figure 49)
1. Sill trim plate.

2. Screws.
Tighten
Door sill trim plate screws to 2 N-m (18 lb in).
-► 4- Install o r C onnect (Figure 47)
1. Carpet.
2. Carpet panel.
3. Carpet retainers.
this section.
HINGE PILLAR TRIM PANEL

REPLACEMENT
B Rem ove or D isconnect (Figure 48)
1. Retainer screw.
2. Trim panel from the retainers.
Figure 49— D oor S ill trim plate Replacem ent

PILLAR MOLDING
REPLACEMENT
Suburban, U tility, and C rew Cab
1. Door sill trim plates. Refer to Door Sill trim plate

2. Seat belt from pillar anchors (side door lock pillars
only). Refer to Seat Belts in Restraints.
3. Pillar molding screws.
4. Pillar moldings.
-M - Install o r C onnect (Figure 50 through 56)
1. Pillar moldings.
2. Pillar moldings screws to pillar.
G arnish M olding (Suburban w /o C onvenience

Package)
M olding (Suburban and C rew Cab)
Figure 53— R ight Rear Side Door Lock P illar

G arnish M olding (Suburban w /C onvenience
Package)
^ Tighten
• Pillar molding screws to 2 N-m (18 lb in).

3. Seat belt anchors to pillars. Refer to Seat Belts in
Restraints.
4. Door sill trim plates. Refer to Door Sill trim plate
FLOOR CARPET OR MAT

REPLACEMENT
Pickup
|» + | Remove o r Disconnect (Figures 57 through 59)
1. Remove left front seat belt retractor.

(TW o-Door U tility) 2. Remove left front sill trim plate.
Figure 56— R ight R ear Body C o m er G arnish

(TW o-Door U tility)
G arnish M olding (U tility)
3. Install front seat bolts.

(S uburban)
4. Install left seat track garnish molding.
3. Remove right front seat belt retractor. 5. Install right seat track garnish molding.
4. Remove right front sill trim plate. 6. Install front seat center belt anchor bolts.
5. Remove transfer case shift console (if equipped). 7. Install left kick panel.
6. Remove transfer case shift handle (if equipped). 8. Install right kick panel.
7. Remove heater duct. 9. Install heater duct.
8. Remove left kick panel. 10. Install transfer case shifter handle (if equipped).
9. Remove right kick panel. 11. Install transfer case shift console (if equipped).
10. Remove front seat center belt anchors. 12. Install right front sill trim plate.
11. Remove right front seat track garnish molding. 13. Install right front seat belt retractor.
12. Remove left front seat track garnish molding. 14. Install left front sill trim plate.
13. Remove seat hold down bolts. 15. Install left front seat belt retractor.
14. Remove seat from vehicle. Suburban
15. Remove carpet from vehicle.
■ M-
|* + | Remove or Disconnect (Figures 60 through 63)
1. Remove left front seat belt retractor.

1. Install new carpet into vehicle.
2. Remove left front sill trim plate.
2. Install front seat into vehicle.
3. Remove right front seat belt retractor.
Figure 58— Floor Panel M at o r C arpet (Extended Figure 60— Floor Panel M at o r C arpet (Suburban)
Cab)
22. Remove right rear sill trim plate.
23. Remove right rear seat bolts.
24. Remove right rear seat from vehicle.
25. Remove left rear seat belt anchor bolt.
26. Remove right rear seat belt anchor bolt.
27. Remove center carpet retainer.
28. Remove left passenger assist handle.
29. Remove left front shoulder belt pivot.
30. Remove left B-Pillar molding.
31. Remove right passenger assist handle.
32. Remove right front shoulder belt pivot.
33. Remove right front B-Pillar molding.
34. Remove left C-Pillar molding.
35. Remove right C-Pillar molding.
36. Remove floor vent grilles.
37. Remove carpet from vehicle.
1. Install new carpet into vehicle.

2. Install floor vent grilles.
Figure 59— Floor Panel M at o r C arpet (C rew Cab) 3. Locate and cut transfer case or manual transmis
sion access hole (if equipped).
4. Remove right front sill trim plate. 4. Install right C-Pillar molding.
5. Remove transfer case shift console (if equipped). 5. Install left C-Pillar molding.
6. Remove transfer case shift handle (if equipped). 6. Install right front B-Pillar molding.
7. Remove heater duct. 7. Install right front shoulder pivot.
8. Remove left kick panel. 8. Install right passenger assist handle.
9. Remove right kick panel. 9. Install left B-Pillar molding.
10. Remove front seat center belt anchors. 10. Install left front shoulder belt pivot.
11. Remove right front seat track garnish molding. 11. Install left passenger assist handle.
12. Remove left front seat track garnish molding. 12. Install center carpet retainer.
13. Remove seat hold down bolts. 13. Install right rear seat belt anchor bolt.
14. Remove seat from vehicle. 14. Install left rear seat belt anchor bolt.
15. Remove left rear sill trim plate. 15. Install right rear seat into vehicle.
16. Remove left rear seat front garnish molding. 16. Install right rear seat bolts.
17. Remove left rear seat rear garnish molding. 17. Install right rear sill trim plate.
18. Remove left rear seat release handle. 18. Install left rear seat into vehicle.
19. Remove left rear seat bolts. 19. Install left rear seat bolts.
20. Remove left rear center seat belt bolt. 20. Install left rear center seat belt bolt.
21. Remove left rear seat from vehicle. 21. Install left rear seat rear garnish molding.
Figure 61— Rear Floor Panel M at o r C arpet Figure 63— Rear Floor Front Trim Plate(Suburban
(Suburban) and U tility)
U tility
4 -+ Remove or Disconnect (Figures 62 through 65)
1. Remove front passenger seat.

2. Remove front driver seat.
3. Remove floor center console.
4. Remove rear right side seat bolt covers and bolts.
5. Remove rear right side seat.
6. Remove rear left side seat bolts.
7. Remove rear left side seat.
8. Remove floor mats.
9. Remove transfer case shifter bezel (if equipped).
10. Remove right side seat belt retractor covers and
bolts.
11. Remove left side seat belt retractor covers and
bolts.
12. Remove right side sill trim plates.
13. Remove left side sill trim plates.
14. Remove right side center pillar trim.
15. Remove left side center pillar trim.
and U tility) 16. Remove right side kick panel.
17. Remove left side kick panel.
22. Instal left rear seat front garnish molding. 18. Remove floor vent grilles.
23. Instal left rear seat release handle. 19. Remove carpet.
24. Instal left rear sill trim plate.
25. Instal front seat into vehicle. -M - Install o r Connect (Figures 62 through 65)
26. Instal front seat bolts.
27. Instal left seat track garnish molding. 1. Install carpet.
28. Instal right seat track garnish molding. 2. Install floor vent grilles.
29. Instal front seat center belt anchor bolts. 3. Install left side kick panel.
30. Instal left kick panel. 4. Install right side kick panel.
31. Instal right kick panel. 5. Install left side center pillar trim.
32. Instal heater duct. 6. Install right side center pillar trim.
33. Instal transfer case shifter handle (if equipped). 7. Install left side sill trim plates.
34. Instal transfer case shift console (if equipped). 8. Install right side sill trim plates.
35. Instal right front sill trim plate. 9. Install left side seat belt retractor bolts and covers.
36. Instal right front seat belt retractor. 10. Install right side seat belt retractor bolts and
37. Instal left front sill trim plate. covers.
38. Instal left front seat belt retractor.
Figure 64— Floor Panel M at or C arpet (U tility)
1. Luggage shade assembly from vehicle.

• Pull back and up to release rear of luggage
shade.
• Pull in and up to release front of luggage shade.
-►4- install or C onnect (Figure 66)
1. Luggage shade assembly to vehicle.

• Insert front of luggage shade into right side first
then push in and insert left side into interior side
panel.
• Pull back and insert into one of three available
positions.
AUXILIARY DOOR LOCK

SWITCH REPLACEMENT
On the passenger side of the rear cargo door or tail
gate, there is a power lock switch which can be used to
Figure 65— R ear F loor Panel M at or C arpet (U tility) lock or unlock all of the doors.
On vehicles with cargo doors, if the rear cargo lock
11. Install transfer case shifter bezel (if equipped). switch is pressed with the cargo doors open, all of the
12. Install floor mats. doors will lock five seconds after the cargo doors are
13. Install rear left side seat. closed. If the cargo doors are closed, the vehicle doors
14. Install rear left side seat bolts. will lock when a power door lock switch is pressed.
15. Install rear right side seat.
16. Install rear right side seat bolts and covers. R Rem ove o r D isconnect (Figure 67)
17. Install floor center console.
18. Install front driver seat and bolts. 1. Two screws on right D pillar trim panel.
19. Install front passenger seat and bolts. 2. Wiring connector.
3. Unclip switch.
4. Switch.
LUGGAGE SHADE
REPLACEMENT Install o r Connect (Figure 67)
If equipped the vehicle will have a luggage shade 1. Clip switch into location.
located in the rear compartment. The luggage shade is 2. Wiring connector.
adjustable to three positions to cover the rear compart 3. Two screws into right D pillar trim panel.
ment area of the vehicle.
Tighten
D pillar trim panel screws to 2 N-m (18 lb in).

Com partm ent

JACK TOOL AND STOWAGE
Pickup and C rew Cab
Remove o r Disconnect (Figures 68 through 70)
1 . The nut retaining the jack and tool stowage

container.
2. The retainer from the jack.
3. The tool stowage container from the bracket.
4. The jack from the bracket.
1. The jack to the bracket.

2. The tool stowage container to the bracket.
3. The retainer to the jack.
4. The nut to retain the jack and tool stowage
container.
Figure 70— Jack and Tool Stow age to Tray
|$ Q Tighten
• The nut to retain the jack and tool stowage con

tainer to 5 N-m (44 ib in).
Extended Cab
|+-»| Remove or Disconnect (Figures 71 through 73)
1. The nut retaining the jack and tool stowage

container.
|-M -| Install o r C onnect (Figures 71 through 73)

Figure 68—J a c k and Tool Stow age Cover 2. The tool stowage container to the bracket.
Installation
Figure 71— Jack and Tool Stow age C over Figure 73— Jack and Tool Stow age to Tray
Installation
++ Install or Connect (Figures 74 through 76)

container.
Tighten

tainer to 5 N-m (44 lb in).

container.•
Tighten

tainer to 5 N.m (44 lb in).
Suburban
|<"»| Rem ove or Disconnect (Figures 74 through 76)
1. The nut retaining the jack and tool stowage

container.
4. The jack from the bracket. Figure 74—Jack and Tool Stowage Stud to Tray
Figure 75— Jack and Tool Stow age C ontainer to Figure 77— Jack and Tool Stow age C over
Tray Installation
Figure 76— Jack and Tool Stow age C ontainer to Figure 78—Jack and Tool Stow age Tray
Tray
Ttoo Door U tility container.
Remove or Disconnect (Figures 77 through 79) Tighten
1 . The nut retaining the ja ck and tool stowage • The nut to retain the jack and tool stowage con
container. tainer to 5 N-m (44 lb in).
Four Door U tility
B Remove or Disconnect (Figures 80 through 81)
1. The nut retaining the jack and tool stowage con
1. The jack to the bracket. tainer.
2. The tool stowage container to the bracket. 2. The retainer from the jack.
3. The retainer to the jack. 3. The tool stowage container from the bracket.
Figure 79— Jack and Tool Stow age to Tray Figure 80— Jack and Tool Stow age C over
Installation
Install or C onnect (Figures 80 through 81)

container.
Tighten

tainer to 5 N-m (44 lb in).
FLEXIBLE PLASTIC PART

REFINISHING
N O T IC E : Use supplies, prim er, basecoats
and clearcoats from the same manufacturer
for the best results. Do not Intermix paint
systems.
Figure 81— Jack and Tool Stow age Tray
To refinish repaired or replacement flexible parts, fol
low the paint manufacturer’s system regarding prepara
tion, priming, and refinishing. Because these parts are
flexible, they may require special additives in the prim
ers and topcoat to prevent cracking and poor adhesion.
Always use manufacturer’s recommended materials.
Never intermix with other systems.
To identify the type of paint to use when refinishing
interior panels, refer to Service Parts Identification Label
in General Information. This label contains all paint
technology, paint codes, trim level, and any special
order paint color codes necessary to identify the correct
paint.
SPECIFICATIONS

Floor Console Bolts 6 — 53
Jack and Tool stowage container Retaining Nut 5 — 44
Overhead Console Screws 2 — 18
Pillar Molding Screws 2 — 18
Door Sill trim plate Screws 2 — 18
Quarter Panel Trim Screws 2 — 18
Quarter Panel Trim Armrest Screws 2 — 18
Upper Garnish Molding Screws 2 — 18
D Pillar Trim Panel Screws 2 — 18
BLANK
FRAME AND BUMPERS 10A5-1
SECTION 10A5
FRAME AND BUMPERS

GENERAL DESCRIPTION
Proper frame alignment is critical to ensure normal life 5. DIAMOND refers to the condition where one side of
and function of many parts on the vehicle. If the vehicle the frame has been moved forward or rear causing
has been involved in a fire, collision, or has been over the frame structure to be out of square (Figure 2).
loaded, check the frame alignment. If for any other rea 6. SAG refers to a vertical misalignment resulting in
son alignment is suspected, it should be checked. Refer an incorrect datum line. When both sides are
to Checking Frame Alignment, in this Section. equally misaligned, this condition is known as
It is possible that certain conditions make the frame kick-up (Figure 3).
appear to be out of alignment when, in fact, it is not.
These conditions are described under Checking Frame
Alignment, in this Section.
Terms used in this section are briefly defined below:
1. SECTION MODULUS is a measure of the strength
of a frame based on height, width, thickness, and
shape of the side rails. It does not account for the
strength of the material used in the frame.
2. YIELD STRENGTH is a measure of the strength of
the material from which the frame is made. It is the
maximum load that can be placed on a material
and still have it return to its original shape. It is
measured in kPa (psi).
3. RESISTANCE TO BENDING MOMENT (RBM) is a
single measure of frame strength that accounts for
both section modulus and the strength of the mate
rial used.
4. COLLAPSE refers to the condition that occurs
when buckles appear on more than one surface of
the box section of the side rail, or when a section
of the underbody or frame structure has been
shortened in length (Figure 1). Figure 2— Diam ond (Dam age C ondition)
Figure 1— C ollapse (Dam age C ondition) Figure 3— S ag (Dam age C ondition)

10A5-2 FRAME AND BUMPERS
Figure 4— S idesw ay (Dam age C ondition) Figure 5— TWIst (Dam age C ondition)
7. SIDESW AY refers to a section of the frame that is 10. WEB refers to the vertical part of a channel-type
positioned to the left or right of centerline, when frame rail.
compared to the rest of vehicle (Figure 4). 11. DATUM Refers to the plane of the underbody of
8 . TR AC KING refers to the alignment of the vehicle frame from which all vertical measurements origi
axles with each other. A misaligned frame can nate.
cause improper tracking. If the vehicle is tracking 12. TRAM LENGTH Refers to measurements that are
correctly, all axles will be parallel to each other and two dimensional and parallel to the datum line.
perpendicular to the centerline of frame.
9. TW IS T refers to the condition where the sides of
the underbody plane (datum) are not parallel. One
rail will slope up while the other rail will slope down
(Figure 5).
DIAGNOSIS OF THE FRAME

PROBLEM PO SSIBLE CAUSE CORRECTION
Sag 1. Loads g re a te r tha n the fra m e is 1-7. Straighten and reinforce the frame.
designed to carry. See Straightening Frames.
2. Uneven load distribution.
3. Abrupt changes in section modulus.
4. Improper body, or accessory, mounting:
— Holes drilled in the flange of the frame
rail.
— Too many holes in the web section of
the rail.
— Holes in the web section which are too
close to each other.
— Four or more holes in the same vertical
line of the rail web.
— Welds on the flange, particularly across
the flange or along its edge.
— Cutting holes in the rail with a torch.
— Cutting notches anywhere on the rails.
5. A fire involving the vehicle.
6. A collision involving the vehicle.
7. The use of equipment for which the
frame has not been designed or rein
forced.
DIAGNOSIS OF THE FRAME (cont’d)

Buckle 1. Using equipment such as snow plows 1-4. Straighten and reinforce the frame.
for which the frame was not designed. See Straightening Frames.
2. A collision involving the vehicle.
3. A fire involving the vehicle.
4. In addition to these causes, refer to
possible causes 3 and 4 under Sag.
Sidesw ay 1. A collision involving the vehicle. 1-4. Straighten and reinforce the frame.
2. A fire involving the vehicle. See Straightening Frames.
3. The use of equipment such as snow
plows for which the frame was neither
designed nor properly reinforced.
4. In addition to these causes, refer to
possible causes 3 and 4 under Sag.
Diam ond 1. A collision involving the vehicle. 1-2. Straighten and reinforce the frame.
2. Towing another vehicle with a chain See Straightening Frames.
attached to one corner of the frame.
Tw ist 1. An accident or collision involving the 1-2. Straighten and reinforce the frame.
vehicle. See Straightening Frames.
2. Operating the vehicle in very rough ter
rain.
Im proper Tracking 1. Frame is out of alignment. 1. Replace or weld and reinforce rail.
Ream bolt holes and replace with larger
bolts if necessary. Retighten bolts.
2. Front or rear axle has shifted. 2. Replace or weld and reinforce the rail.
See the appropriate heading, later in
this section.
3. Incorrect wheel alignment. 3. Refer to Front Wheel Alignment.
C racks in W eb of 1. Loose crossmember attaching bolts. 1. Replace or weld and reinforce rail.
R ails Ream bolt holes and replace with larger
bolts if necessary. Retighten bolts.
2. Concentration of stress that may result 2. Replace or weld and reinforce rail as
from many different factors. (See Sag explained later in this section.
under Diagnosis previously described in
this chart. Also see Minimizing Frame
Damage and Reinforcements (later in
this section).
D0094
2. Follow recommended practices when repairing a

M INIM IZING FRAME SERVICE frame or mounting a body or equipment on a
Generally, frame service can be minimized or elimi frame.
nated by minimizing the concentration of stress in small • Avoid sudden changes in the section modulus.
areas of the frame. • Do not drill holes in the frame rail flanges.
1. Vehicles should be used only for those purposes • Space holes in the web section of a rail at least
for which they were designed. 13 mm (1/2 inch) from one another.
• Do not overload. • Use existing holes whenever possible.
• Load evenly; localized loads should be avoided. • Do not cut holes with a torch.
• Do not operate the vehicle on extremely rough • Do not overheat the frame rails.
terrain at excessive speeds. • Avoid welding on the flanges.
• Take into account the forces that will be placed • Do not allow four or more holes to exist on the
on a frame from the operation of equipment same vertical line of the web.
(such as snow plows) when picking a frame for
a new vehicle or reinforcing a frame.
CHECKING FRAME ALIGNMENT 5. Measure the distance from the dead center of each
frame rail at points 1 and 2. This distance should
The main components of a frame are the side rails be 860 mm (33.85 inches).
and crossmembers. The rails carry the load and the 6. Make a mark on the floor exactly halfway between
crossmembers stabilize the rails. points 7 and 8. Make a sim ilar mark between
Types of frame misalignment can be divided into five points 1 and 2.
groups. The five groups are; sag, collapse, diamond, 7. Use a chalk line to mark a line through the points.
sidesway, and twist. This is the centerline of the frame.
A misaligned frame rail may have moved forward
from, up or down from, or to the side of where it should H orizontal Check
be. These possibilities must be checked.
The easiest way to check frame alignment is with 1. Measure the distance between the frame rails, and
tramming gauges and universal measuring systems the centerline. Each pair of corresponding points
made for this purpose. Detailed instructions are normal should be an equal distance from the centerline
ly supplied with the equipment at the time of purchase. within 3 mm (1/8 inch). Example: Points 3 and 12
Therefore, instructions for equipment usage are not giv should measure equally from the centerline as
en in this manual. should points 6 and 9, 5 and 10, and points 4
Whether alignment is checked with or without gauges, and 11.
the vehicle must be parked on a level section of floor.
Certain conditions call for preliminary checks before
actually checking the frame. Suspension or axle prob
lems may make it appear that the vehicle frame is out
of alignment. If an axle has shifted, a Diamond or Side
sway may appear to exist when, in fact, they do not. A
weak spring may make the vehicle appear to have a
twisted frame.
A visual inspection of the top and bottom flanges of
each rail may reveal the specific area where sag or
buckle exists. In the case of sag, wrinkles may appear
on the top of the upper flange. Wrinkles on the bottom
of the lower flange are definite evidence of buckle.
D eterm ining the Fram e C enterline
Centerline length measurements are three dimension
al measurements. These three dimensions are:
1. Length (distance between two points when
height is parallel to center plane)
2. Height (measurement is parallel to datum plane)
3. Width (measurement is parallel to center plane)
When reading dimension charts, horizontal width and (R ear-W heel D rive)
length dimensions of the underbody are shown as
viewed from the bottom of the underbody. Vertical
dimensions are shown from the side of the underbody
and use the datum plane as a base for all vertical
(height) measurements.
1. Move the vehicle to a level, well-lighted section of
the floor.
2. Make a diagram of the frame on the floor beneath
the vehicle as follows:
A. Using a plumb bob, transfer points 1, 2, 7, and
8 from the inside of the web to the floor. Mark
the points (Figure 6 through 8).
B. Using a plumb bob, transfer the remaining
points from the outside of the web to the floor.
Mark the points. The actual placement of these
points is not so important as is the fact that the
points must be taken from the same place on
both the right and left frame rail.
3. Move the vehicle away from the points on the floor.
4. Measure the distance from the outer edge of each
frame rail at points 7 and 8. This distance should
be 866 mm (35.31 inches). (Selectable Four-W heel D rive)
Datum Plane
A datum (Figure 9) is an imaginary horizontal plane
that runs below and parallel to the vehicle. Height
dimensions are calculated at right angles from the
datum to a given control or reference point on the
underbody.
The company that develops height dimensions deter
mines the location of the datum based on the equip
ment being used. Therefore, different datum lines are
established for the same vehicle. You can add or sub
tract an equal amount from all height dimensions and
create a new datum line for your usage.
C enter Plane
A centerline (Figure 10) is an imaginary vertical plane
that is perpendicular to the length of the datum plane
through the center of the vehicle. The centerline is any
line drawn through the center of the vehicle’s datum.
The symbol for centerline is CL.
C enterline Length
(S electable Four-W heel D rive C ab-C hassis) Centerline length measurements are three dimension
al measurements. These three dimensions are:
1. Length (distance between two points when
2. Measure diagonally from point 6 to point 8, and
height is parallel to center plane).
from point 7 to point 9. Mark the floor where the
2. Height (m easurem ent is parallel to datum
diagonals pass the centerline. The diagonals plane).
should measure the same distance within 5 mm 3. Width (measurement is parallel to center plane).
(3/16 inch), and should cross at the centerline. If When reading dimension charts, horizontal width and
the frame is within specifications, the frame within length dimensions of the underbody are shown as
these points is properly aligned. viewed from the bottom of the underbody. Vertical
3. Repeat Step 2 on other pairs of diagonals until the dimensions are shown from the side of the underbody
entire frame has been checked. Example: Point 3 and use the datum plane as a base for all vertical
to point 9 and point 6 to point 12 or point 10 to (height) measurements.
point 2 and point 5 to point 1, etc.
V ertical Body Zero Line
4. Refer to Straightening Frames in this section to
repair any damage that is found. The vertical Body Zero Line (Figure 11) is a line
drawn through the frame either at the forward or rear
ward torque box area of the frame. This is the starting
point for determining length measurements.
Figure 9— Datum Plane Figure 10— C enterline Plane

d a tu m
Figure 11— V ertical Body Zero Line

(1) Straight Crack
STRAIGHTENING FRAMES (2) Sunburst Crack
Frame straightening can be complicated and usually Figure 12— Types of Fram e C racks
requires special equipment. It should be attempted by
qualified technicians only. excessive bending movement, and torsional loading.
A complete analysis of the condition of the frame Refer to Minimizing Frame Service, in this section.
should be made before any steps are taken to straight Sunburst crack(s) will radiate outward from a hole in
en it. Analyzing the cause of failure will help determine the web section of a rail or crossmember. They are
the correct sequence of steps in the repair. (Refer to caused by high loads being applied at a mounting
Possible Causes under Diagnosis and M inim izing bracket or crossmember which is not securely or prop
Frame Service in this section.) Use corrective proce erly attached to the rail.
dures to reverse the flow of the damaging forces. In If cracks occur to both the rail and reinforcement at a
many instances, to reverse the flow of forces, pressure particular area of the frame, they must be repaired sep
must be applied from different directions at the same arately. The flanges must react independently to prevent
time. localized stress concentration. Use a copper spacer
Careful use of controlled heat is critical. Too much or between the flanges of cracked base rail flanges and
too little heat, or the improper application of heat, is a reinforcement flanges.
major source of trouble. Before any flame is used on Crossm em ber m ounting flange cracks may be
the frame, all of the protective coating material must be repaired in the same manner as side rail cracks. How
removed to prevent a fire, after repair is complete the ever, a weld bead should be built up to provide a good,
frame needs to be recoated with protective material. smooth radius. If a crossmember is badly damaged,
Frame heating should be done with a large sized replace it.
(multi-hole) heating tip, and a neutral flame should be It may be necessary to align the frame and level the
used (oxygen adjustm ent opened ju st enough to rails before repairing the frame.
remove the feathers or stringers from the blue center at 1. Remove any equipment that will interfere with
tip of torch). Heat the area that will be stretched as the access to the crack.
frame is straightened. Heat the area AFTER SUFFI 2. Locate the extreme end of the crack and drill a
CIENT PRESSURE HAS BEEN EXERTED to cause a 3 mm (0.12 inch) hole.
slight checking, or silvery cracks, to appear on the sur 3. V grind the entire length of the crack from the start
face of the metal. Gradually increase the pressure while ing point to the 3 mm (0.12 inch) hole at the
heating. Do not heat beyond 606* C (1200* F). A red extreme end.
glow indicates that the material is overheated. Over 4. Remove protective coating on the frame in the are
heating will cause distortion and stretching, as well as a of the repair. Open up the bottom of the crack
change in the characteristics of the metal. 2 mm (1/16 inch) to allow good penetration of the
weld. (A hacksaw blade may be used for this).
REPAIRING CRACKS 5. Weld with proper electrode and proper welding
techniques. Refer to Welding in this section for tips
Two common types of cracks are shown in Figure 12. on welding.
The straight crack will normally start from the edge of a 6. Grind the weld smooth on both the inside and the
flange. It will go across the flange and through the web outside of the rail or crossmember. Be extremely
section of a rail. Finally, it will continue through the careful to eliminate weld buildup or notches on the
other flange. This type of crack may result from high edge of the flange. Recoat the frame with protec
concentrations of stress in small areas of the frame, tive material.
WELDING 4. Whenever possible, use smaller diameter elec
trodes and make several passes; this is preferred
Using improper welding techniques causes many to using a large diameter electrode and making
weld and/or frame failures. The following information fewer passes.
points out potential areas of difficulty and provides 5. Do not use more heat than is necessary to give
some general guidelines for successful frame welding. good penetration.
Most weld failures occur at the end of the weld in 6. Do not run more passes than necessary.
areas of the frame that are under high stress. By elimi 7. Make sure the weld is free from craters, undercuts,
nating the ends of a weld, failures can be reduced. This slag inclusion, and porosity.
can be done by making a hole or slot in the part to be 8. Make sure scale is removed from each successive
pass.
attached and then using a fillet weld around a slot or
9. If repairing a crack, grind the surface of the weld
plug weld. Do not leave a notch at the end of a weld.
flush with the parent material.
Over-welding can be harmful, especially if it is in an 10. When mounting accessories, do not weld across,
area of the frame that receives high concentrations of or within 19 mm (3/4 inch) of a flange.
stress. 11. Do not weld up to the edge of a part being welded
Small cracks in a crossmember may be welded. to a frame. Leave 6 mm (0.25 inch) between the
(Refer to Repairing Cracks in this section). end of the weld and the edge of the part.
12. Do not weld cast brackets to the frame.
W hen W elding: 13. Do not weld the flanges of cracked reinforcements
1. Disconnect the battery. Refer to Battery Disconnect and base rails together.
Caution in General Information. 14. Do not attach the ground cable to the engine. Con
2. The frame is covered with a protective wax coating. nect the welding machine ground cables as close
to the working area as possible.
Use a wire brush to remove any concentration of
15. Do not get the welding cables near the vehicle
wax before welding. When finished, re-coat the
wiring. Avoid direct contact between the welding
area with new wax.
cables and any part of the vehicle.
3. Do not use oxyacetylene welding equipment.
ON-VEHICLE SERVICE
FRONT AIR DEFLECTOR r»4-| Install o r C onnect (Figures 14 and 15)
REPLACEMENT I.A ir deflector to the bumper. Refer to Front Air

Deflector Replacement in this section.
1. Deflector to the bumper bolts.

2. Deflector from the vehicle.
++ Install o r Connect (Figure 13)
1. Deflector to the vehicle.

2. Deflector to the bumper bolts.
Q Tighten
• D eflector to the bum per bolts to 10 N.m

(89 lb in).
FRONT BUMPER REPLACEMENT

|+ + | Rem ove o r D isconnect (Figures 14 and 15)
1. Grille. Refer to Grille Replacement in Sheet Metal.

2. Bumper to brace bolts and washers (Figure 14). Legend
3. Bumper to bracket bolts and washers. (1) Bolt
4. Bumper from the vehicle. (2) Front Bumper
5. Guards from the bumper (if equipped) (Figure 15). (3) Nut
6. Air deflector from the bumper (if equipped). Refer (4) Front Air Deflector
to Front Air Deflector Replacement in this section. Figure 13— Front A ir D eflector
2. Guards to the bumper with nuts (if equipped). FRONT BUMPER FILLER
Tighten SIDE PANEL REPLACEMENT
• Guard to the bumper nuts to 25 N-m (18 lb ft). Rem ove or D isconnect (Figure 16)
3. Bumper to the vehicle. 1. Grille. Refer to Grille Replacement in Sheet Metal.

4. Bumper bolts and washers to the bracket. 2. Filler panel to the fender bolts.
5. Bumper bolts and washers to the brace. 3. Filler side panel.
• Align the bumper laterally to the grille area.
|^ | Tighten
1. Filler side panel.
• Bumper to the bracket and the brace bolts to 2. Filler side panel to the fender bolts.
112 N-m (83 lb ft). 3. Grille.
FRONT BUMPER FILLER FRONT LICENSE PLATE

CENTER PANEL REPLACEMENT BRACKET
REPLACEMENT
1. Grille. Refer to Grille Replacement in Sheet Metal.
2. Filler panel to the radiator support screws. 1. License plate bracket to the bumper nuts.
3. Filler center panel from the vehicle. 2. License plate bracket to the bumper bolts.
0 In stall o r C onnect (Figure 16)

3. License plate bracket.

1. Filler panel to the vehicle.
2. Filler panel to the radiator support screws. 1. License plate bracket.
3. Grille to the vehicle. 2. License plate bracket to the bumper bolts.
3. License plate bracket to the bumper nuts.
Tighten
• License plate bracket to the bumper bolts to

13 N-m (115 lb in).
TOW HOOKS
1. Tow hook bolts from the frame rail.

2. Tow hook and plate from the vehicle.
-M - Install or C onnect (Figure 18)
1. Tow hook and plate to the frame rail.

2. Frame rail to the tow hook bolts.
^ Tighten
• Frame to the tow hook bolts to 60 N-m

(44 lb ft).
ENGINE PROTECTION SHIELD
1. Four frame to shield bolts.

2. Shield from vehicle.
(1) Bumper (5) Air Deflector

(2) Bolt (6) Bumper Guards
(3) Bolt (7) Rub Strip
(4) Brace
F ig u re 15— B u m p e r A s s e m b ly C o m p o n e n ts
+«■ In s ta ll o r C o n n e c t (F ig u re 1 9 ) REAR BUMPER, BRACE AND

1. Shield to vehicle.
BRACKET REPLACEMENT
2. Four frame to shield bolts.
T ig h te n R em o v e o r D is c o n n e c t (F ig u re s 21 th ro u g h 2 3 )
1. License plate lamp harness. Refer to License Lamp

• Frame to shield bolts to 35 N-m (26 lb ft).
Replacement in Lighting Systems.
2. Brace to bumper nuts and bolt assemblies.
REAR BUMPER STEP PAD 3. Bracket to bumper nuts, washers and bolts.
REPLACEMENT 4. Bumper from the vehicle.
5. Brace and bracket nuts, washers and bolts.
6. Braces and brackets from the frame.
|+ + | R e m o v e o r D is c o n n e c t (F ig u re 2 0 )
■M- In s ta ll o r C o n n e c t (F ig u re s 21 th ro u g h 2 3 )
1. Step pad to bumper nuts.
2. Step pad. 1. Braces and brackets to the frame.
2. Brace and bracket bolts, washers and nuts.
I+ 4 -I In s ta ll o r C o n n e c t (F ig u re 2 0 )
• Be sure the harness is in place, if used.
1. Step pad to bumper. T ig h te n

2. Step pad to bumper nuts.
• Brace and bracket bolts to 90 N-m (66 lb ft).
• Front bracket nut to 47 N-m (35 lb ft).
Legend
(1) Nut (1) Plate
(2) Screw (2) Tow Hook
(3) Front Bumper Outer Filler Panel (3) Bolt
(4) Screw F ig u re 1 8 — T o w H o o k s
(5) Nut
(6) Nut
(7) Screw
(8) Front Bumper Filler Panel
F ig u re 1 6 — F ro n t B u m p e r F ille r P a n e ls
3. Bumper to the vehicle.

4. Bracket to the bumper bolts, washers and nuts.
• Align the bumper (Figure 21).
(1)
(2)
Nut
Bumper
Q T ig h te n
(3) License Plate Bracket

(4) Bolt • Bracket to the bumper bolts to 90 N.m (66 lb ft).
F ig u re 1 7 — F ro n t L ic e n s e P la te B ra c k e t 5. Brace to bumper bolts, and nuts.
T ig h te n
• Brace to the bumper bolts to 90 N.m (66 lb ft).

6. License plate lamp harness.
(1) Rear Bumper Step Pad (1) Nut

(2) Rear Bumper Center Step Pad (2) Bolt Assembly
(3) Rub Strip (3) Bracket
(4) Nut (4) Nut
(5) Nut (5) Grommet
F ig u re 2 0 — R e a r B u m p e r S te p P a d s a n d R u b S trip s (6) Rear Bumper
(7) Washer
HITCH PLATFORM and LICENSE (8) Bracket Bolt
(9) Nut
PLATE BRACKET (10) Bolt Assembly
REPLACEMENT (11) Brace
(12) Bolt Assembly
R e m o v e o r D is c o n n e c t (F ig u re s 2 4 a n d 2 5 ) (13) Nut
(14) Washer
1. Bracket plate to hitch platform bolts and nuts (15) Bracket and Brace Bolt
(Figure 24). (16) Washer
2. License plate bracket assembly from hitch platform. (17) Bolt Assembly
3. Bolts, washers, and nuts from the hitch platform F ig u re 2 1 — R e a r S te p B u m p e rs
and frame rail.
4. Hitch platform from the vehicle.
-► 4- In s ta ll o r C o n n e c t (F ig u re s 2 4 a n d 2 5 )
1. Hitch platform to the vehicle.

2. Hitch bolts and washers through the frame rails
with nuts.
T ig h te n
• Hitch to the frame bolts to 100 N-m (74 lb ft).

3. License plate bracket assembly to the hitch plat
form.
4. Bolts and nuts.
Legend
(1) Bolt (1) Hitch Platform
(2) Nut (2) Bolt
(3) Bolt (3) License Plate Bracket
(4) Nut (4) Nut
(5) Bolt F ig u re 24— H itc h P la tfo rm a n d L ic e n s e P la te
(6) Bumper B ra c k e t
(7) Brace
(8) Bolt
F ig u re 2 2 — R e a r B u m p e r
(1) Washer
(2) Nut
(3) Weld Nut
(1) 6.0 mm (0.24 in) (4) Rear Bumper
(2) Grommeted Hole 6.0 mm (0.24 in) (5) Hitch Platform
(3) Rear Bumper (6) Bolt
F ig u re 2 3 — R e a r B u m p e r A lig n m e n t F ig u re 2 5 — W e ig h t D is trib u tio n H itc h P la tfo rm
SPECIFICATIONS
Air Deflector to Bumper Bolts 10 — 89
Bumper Filler Panel to Radiator Support Screws 2 — 18
Bumper Guard to Bumper Nuts 25 18 —
Bumper Side Filler Panel to Fender Screws 2 — 18
Engine Protections Shield to Frame Rail Bolts 35 26 —
Front Bumper to Brace Bolts 112 83 —
Front Bumper to Bracket Bolts 112 83 —
License Plate Bracket to Front Bumper Bolts 13 — 115

Platform Hitch to Frame Rail Bolts 100 74 —
Rear Bumper Brace to Bracket Bolts 90 66 —
Rear Bumper Bracket to Frame Nut 47 35 —

Rear Bumper to Brace Bolts 90 66 —
Rear Bumper to Bracket Bolts 90 66 —
Tow Hook to Frame Rail Bolts 60 44 —
BLANK
SHEET METAL 10A6-1
SECTION 10A6
SHEET METAL
ON-VEHICLE SERVICE
HOOD REPLACEMENT HOOD BUMPER REPLACEMENT
C A U TIO N : W hen a hood hold open d evice is
being rem oved o r in stalled pro vid e a ltern a te Rem ove or D isconnect (Figure 3)
su p p o rt to avo id th e p o s sib ility o f dam age to
th e v e h ic le o r personal in ju ry. 1. Remove front hood bumper by turning out counter
clockwise.
Rem ove or D isconnect (Figure 1) 2. Remove side hood bumper by sliding forward and
pulling up.
• Raise and support the hood at the front and rear.
• Place protective coverings over the cowl and
fenders.
1. Bolt holding the hinge to the link assembly.
• Lower the hood and support.
2. Outboard sections of the cowl vent grille.
3. Pivot bolt.
4. Hood from the vehicle.
-► 4- install o r Connect (Figure 1)
1. Hood to the vehicle.

2. Pivot bolts.
Tighten
• Hood to fender bolts to 25 N.m (18 lb ft).

3. Outboard section of the cowl vent grille.
• Raise the hood.
4. Bolt holding the hinge to the link assembly.
Tighten
• Link assembly bolts to 25 N.m (18 lb ft).

• Lower the hood.
HOOD INSULATOR
REPLACEMENT V iew l
Tool Required:
J 38778 Door Trim Pad and Garnish
Legend
Clip Remover.
(1) Hood
Rem ove o r D isconnect (Figure 2) (2) Hinge
(3) Nut
1. Insulator from hood retainers using J 38778. (4) Bracket
2. Insulator from the hood. (5) Bolt
(6) Bolt
■ M- Install or C onnect (Figure 2) (7) Link Assembly
(8) Bolt
1. Insulator to the hood. (9) Bolt
2. Insulator to the hood retainers. Figure 1—Hood Hinge Components
10A6-2 SHEET METAL
Legend
(1) Hood (1) Front Hood Bumper
(2) Hood Insulator Retainer (2) Side Hood Bumper
(3) Hood Insulator Figure 3— Hood Bum per
(4) Hood Insulator Retainer
Figure 2— Hood Insulator 4. Hinge to fender bracket bolts.
■M" In stall o r C onnect (Figure 3) S Tighten
1. Install side hood bumper by pushing down and slid • Hinge to fender bolts to 25 N.m (18 lb ft).
ing rearward.
2. Install front hood bumper by turning in clockwise 5. Outboard section of the cowl vent grille.
until hood closes flush with fender.
LINK ASSEMBLY
HOOD HINGE REPLACEMENT
REPLACEMENT
|+-»| Rem ove o r D isconnect (Figures 1 and 7)
|*-» | Rem ove o r D isconnect (Figure 1)
1. Outboard section of the cowl vent grille.
2. Hinge to fender bracket bolt. • Raise and support the front of the hood.
• Raise and support the hood at the front and
rear. 1. Link assembly from the hinge bolts.
3. Link assembly to the hinge bolt. 2. Link assembly from the fender bolts.
4. Hood seals from over the hinges. 3. Link assembly from the vehicle.
5. Hinge to the hood bolts.
6. Hinge from the hood. -M- Install o r C onnect (Figure 1)
In stall o r C onnect (Figures 1 and 7)

1. Link assembly to the vehicle.
1. Hinge to the hood with bolts. 2. Link assembly to the fender bolts.
S Tighten [$ Q Tighten
• Hinge to the hood bolts to 25 N.m (18 lb ft). • Link assembly to the fender bolts to 25 N-m
2. Hood seals over the hinges. (18 lb ft).
3. Link assembly to the hinge bolt.
3. Link assembly to the hinge bolts.
Q Tighten
S Tighten
• Link assembly bolts to 25 N.m (18 lb ft).
• Lower the hood. • Link assem bly to the hinge bolts to 25 N.m
(18 lb ft).
SHEET METAL 10A6-3
PRIMARY HOOD LATCH AND/OR 1. Hood latch height so that when the hood is
closed, the hood is held securely against the
BRACKET REPLACEMENT front hood bumpers. Mark this height.
Rem ove o r D isconnect (Figure 4) • Raise the hood.
• Raise the hood. Tighten

1. Hood latch release cable from the latch. Refer to
Hood Release Cable Replacement in this section. • Bracket to hood latch bolts to 25 N.m (18 lb ft).
2. Bracket to hood latch bolts.
3. Hood latch from the vehicle. SECONDARY HOOD LATCH
4. Bracket to radiator support bolts.
5. Bracket from the vehicle. AND/OR SPRING REPLACEMENT
| 2 A djust Rem ove or D isconnect (Figure 5)
• Front hood bumpers, so that the top of the hood

is flush with the fenders. • Mark the position of the secondary hood latch on
the hood.
[»4-| Install o r C onnect (Figure 4)
1. Secondary hood latch to hood bolts.
2. Secondary hood latch from the vehicle.
1. Bracket to the radiator support.
3. Spring from the hood.
2. Bracket to support bolts loosely.
3. Primary hood latch to the bracket. • Twist the spring from the reinforcement.
4. Latch to bracket bolts loosely.
5. Hood latch release cable to the latch. Install o r C onnect (Figure 5)
|2 J A djust 1. Spring to the hood.

• Hood latch bracket left and right until the striker • Twist the spring into the reinforcement.
in the hood easily engages the primary latch.
2. Secondary hood latch to the vehicle.
• Raise the hood.
3. Secondary hood latch to hood bolts.
Q Tighten
Tighten
• Bracket to radiator support bolts to 25 N-m
(18 lb ft). • Latch to hood bolts to 25 N-m (18 lb ft).
(1) Latch (1) Hood

(2) Bracket (2) Reinforcement
(3) Latch Support (3) Spring
(4) Bolt (4) Secondary Hood Latch
(5) Bolt (5) Bolt
Figure 4— Primary Hood Latch Components Figure 5—Secondary Hood Latch Components
10A6-4 SHEET METAL
HOOD RELEASE CABLE 4. Cable from the radiator support and from the
wheelhouse retaining clips.
REPLACEMENT 5. Two bolts from under the instrument panel inside
E3 Rem ove o r D isconnect (Figure 6 and 7)

the cab retaining the hood release handle.
• Push the cable and grommet into the cab from
the engine compartment.
• If the cable is broken, release the hood by pressing 6. Cable from the vehicle.
the primary latch tab on the left side of the lock
assembly. Use a rod to press the tab. Install or Connect (Figure 6 and 7)
• Raise the hood.
1. Cable to the vehicle.
1. Cable from the primary latch. 2. Cable from the driver’s side of the cowl.
• Insert a screwdriver into the clip, and lift the • Push the cable and the grommet into the engine
cable from the lock, then carefully pry the cable compartment.
grommet from the lock flange. 3. Two bolts holding the hood release handle to the
2. Five upper radiator grille screws. bottom of the instrument panel.
3. Move grille forward to access cable. • Seat the grommet.
4. Cable through the retaining clips and the radiator
support.
5. Five screws into the upper radiator grille.
6. Cable to the primary latch.
COWL VENT GRILLE

REPLACEMENT
Tool Required:
J 8966 Windshield Wiper Arm Remover
and Installer
1. W iper arm s. Refer to W iper Arm A ssem bly

Replacement in Windshield Wiper/Washer System.
2. Cowl weatherstrip.
3. Cowl vent grille panel screws.
4. Windshield washer hoses and nozzles.
5. Three cowl vent grille panels from the vehicle.
Figure 6— Hood R elease C able Routing
(1) Cowl Vent Grille Panels

Legend (2) Screws
(1) Primary Hood Latch (3) Oval Nut
(2) Radiator Support (4) Square Nut
Figure 7—Hood Release Cable Figure 8—Cowl Vent Grille Components
SHEET METAL 10A6-5
Install o r C onnect (Figure 8) 2. Grille and filler panel to the vehicle with bolts.
• Screws holding the grille to the radiator support.
1. Windshield washer hoses and nozzles to the cowl • Screw holding the grille to the latch support.
vent grille.
Tighten
2. Three cowl vent grille panels to the vehicle.
3. Cowl vent grille panel screws.
• Be sure the nuts below the center panel are in • Grille screws to 2 N-m (18 lb in).
3. Parking lamps and sidemarkers with screws.
place with the square nut second from the right.
4. Cowl weatherstrip.
5. Wiper arms.
LOWER GRILLE REPLACEMENT
(C 3500HD ONLY)
RADIATOR GRILLE Rem ove or D isconnect (Figure 10)
REPLACEMENT
1. Radiator grille. Refer to Radiator Grille Replace
Rem ove or D isconnect (Figure 9) ment in this section.
2. Five screws retaining lower grille to core support.
1. Bolts holding the grille to the vehicle. 3. Three screws in each front fender well retaining
• Screw holding the grille to the latch support. lower grille to fender extension.
• Screws holding the grille to the radiator support. 4. Lower grille.
2. Grille from the fille r panel and the vehicle by
unsnapping. ■M- Install o r Connect (Figure 10)
|+ + | Install o r C onnect (Figure 9) 1. Lower grille.

2. Three screws in each front fender well in order to
1. Grille to the vehicle and the filler panel by snapping retain lower grille to fender extension.
into place. 3. Five screws to retain lower grille to core support.
4. Radiator grille.
Legend
(1) Nut (4) Screw
(2) Front Bumper Filler Panel (5) Screw
(3) Grille (6) Bracket
Figure 9—Typical Radiator Grille Components
10A6-6 SHEET METAL
FENDER REPLACEMENT
R ight Fender
Rem ove or D isconnect (Figures 11 through 13)

2. Hood link assembly from the fender. Refer to Link
Assembly Replacement in this section.
3. Hinge to fender bolt and outboard cowl section.
4. Hood. Refer to Hood Replacement in this section.
5. Radio antenna from the fender.
6. Wiring inside the fender.
7. Air cleaner hose from the fender in the engine com
partment.
8. Battery and battery tray.
9. Forward air inlet duct assembly from the fender.
10. Wiring from the clips.
11. Underhood lamp (if present).
12. Bolt from inside the engine compartment.
Legend
(1) Wheelhouse (5) Radiator Support
(2) Fender (6) Fender
(3) Bolt (7) Battery Tray
(4) Wheelhouse
Figure 11— Fender and Wheelhouse Assemblies
SHEET METAL 10A6-7
13. B olts holding the fender to the wheelhouse Tighten
(Figure 11).
14. B olt by reaching up behind the wheelhouse • Fender to radiator support bolts to 25 N-m
(Figure 12). (18 lb ft).
15. Bolt holding the fender to the cab assembly 4. Bolts and nuts holding the fender to the door
(Figure 13). hinges.
• Open the door.
Q Tighten
16. B olts holding the fender to the door hinges
(Figure 13). • Fender to door hinge bolts to 25 N-m (18 lb ft).
17. Bolt holding the fender to the radiator support. 5. Bolt and nut from the fender to the cab assembly
18. Fender from the vehicle. (Figure 13).
■M- Install o r C onnect (Figures 11 through 13) |^ | Tighten
1. Fender to the vehicle. • Fender to cab bolts to 25 N-m (18 lb ft).

2. B o lt from in s id e th e e n g in e co m p artm en t 6. B olt by reaching up behind the wheelhouse
(Figure 11). (Figure 12).
7. B olts through the wheelhouse to the fender
Tighten (Figure 11).
8. Forward air inlet duct assembly to the front section
• Fender bolts to 25 N-m (18 lb ft). of the fender in the engine compartment.
3. Bolt to the radiator support.
(1) Cowl Bracket (8) Bolt

(2) Bolt (9) Frame
(3) Upper Door Hinge (10) Front Bumper Bracket
(4) Lower Door Hinge (11) Radiator Support
(5) Bolt (12) Bolt
(6) Hood Hinge Bolt (13) Bolt
(7) Fender
Figure 12—Fender to Vehicle Attachment
10A6-8 SHEET METAL
9. Battery tray and battery. 2. Link assembly from the fender. Refer to Link
Assembly Replacement in this section.
Tighten 3. Hinge to fender bolt.
• Outboard cowl grille section (Figure 8).
. Tray bolts to 25 N-m (18 lb ft). 4. Hood. Refer to Hood Replacement in this section.
10. Air cleaner hose to the fender. 5. Battery and battery tray (if present).
11. Wiring inside the fender. 6. Windshield washer reservoir.
12. Radio antenna into the fender. • Electrical connector.
13. Wiring into clips. • Four retaining bolts.
14. Underhood lamp (if present). 7. Four washer reservoir bracket bolts from fender.
15. Hood lin k assem bly. Refer to Link Assem bly 8. Hood release cable from the clip on the fender.
Replacement in this section. 9. Wiring harness from the clips.
16. Hood hinge to the hood. 10. Auxiliary battery relay (if present).
11. B olts holding the fender to the wheelhouse
Q Tighten (Figure 11).
12. B olt by reaching up behind the wheelhouse
• Hinge to hood bolts to 25 N-m (18 lb ft). (Figure 12).
17. Outboard cowl grille to vehicle. 13. Bolt holding the fender to the cab assem bly
18. Hood to the vehicle. Refer to Hood Replacement in (Figure 13).
this section. • Open the door.
• Check the fender for proper clearance. Refer to 14. B olts holding the fender to the door hinges
Sheet Metal Adjustments in this section. (Figure 13).
19. Negative battery cable. 15. Bolt holding the fender to the radiator support.
16. Bolt from inside the engine compartment.
Left Fender 17. Fender from the vehicle.
Rem ove o r D isconnect (Figures 1 and 11 Install or Connect (Figures 1 and 11 through 13)
through 13)
1. Fender to the vehicle.
1. Negative battery cable. Refer to Battery Disconnect 2. B o lts from in s id e th e e ngine com partm ent
Caution in General Information. (Figure 12).
Tighten

3. Bolts to the radiator support.
S Tighten
• Fender bolts to 25 N.m (18 lb ft).

• Open the door.
4. Bolts and nuts holding the fender to the door
hinges.
Tighten
• Fender bolts to 25 N-m (18 lb ft).

5. Bolt and nut from the fender to the cab assembly
(Figure 13).
S Tighten
• Fender bolts to 25 N.m (18 lb ft).

Legend
6. B olt by reaching up behind the wheelhouse
(1) Bolt (Figure 12).
(2) Hood Hinge Bolt 7. B olts through the w heelhouse to the fender
(3) Bracket (Figure 11).
(4) Nut 8. Auxiliary battery relay.
(5) Bracket 9. Wiring harness into the clip on the fender.
(6) Bolt 10. Hood release cable into the clips.
(7) Lower Door Hinge 11. Four windshield washer bracket to fender bolts.
(8) Nut 12. Reservoir to bracket.
(9) Radiator Support 13. Battery and tray (if present).
(10) Cowl Bracket 14. Link assembly.
Figure 13— Fender Assembly
SHEET METAL 10A6-9
15. Outboard cowl grille section (Figure 8). 3. Fender to side panel screws. Do not tighten screws
16. Hood hinge to the vehicle. until the lower mounting screws are installed.
Tighten Tighten
• Hood hinge to vehicle bolts to 25 N.m (18 lb ft). • Fender to the side panel screws to 18 N.m
17. Hood to the vehicle. (13 lb ft).
18. Negative battery cable. 4. Fender to bracket screws.
STEPSIDE FENDER ^ Tighten
REPLACEMENT • Stepside fender to the bracket screws to

E3 Remove or Disconnect (Figures 14 through 17)
18 N.m (13 lb ft).
5. Side panel screws and taillamp.
1. Pads from the fender steps (Figure 15). Tighten
2. Fender to brace screws (Figure 16).
3. Brace to support bolts. • Side panel screws to 18 N.m (13 lb ft).
4. Fender to support bolts (Figure 17). 6. Fender to support screws.
5. Taillamp side panel screws.
6. Fender to bracket screws. ^ Tighten
7. Fender to side panel screws.
8. Fender. • Fender to support screws to 18 N.m (13 lb ft).
9. Fender supports and bolts. 7. Brace to support screws.
■►4- Install o r C onnect (Figures 15 through 18) ^ Tighten
1. Fender supports and screws. • All other screws to 18 N.m (13 lb ft).
8. Pads to the fender steps.
^ Tighten
• Stepside support screws to 18 N.m (13 lb ft).

2. Fender to the pickup box with screws.
Tighten
• Fender to pickup box screws to 18 N.m

(13 lb ft).
Legend
(1) Support
(2) Bolt
(3) Brace
Legend (4) Bolt
(1) Front Step Pad (5) Bolt
(2) Rear Step Pad (6) Brace
Figure 14— Step Pads Figure 15— Fender Braces
10A6-10 SHEET METAL
REAR FENDER REPLACEMENT Tighten
(DUAL WHEEL) • Fender to the side panel bolts to 25 N m

(18 lb ft).
Rem ove o r D isconnect (Figure 18) 2. Nuts to the fender studs.
1. Wiring connector to the sidemarker. Tighten
2. Fender to side panel bolts.
m
3. Fender to brace bolts. • Nuts to fender studs to 25 N.m (18 lb ft).
4. Wheelhouse filler panel and bolts. 3. Wheelhouse filler panel with bolts.
5. Nuts from the fender studs. 4. Fender to brace bolts.
6. Fender from the side panel.
Tighten
• Fender to the brace bolts to 25 N.m (18 lb ft).
1. Fender to the side panel with bolts. 5. Wiring connector to the sidemarker.
Legend
(1) Screw (5) Screw
(2) Screw (6) Screw
(3) Screw
(4) Screw
Figure 16—Stepside Fender
SHEET METAL 10A6-11
WHEELHOUSE PANEL Install or Connect (Figures 19 and 20)
REPLACEMENT 1. Wheelhouse panel to the vehicle.
Right Panel Replacement • Tilt the panel into the vehicle.
2. Three wheelhouse to radiator support bolts and
B Remove or Disconnect (Figures 19 and 20) nuts.
Q Tighten
• Raise the hood.
1. Battery cables. Refer to Battery Disconnect Caution • Wheelhouse to radiator support bolts to 25 N-m
in General Information. (18 lb ft).
2. Remove battery. Refer to Battery Replacement in 3. Two wheelhouse to cowl mounting bracket bolts.
Engine Electrical.
3. Remove battery tray. R efer to B attery Tray ^ Tighten
Replacement in Engine Electrical.
4. Heater hoses from the clip on the wheelhouse. • Wheelhouse to cowl bolts to 25 N-m (18 lb ft).
5. Air cleaner hose bracket. 4. Fender to wheelhouse bolts and nuts.
6. Air conditioning evaporator tube from the clip.
Q Tighten
• Raise and support the vehicle.
7. Right front tire and wheel assembly. • Fender to wheelhouse bolts to 25 N.m (18 lb ft).
8. Fender to wheelhouse bolts. 5. Right front wheel.
9. Two bolts holding the wheelhouse to the cowl • Lower the vehicle.
mounting brackets (Figure 19). 6. Air conditioning evaporator tube into the clip.
10. Three wheelhouse to radiator support bolts. 7. Air cleaner hose bracket to the wheelhouse.
11. Wheelhouse panel from the vehicle. 8. Heater hoses into the clip.
• Tilt the panel out of the vehicle. 9. Battery tray.
Legend
(1) Bolt (4) Bolt
(2) Bolt (5) Support
(3) Support
Figure 17—Fender Supports
10A6-12 SHEET METAL
10. Battery. 2. Three wheelhouse to radiator support bolts and
11. Battery cables. nuts.
Left Panel Replacement ^ Tighten
0 Remove o r Disconnect (Figures 19 and 20) • Wheelhouse to radiator support bolts to 25 N.m
(18 lb ft).
1. Battery cables (diesel models). Refer to Battery 3. Two wheelhouse to cowl mounting bracket bolts.
Disconnect Caution in General Information.
2. Battery (diesel models). Refer to Battery Replace ^ Tighten
ment in Engine Electrical.
3. Battery tray (diesel models). Refer to Battery Tray • Wheelhouse to cowl bolts to 25 N.m (18 lb ft).
Replacement in Engine Electrical. 4. Fender to wheelhouse bolts and nuts.
• Raise and support the vehicle. Tighten
4. Left front tire and wheel assembly.
5. Fender to wheelhouse bolts. • Fender to wheelhouse bolts to 25 N-m (18 lb ft).
6. Two bolts holding the wheelhouse to the cowl 5. Left front tire and wheel assembly.
mounting brackets. • Lower the vehicle.
7. Three wheelhouse to radiator support bolts. 6. Battery (diesel models).
8. Wheelhouse panel from the vehicle. 7. Battery tray (diesel models).
• Tilt the panel out of the vehicle.
Tighten
Install o r Connect (Figures 19 and 20)
• Tray bolts to 25 N-m (18 lb ft).
1. Wheelhouse panel to the vehicle. 8. Battery cables (diesel models).
• Tilt the panel into the vehicle. • Close the hood.
Legend
(1) Nut (6) Bolt
(2) Nut (7) Bolt
(3) Stud (8) Bolt
(4) Fender (9) Nut
(5) Bolt
Figure 18—Rear Fender (Dual Wheel)
SHEET METAL 10A6-13
Legend
(1) Fender (4) Bolt
(2) Nut (5) Nut
(3) Bolt (6) Radiator Support
Figure 19— W heelhouse Panel to R adiator Support Attachm ent
WHEELHOUSE 4. Flare to fender screws starting at the center.
OPENING FLARES Tighten
Front Fender
• Flare to fender screws to 2 N-m (18 lb in).
B Rem ove o r D isconnect (Figure 21)
5. Fender to the vehicle. Refer to Fender Replace
Rear Fender (P ickup M odels)
1. Fender. Refer to Fender Replacement in this
section. |*“ »| Rem ove o r Disconnect (Figure 221)
2. Flare to fender screws around the wheel opening.
3. Fender to flare nut at each end of the flare from 1. Tire and wheel assembly. Refer to Wheel and Tire
inside the fender. Installation in Tires and Wheels.
4. Flare. 2. Flare to quarter panel screws.
B Install o r Connect (Figure 22)

3. Inner fender water deflector.
4. Access plugs inside quarter panel liner.
5. Quarter panel to flare nuts.
1. Flare to the fender. 6. Hidden nuts between fender outer panel and inner
2. One screw through the flare to fender center. wall of bed.
3. Nuts to the flare at each end inside the fender.
Tighten
Flare to the fender nuts to 3 N-m (27 lb in).

10A6-14 SHEET METAL
U tility and Suburban M odels
1. Flare to fender screws.

2. Rear seat blower motor cover (if equipped). Refer
to Quarter Panel Trim Replacement in Interior Trim.
3. Spare tire (left side only) (if equipped). Refer to
Spare Tire Mounting in Tires and Wheels.
4. Quarter panel interior trim. Refer to Quarter Panel
Trim Replacement in Interior Trim.
5. Flare to quarter panel nuts from inside wheel well.
6. Flare from the vehicle.
-►4- Install or C onnect (Figure 22)
1. Flare to the vehicle with nuts and screws.
Tighten
• Flare to the fender nuts to 3 N.m (27 lb in).

• Flare to the fender screws to 2 N.m (18 lb in).
2. Quarter panel interior trim.
3. Rear seat blower motor cover (if equipped).
SHEET METAL SUPPORT

1. Grille. Refer to Grille Replacement in this section.

2. Primary hood latch bracket. Refer to Primary Hood
Latch Replacement in this section.
(1) Cowl Side Panel Bracket 3. Horn from the sheet metal support.
(2) Fender 4. Three sheet metal support to radiator support bolts.
(3) Bolt 5. Sheet metal support.
(4) Bolt
(5) Bolt Install or C onnect (Figure 24)
(6) Lower Mounting Bracket
(7) Upper Mounting Bracket 1. Sheet metal support to radiator support with three
Figure 20— W heelhouse Panel to Cowl M ounting bolts.
In stall o r C onnect (Figure 22) Tighten
1. Hidden nuts between fender outer panel and inner • Sheet metal support to radiator support bolts to
wall of bed. 25 N-m (18 lb ft).
2. Horn to the support. Refer to Horn Replacement in
Tighten
Chassis Electrical.
3. Primary hood latch bracket. Refer to Primary Hood
Latch Replacement in this section.
• Flare to the fender nuts to 3 N.m (27 lb in). 4. Grille. Refer to Grille Replacement in this section.
2. Inner fender water deflector.
3. Fender to flare nuts. RADIATOR SUPPORT
Tighten Rem ove or D isconnect (Figures 19, and 24
through 27)
• Flare to the fender nuts to 3 N-m (27 lb in).
1. Battery cables. Refer to Battery Disconnect Caution
4. Flare to fender screws.•
in General Information.
2. Battery(ies) and tray(s) from the wheel house(s).
Tighten
3. Engine cooling fan shroud.
4. Radiator from the vehicle. Refer to Radiator
• Flare to the fender screws to 2 N.m (18 lb in). Replacement in Engine Cooling.
5. Access plugs inside fender liner. 5. Radiator grille. Refer to Radiator Grille Replace
6. Tire and wheel assembly. ment in this section.
SHEET METAL 10A6-15
Legend
(1) Screw (3) Fender
(2) Fender Wheelhouse Flare
Figure 21— Front Fender Flare
6. Headlamp and parking lamp connectors and har Install or Connect (Figures 19, and 24 through
nesses from the radiator support.
7. Wiring harnesses from the clips at the front and 27)
back of the support.
1. Braces to the radiator support with bolts.
8. Ground wires from the support. • Place the top of the left brace between the sup
9. Primary hood latch cable from the sheet metal sup
port and the right brace (Figure 27).
port and latch.
10. Headlamps from the vehicle. Refer to Headlamp Tighten
Replacement in Lighting Systems.
11. Fuel vapor canister and lines from the radiator sup • Brace to the radiator support bolts to 25 N-m
port.
(18 lb ft).
12. Sheet metal support from the radiator support.
2. Radiator support into the vehicle.
13. Auxiliary electric engine cooling fan (if present). 3. Upper mounting cushion and shims between the
14. A uxiliary transm ission and engine oil coolers
support and the bracket on the frame (Figure 26).
(if present).
• Level the support by placing shims below the
15. Horn from left rear side of radiator support.
support.
16. Air conditioning condenser and lines, if equipped.
• Shim pack height should not exceed 11 mm
Refer to Condenser Replacement in Heater, Venti
(0.43 inch).
lation, and Air Conditioning.
• The difference between the left and right shim
17. Wheelhouse panel to the radiator support bolts
pack height must not exceed 5 mm (0.19 inch).
(Figure 19).
4. Bolt through the shims, upper cushion, frame
18. Fender to the radiator support bolts (Figure 25).
bracket, lower cushion, retainer and nut.
19. Air cleaner inlet from the right side of the radiator
support. Tighten
20. Bolt holding the support mount to the vehicle
(Figure 26). • R adiator support mounting nut to 57 N-m
21. Radiator support from the vehicle. (42 lb ft).
22. Support braces from the support (Figure 27).
10A6-16 SHEET METAL
5. Air cleaner inlet to the right side of the radiator Tighten

support.
6. Fender to the radiator support bolts (Figure 24). • Fender to support bolts to 25 N.m (18 lb ft).
7. W h e elho u se to th e ra d ia to r s u p p o rt b o lts
(Figure 19).
Tighten
• W heelhouse to support bolts to 25 N.m

(18 lb ft).
8. Air conditioning condenser and lines, if equipped.
9. Horn to the sheet metal support.
10. A uxiliary transm ission and engine oil coolers
(if present).
11. Auxiliary electric engine cooling fan (if present).
12. Fuel vapor canister and lines to the radiator sup
port.
13. Sheet metal support to the front of the radiator sup
port with bolts.
Tighten
• Sheet metal support to radiator support bolts to

25 N.m (18 lb ft).
14. Headlamps.
15. Primary hood latch bracket to the sheet metal sup
port. Refer to Primary Hood Latch Replacement In
(1) Radiator Support this section.
(2) Bolt 16. Ground wires to the support.
(3) Sheet Metal Support 17. Wiring harnesses into the clips on the front and
(4) Bolt back of the support.
Figure 23—Sheet Metal Support
SHEET METAL 10A6-17
PICKUP BOX REPLACEMENT
1. Taillamp wiring connectors and ground wire under

the back of the box.
• Open the cover to the gas cap.
2. Screws holding the neck of the gas filler tube to the
side panel.
3. Filler neck ground strap.
4. Eight bolts holding the box to the frame rails from
under the box.
5. Pickup box from the vehicle.
+◄- Install or Connect (Figure 28)
Figure 24— R adiator Support

1. Pickup box to the vehicle.
18. Headlamp and parking lamp connectors to the 2. Eight bolts holding the box to the frame rails, from
lamps. inside the frame rails.
19. Radiator grille. Refer to Radiator Grille Replace*
ment in this section. Tighten
20. Radiator.
21. Engine cooling fan shroud. • Box to frame rail bolts to 70 N-m (52 lb ft).
22. Battery tray to the wheelhouse.
3. Neck of the gas filler tube to the side panel with
Q Tighten screws.
4. Filler neck ground strap.
5. Wiring connectors and ground wire to the taillamp
• Battery tray to wheelhouse bolts to 25 N-m
assemblies under the back of the box.
(18 lb ft).
23. Battery(ies) and cables.
(1) Bolt
(2) Radiator Support
(1) Bolt (3) Frame
(2) Bolt (4) Lower Cushion
(3) Fender (5) Retainer
(4) Bolt (6) Nut
(5) Nut (7) Upper Cushion
(6) Radiator Support (8) Shim
Figure 25—Fender to Radiator Support Attachment Figure 26—Radiator Support Mounting
10A6-18 SHEET METAL
3. Align the front face of the hood with the radiator
grille, so that there is a gap of 1.5 mm ± 1.0 mm
(0.06 inch ± 0.03 inch) between the leading edge
of the hood and the top of the radiator support.
There should also be a 4.5 mm + 1.0 mm
(0.17 inch + 0.03 inch) gap between the lower hood
surface and the top of the radiator support. Adjust
the hood bumpers on top of the radiator support to
give the proper gap.
CAB MOUNT REPLACEMENT

When changing cab mounts, it is important to properly
support the frame while changing the mount. If only one
mount is to be changed, the side on which the mount is
placed must be lowered enough to provide clearance
for the mount.
A. Raise the vehicle slightly on the hoist.

B. Place jack stands under the cab on the side of the
(1) Bolt vehicle where the mounts will be replaced.
(2) Bolt C. Loosen mounting bolts on that side.
(3) Brace 1. Mounting bolt.
(4) Radiator Support 2. Lower cushion retainer.
Figure 27— R adiator Support Braces
3. Lower cushion.
• Lower the hoist enough to leave the cab sup
ported by the jacks.
SHEET METAL ADJUSTMENTS 4. Upper cushion.
In order to have the proper operation and appearance
of sheet metal components, it is critical that certain fits 0 Install or C onnect (Figure 30)
and gaps between components be maintained. The
gaps given in this procedure are suggested as the best 1. Upper cushion.
• Raise the frame slightly on the hoist.
alignment for these components (Figure 29).
2. Lower cushion.
In aligning sheet metal, it is best to start with the rear
3. Lower cushion retainer.
most component, and work forward. 4. Mounting bolt, and remove the jacks.
1. Starting with the fenders, align the rear edge of
each fender to the rocker panel and the door. The Tighten
gap between these components should be 5 mm
± 1.0 mm (0.19 inch ± 0.03 inch). This adjustment • Mounting bolts to 75 N.m (55 lb ft).
should be accomplished by moving the fender for • Lower the hoist.
ward or rearward. The surface of the fender should
be flush with the rocker panel and the door. Add or
ADHESIVE-RETAINED
remove shims to perform this adjustment. MOLDINGS,
2. Align the left and right edges of the hood so that a APPLIQUES, AND
gap of 4.0 mm ± 1.0 mm (0.15 inch ± 0.03 inch)
exists between the hood and fenders. The hood EMBLEM REPLACEMENT
surface should be flush with the fender surface These items should be applied in an environment free
within +0.5 mm -1.5 mm (+0.02 inch to 0.06 inch). of dust or dirt that could come in contact with the adhe
If this gap is difficult to obtain, and the hood sive backing and prevent proper adhesion.
appears to be cocked in between the fenders, the 1. Clean the area where the replacement item is to be
radiator support may need to be shifted. By shifting mounted (Figure 30). Use a suitable solvent such
the radiator support, the entire front end sheet met as flash naphtha or a m ixture of 50 percent
isopropyl/alcohol and 50 percent water. Dry the
al can be aligned as a unit. Loosen the support to
area thoroughly.
the frame bolts, and shift the radiator support to
2. The body area must be a temperature range of 27*
obtain the proper gaps. Then, while holding the
to 41 * C (80 * to 105 ‘ F). Heat the area if necessary.
support in position, retighten the radiator support to 3. The item to be mounted must be at a temperature
frame bolts. of 2 9 ' to 32 * C (80' to 90 * F). Carefully apply heat to
the item if needed.
4. Remove the protective liner.
SHEET METAL 10A6-19
Legend
(1) Pickup Box (6) Platform
(2) Frame (7) Bolt
(3) Platform (8) Frame
(4) Bolt (9) Box Rear Cross Sill
(5) Box Rear Cross Sill
Figure 28— Pickup Box Mounting
A ppliques • Pry off molding between sealer and joint using a

A. Press the molding to the body along its entire flat-blade tool. Pliers or a similar tool may be
length at a pressure of 13.3 to 44.5 N (3 to 10 lbs). used for adequately grasping the hot molding to
B. Tape clear plastic, 0.12 mm (0.005 inch) thick, over pull it loose. Molding and sealer should come
the item and apply high pressure along the entire off body together in one piece. Care should be
area to wet out about 75 percent of the adhesive. taken to prevent paint damage on cab.
Roof Jo in t M oldings
Clean
Tool Required:
J 25070 Heat Gun
• Joint to remove any remaining sealer that would
|» + | Rem ove or D isconnect (Figure 30) interfere with the replacement molding fit.
1. Roof joint molding.

• Using a heat gun, heat molding and surrounding
area to approximately 9 3 ' C (200* F).
10A6-20 SHEET METAL
Legend
(1) Flush ± 1 mm ( ± 0.03 inch) (11) Door
(2) Fender (12) Fender
(3) 4 mm ± 1 . 0 mm and parallel w ithin 1.0 mm (13) Fender
(0.15 inch ± 0.03 inch and parallel within 0.03 inch) (14) 3.0 mm ± 1.0 mm and parallel within 1.0 mm
(4) Hood (0.01 inch ± 0.03 inch and parallel within 0.03 inch)
(5) 5 mm ± 1 . 0 mm and parallel w ithin 1.0 mm (15) 1.5 mm ± 3.0 mm and parallel within 1.0 mm
(0.19 inch ± 0.03 inch and paallel within 0.03 inch) (0.06 inch ± 0.01 inch and parallel within 0.03 inch)
(6) Door (16) Radiator Grille
(7) Flush ± 1 .0 mm ( ± 0.03 inch) (17) 1.5 mm ± 1 .0 mm (0.06 inch ± 0.03 inch)
(8) Fender (18) Hood
(9) Feature lines flush ± 1.0 mm ( ± 0.03 inch) (19) Radiator Grille
(10) 5 mm ± 1.0 mm (0.19 inch ± 0.03 inch) (20) 4.5 mm ± 1.0 mm and parallel within 1.0 mm
(0.17 inch ± 0.03 inch and parallel within 0.03 inch)
Figure 29— Sheet M etal Gap S pecifications
0 In stall o r C onnect (Figure 31) Em blem s

• Emblems can be clamped to the body at the center
of the emblem. Place foam between the clamp and
N O TIC E :If molding Is painted prior to instal the emblem to protect it.
lation, care should be taken to ensure that
paint does not coat bottom o f sealer. FENDER PROTECTORS
A pplication
1. Roof joint and molding.
1. Be sure the fender is clean (Figure 32).
• Using a heat gun, apply heat to cab in joint area
2. Mix a solution of 50 percent isopropyl alcohol and
and preheat sheet metal to approximately 93 * C
50 percent water. Spray the solution on the fender
(200* F).
where the protector is to be mounted or on the
• Install molding into joint area and preheat sheet
adhesive side of the protector.
metal to melt sealer and bond molding into joint.
3. Mount the protector, working out any wrinkles or
Sealer begins to flow at approximately 93* C
bubbles. Be sure the protector does not extend
(200* F).
over the edge of the flange.
4. The tape should not be peeled more than 10 sec
onds prior to usage.
SHEET METAL 10A6-21
Legend
(1) Weldnut (4) Retainer
(2) Inner Rocker Panel (5) Lower Cushion
(3) Mounting Bolt (6) Upper Cushion
Figure 30—Fender to Radiator Support Attachment
STRIPE AND DECAL Important

REPLACEMENT • The striping material highlights vehicle surface
NOTICE: Freshly painted surfaces must be im perfection. All dings, rough metal, paint
allow ed to dry thoroughly before installing defects and uneven two-tone paint breaklines
stripe or decal. Residual solvents in fresh must be eliminated before stripe/decal applica
painted surfaces can lead to subsequent blis tion can take place.
tering problems if stripe or decal Is applied
1. Clean the area where the decal will be mounted.
before complete release o f solvents.
Use a suitable solvent such as flash naphtha or a
NOTICE: To prevent possible vehicle, stripe mixture of 50 percent isopropyl alcohol and 50 per
or decal damage, always refer to manufactur cent water. Dry the area thoroughly. If paint in the
er's packaged Instructions. area is chipped, repaint the area and feather it in.
2. The body surface and the decal must be warmed to
Stripes and decals should be applied in a clean envi 27* to38*C (80 * to 100 * F).
ronment where dust or fibers will not interfere with prop
er adhesion.
10A6-22 SHEET METAL
Legend
(1) Pickup Box Moldings (5) Body Side Molding
(2) Rear Body Side Moldings (6) Body Side Emblem
(3) Rear Door Molding (7) Body Side Nameplate
(4) Roof Molding (8) Front Door Nameplate
Figure 31— M oldings and Em blem s
3. Most stripes and decals can be applied dry as long 2. Remove the backing from the decal by peeling it
as this results in a bubble-free application. Stripes away. In hot, humid weather, the adhesive back of
or decals that wrap into body openings or are to be the decal can be sprayed with a mist of the wetting
mounted on flexible surfaces must be mounted wet. solution.
3. Using a squeegee and starting at the center of the
W et A pplication decal, squeegee the decal onto the body, removing
1. Use a wetting agent such as Dupont Duponal WA air bubbles and wetting solution.
(or equivalent). Do not use a soap solution. Spray 4. Remove the premask from the decal by pulling it
a mist of the solution onto the body area. back onto itself. Do not lift the premask straight up.
5. Go over the decal again with the squeegee.
6. If air bubbles are still present, prick them with a
pin.
SHEET METAL 10A6-23
Spray-on materials such as zinc-rich primers and
waxes may also be applied to interior surfaces. These
are mainly used in areas where moisture might gather.
Sealers are applied along exposed joints and mois
ture-repelling asphaltic sound deadeners are applied
inside wheel wells and doors, and on some underbody
parts.
If, while repairing damaged areas these special treat
ments are disturbed, the metals may be left unprotect
ed. This could lead to corrosion; therefore, these
surfaces should be re-coated with service-type anti-cor
rosion materials. Follow these steps in applying the
materials.
1. C leanup and Preparation
Depending on the location of the area, sandblast
ing, scraping, wire brushing, sandpaper, and steel
wool can be used to remove residue.
2. A pplying Prim er Coats
Prime all bare metal with an acrylic chromate
material.
3. Applying S ealers
(1) Rear Fender Seal all flanged joints, overlap joints, and seams
(2) Fender Protector
with a medium-bodied consistency sealer which
Figure 32— Fender Protectors stays flexible and is paintable.
All open joints which require bridging of sealer to
ANTI-CORROSION TREATMENT close a gap should take a heavy-bodied caulking
C A U TIO N : W hen a p p lyin g sound dead en ers
material.
4. A pplying C olor
o r a n ti-c o rro sio n m aterials, due care and pre
v en tativ e m easures m ust be exercised to pre
If areas such as underbody, hem flanges,
v e n t an y m a te ria l fro m b ein g sp rayed in to
exposed joints and engine compartment need color,
d o o r and q u a rte r p an el m echanism s such as follow conventional refinishing preparation, under
d o o r lo cks, g lass run ch an n els, w indow quar coat buildup, and color application procedures.
te rs and seat b elt retrac to rs , as w ell as an y Rub-out and extensive sanding of the undercoats
m oving o r ro tatin g m ech an ical o r suspension are not necessary.
p arts on th e u n derbody, p a rticu la rly th e park 5. Applying Deadeners
ing brake cab le. A fter m a terial ap p licatio n , be Use a heavy bodied undercoat with a rubberized
su re a ll body d rain h oles are open. Im proper or asphaltic base. Areas for application can be
ap p licatio n m ay lim it th e o p eratio n o f m oving determined by original production application.
p a rts o r in c re a se th e ch an ce o f co rro sio n 6. Applying A nticorrosion M aterial
dam age. P ersonal in ju ry could resu lt. Use a light-bodied material designed to penetrate
between close metal-to-metal surfaces such as
This vehicle was designed and built to resist corro pinch weld joints, hem flanges, and other attaching
sion. Application of additional rust-inhibiting materials is points where metal surfaces are difficult to coat
not necessary or required under the 6 year/100,000 mile
with conventional materials.
corrosion coverage.
7. C onventional Undercoating
• Some after-m arket rustproofing may create a
Apply to large areas such as doors, hoods, fend
potential environment which reduces the corrosion
ers, etc. Use care not to spray material into door
resistance designed and built into this vehicle.
• Depending upon application technique, some hardware such as locks, run channels and window
after-market rustproofing could result in damage or regulator.
failure of some electrical or mechanical systems of On the underbody, the material should not be
the vehicle. applied to any moving or rotating parts.
• Repairs to correct damage or malfunctions caused After undercoating, make sure that all body drain
by after-market rustproofing are not covered under holes are open.
any of the GM new vehicle warranties.
DINGING AND FINISHING
SHEET METAL REPAIR
To help prevent rust, special anti-corrosion materials Paint is quickly scuffed off sharp dents leaving metal
are used on interior surfaces of metal panels. These exposed to rusting and corrosion; therefore, damaged
materials include special metals such as one-sided and panels should be repaired as soon as possible. Repair
two-sided galvanized, zincrometal and zinc-iron alloy damaged panels by forcing outward in the direction
steels. These specially treated metals are used in fend opposite to the force which caused the damage. In this
ers, doors, quarter panels, rocker panels, floor pans, way, metal strains that began when the damage
and other critical areas. occurred, are relieved.
10A6-24 SHEET METAL
The importance of proper metal finishing to produce a these areas are being repaired the anti-chip coating
smooth surface should not be underestimated. The should be applied before the paint.
application of a hammer directly to the panel tends to 1. Clean the area with a wax remover.
stretch the metal and cause a great deal of unneces 2. Sand the old paint and anti-chip material away.
sary work. Whenever possible, use a spoon under the Feather the edges of the area being treated.
hammer when bumping a panel. 3. If the coating is hard to remove, a heat gun and a
putty knife can be used to strip it.
ANTI-CHIP COATING 4. Apply primer to the area.
5. Apply the new anti-chip coating following the manu
REPLACEMENT facturer’s directions.
An anti-chip coating was applied to the lower portion
of the vehicle from behind the front wheels to the back
of the vehicle before the color coat application. When
PAINT
C A U TIO N : M any p ain t re p air system s req u ire When ordering DuPont paint, use L , A , J , K , 350S
a d d itiv e s co n tain in g iso cyan ates. It is essen or 123 White or 123 Black with the appropriate DuPont
tia l th a t a ll reco m m en d atio n s and w arn in g s code.
lis te d on th e c o n ta in e r la b e l fo r m a te ria ls
s e le c te d b e fo llo w e d . It is m an d ato ry th a t PPG (Ditzler) refinish paints are available in:
ad eq u ate re sp ira to ry p ro tectio n such as a ir
lin e re s p ira to rs w ith a fu ll hood b e w o rn . • D D L -D u ra cryl-A crylic Lacquer or A c ry lic
S u ch p ro tectio n sh o u ld be w orn durin g th e Basecoat/Clearcoat
e n tire p ain tin g p ro cess. P ersons w ith resp ira • DBU-Deltron-Basecoat/Clearcoat
to ry p ro b lem s o r th o s e a lle rg ic to iso cyan • DAR-Delstar—Acrylic Enamel
a te s m u s t n o t b e e x p o s e d to is o c y a n a te • DAU-Deltron—Acrylic Urethane
v ap o rs o r s p ray m ist. . UCV-Vinyl Colors
• DX-369-Flexative-Flexible Finishes
• DX-54 Roadguard— Road Abrasion Protection
T h e se v e h ic le s h ave been fin is h e d w ith a
basecoat/clearcoat paint process (Figure 31). If repair or
repainting is necessary, the technician should use refin When ordering PPG (Ditzler) paint use DDL, DBU,
ishing methods appropriate to this process. DAR, DAU, UCV, DX-369, or DX-54 with the appropriate
Ditzler code.
PAINT CODES
The following is a list of paint code numbers from
various suppliers for the 1998 model year. These colors
can be obtained locally. Refer to Exterior and Interior
Colors in General Information for specific paint codes.
Dupont refinish paints are available in:
• L - Lucite® - Acrylic Lacquer
• A - Centari® - Acrylic Enamel
• J - Cronar® - Polyoxithane Enamel
• K - Chromabase®
• 350S - Flexible Additive
• 31 OS - Black 123 Vinyl Lacquer - Chip Resis
tant
• 330S - White 123 Vinyl Lacquer - Chip Resis
tant
| } | Important
• Vinyl Resin MUST be added to the base color

when painting interior components.
Legend
— DuPont Vinyl Resin #304— Instrument Panel (1) Clearcoat
— DuPont Vinyl Resin #305—All Remaining Interi (2) Basecoat
or Parts Except Seats (3) Primer
— DuPont Vinyl Resin #306— Seats and Vinyl (4) Metal
Roofs Figure 33— B asecoat/C learcoat Finish
SHEET METAL 10A6-25
Sherwin-Williams, Acme, and Martin-Senour are avail Acme Use:
able in acrylic lacquer, acrylic enamel, or acrylic ure
thane. — prefix 84 for acrylic lacquer
— prefix 85 for acrylic enamel
Sherwin-Williams use: — p r e f i x PB f o r a c r y l i c u r e t h a n e in a
— prefix 34, J4, or L10 for acrylic lacquer Basecoat/Clearcoat system
— prefix 35, J5, or F10 for acrylic enamel — prefix PS for acrylic urethane in a single stage
— p r e f i x U7 f o r a c r y l i c u r e t h a n e in a system.
basecoat/clearcoat system
Martin-Senour: jobber will interchange number shown
— prefix USS for acrylic urethane in a single stage
system. when acrylic lacquer is needed.
SPECIFICATIONS

Battery Tray Bolts 25 18 —
Bracket to Radiator Support Bolts 25 18 —
Cab Mount Bolts 75 55 —
Dual Wheel Fender Nuts 25 18 —
Fender Bolts 25 18 —
Fender to Bracket Bolts 18 13 —
Flare to Fender Nuts 3 — 27
Flare to Fender Screws 2 — 18
Grille Support Screws 2 — 18
Hinge to Fender Bracket Bolt 25 18 —
Hood Hinge Bolts 25 18 —
Link Assembly Bolts 25 18 —
Pickup Box to Frame Rail Bolts 70 52 —
Primary Hood Latch Bolts 25 18 —
Radiator Support to Frame Mounting Nut 57 42 —

Secondary Hood Latch Bolts 25 18 —
Sheet Metal Support to Radiator Support Bolts 25 18 —
Stepside Fender Screws 18 13 —
Wheelhouse Panel Bolts 25 18 —
SPECIAL TOOLS
1 J 38778 2 J 8966
3 J 25070
1. DOOR TRIM PAD AND GARNISH CUP REMOVER
2. WINDSHIELD WIPER ARM REMOVER AND INSTALLER
3. HEAT GUN 2902R2093
10A6-26 SHEET METAL
BLANK
ENDGATE 10A7-1
SECTION 10A7
ENDGATE
ON-VEHICLE SERVICE (PICKUP MODELS)
ENDGATE REPLACEMENT 2. Cable on each side onto the side panel striker bolts
(Figure 2).
|*” »| Rem ove or D isconnect (Figures 1 and 2)
ENDGATE LATCH OPERATING
• Lower the endgate to a horizontal position. HANDLE REPLACEMENT
• Pull up on the middle of the cable assembly.
• With the aid of an assistant, raise the endgate 45 M Rem ove o r D isconnect (Figure 3)
degrees.
1. Cable on each side from the side panel striker bolts
(Figure 1). • Lower the endgate.
2. Endgate from the right side hinge assembly and 1. Three bolts and washers from the back of the end-
then the left hinge assembly with the aid of a help gate behind the handle.
er. • Raise the endgate.
2. Bezel from around the handle by prying gently.
Install o r Connect (Figures 1 and 2)
Inspect
• Use a helper to lift the endgate.
1. Endgate to side panel hinge assemblies holding the • Bezel for damage to the retention prongs. If any
gate at a 45 degree angle (Figure 1). are broken or bent, replace the bezel.
3. Latch operating rods from the retainers on the han
dle by pushing the rods back.
(1) Latch Assembly Bolts

(2) Latch Assembly Legend
(3) Endgate (1) Endgate Striker
(4) Endgate Hinge Bolt (2) Endgate Bumper
(5) Endgate Hinge (3) Endgate Hinge
(6) Endgate Hinge (4) Hinge Bolt
(7) Endgate Cable (5) Cable and Striker Bolt
(8) Striker and Cable Bolt (6) Striker Bolt
(9) Endgate Striker Figure 2— S ide Panel S triker and Hinge
Figure 1—-Endgate Cable and Latch Components Com ponents
10A7-2 ENDGATE
4. Handle assembly from the endgate. S Tighten
-► 4- In stall or C onnect (Figure 3) • Latch to endgate bolts to 30 N-m (22 lb ft).

3. Raise the endgate and attach the cables to the
1. Handle assembly into the endgate. striker bolts.
2. Latch operating rods into the retainers on the 4. Operating handle. Refer to Endgate Latch Operat
handle. ing Handle Replacement in this section.
3. Bezel to the handle and endgate.
• Lower the endgate. STRIKER AND STRIKER
4. Three bolts and washers into the handle from the
back of the endgate. BOLT REPLACEMENT
Tighten |4— Remove or D isconnect (Figure 2)
• Endgate to handle bolts to 25 N.m (18 lb ft). 1. Lower the endgate to a support and lift the cables
off the striker bolts.
ENDGATE LATCH AND 2. Striker and cable bolt.
3. Striker bolt.
ROD REPLACEMENT 4. Striker.
0 R em ove o r D isconnect (Figure 1 and 3) ♦ 4- Install or C onnect (Figure 2)
1. Operating handle. Refer to Endgate Latch Operat 1. Striker to the side panel.
ing Handle Replacement in this section. 2. Striker bolt.
• Lower and support the endgate and lift the
cables off the striker bolts. Tighten
2. Three bolts holding the latch assembly to the end-
gate. • Striker bolt to 30 N-m (22 lb ft).
3. Latch assembly and rod. 3. Striker and cable bolt.
+ 4- In stall o r C onnect (Figures 1 and 3) Tighten
1. Latch assembly and rod to the endgate. • Striker and cable bolt to 30 N-m (22 lb ft).
2. Three bolts holding the latch assembly to the end- 4. Raise the endgate and attach the cables to the
gate (Figure 1). striker bolts.
SIDE PANEL LOWER

HINGE REPLACEMENT
1. Endgate. Refer to Endgate Replacement in this

section.
2. Bolts from the panel hinge.
3. Hinge from the side panel.
1. Hinge to the side panel.

2. Lower panel hinge bolts.
Q Tighten

3. Endgate to the side panels.
ENDGATE HINGE
REPLACEMENT
(1) Endgate
(2) Lock Assembly Rem ove o r Disconnect (Figure 1)
(3) Lock Rod
(4) Lock Assembly 1. Endgate. Refer to Endgate Replacement in this
(5) Lock Rod section.
Figure 3—Endgate Latch Operating Assembly • Mark the position of the hinge on the endgate.
ENDGATE 10A7-3
2. Hinge bolt.
3. Hinge from the endgate.
• Drill a pilot hole in center of the weld.
• Drill out the weld from the endgate side of the
hinge with a 3/8 inch drill bit.
1. Hinge to the endgate. Use the marks made previ

ously to position it.
2. Hinge bolt.
I^ lfl Tighten
• Hinge to endgate bolt to 27 N-m (20 lb ft).

• Plug weld the hole that was drilled in the endgate.
• MIG weld the hinge to the endgate around the
edge of the hinge.
• Paint and lubricate the hinge.
3. Endgate to the pickup box.
Legend
(1) Handle
(2) Gasket
(3) Lock Cylinder
(4) Clip
(5) Bolt
Figure 4— Endgate Latch O perating Handle
ON-VEHICLE SERVICE (U TILITY MODELS)

ENDGATE REPLACEMENT 4. Hinge pin clips.
• Spread the clip enough to move the clip above
3 Rem ove o r D isconnect (Figures 1 and 5)
the recess in the pin.
• As the pin is removed, the clip will ride on the
pin, and fall free of the pin.
• Open the endgate to a horizontal position.
5. Hinge pins from the right and left hinges.
1. Torque rod. Refer to Torque Rod Replacement in
6. Endgate from the vehicle.
this section.
2. Electrical connector for rear window release. Install or C onnect (Figures 1 and 5)
• Support the endgate in a horizontal position
with a suitable support. 1. Endgate to the vehicle.
3. Support cable bolts and washers. • Support the endgate in a horizontal position
with a suitable support.
2. Hinge pins into the left and right hinges.
3. Hinge pin clips to the hinge pins.
4. Support cable bolts and washers.
Tighten
• Support cable to body bolts to 29 N-m (21 lb ft).

5. Electrical connector for rear window release.
6. Torque rod. Refer to Torque Rod Replacement in
this section.
TORQUE ROD REPLACEMENT

■+| Rem ove or D isconnect (Figure 6)
1. Bolt at left end with endgate open.

2. Rear bumper. Refer to Rear Bumper Replacement
in Frame and Bumpers.
3. Rear bumper filler panel. Refer to Rear Bumper
Filler Panel Replacement in Frame and Bumpers.
10A7-4 ENDGATE
Figure 7— Trim Panel
4. Bolts retaining the torque rod to the endgate. ENDGATE LATCH OPERATING
• With the gate in the closed position, the bolts HANDLE REPLACEMENT
are accessible from under the vehicle.
Ht| Rem ove o r D isconnect (Figure 8)
5. Torque rod and retainers.
■M- In stall o r C onnect (Figure 6)

this section.
1. Torque rod and retainers to vehicle.
2. Latch assembly cover from the endgate.
• With the gate in the closed position, place the 3. Two bolts and washers from the back of the end-
torque rod and retainers onto the vehicle. gate behind the handle assembly.
• Raise the endgate.
2. Bolts to the torque rod retainers. 4. Handle assembly by prying gently.
5. Latch operating rods from the clips on the handle
^ Tighten
by pushing the rods back.
6. Handle assembly from the endgate.
• Torque rod bracket bolts to 15 N-m (11 lb ft).
3. Bolt at left end with endgate open.
Tighten
• Torque rod retainer bolt to 15 N-m (11 lb ft).

4. Rear bumper filler panel.
5. Rear bumper.


1. Trim panel to endgate screws.
2. Trim panel from the endgate.
-M- In stall or C onnect (Figure 7)
1. Trim panel to the endgate.

2. Trim panel to endgate screws.
(1) Handle
Tighten (2) Lock Cylinder
(3) Lock Rod
• Trim panel to endgate screw s to 2 N-m (4) Lock Rod
(18 lb in). Figure 8—Endgate Latch Handle Replacement
ENDGATE 10A7-5
Install o r C onnect (Figure 8) 4. Screws securing the bumper to the endgate.
1. Handle assembly into the endgate. Tighten

2. Latch operating rods into the clips on the handle.
• Lower the endgate. • Bumper to the endgate screws to 3 N-m
3. Two bolts and washers onto the handle assembly (27 lb in).
from the back of the endgate. 5. Locking rod to the window latch.
6. Latch assembly cover.
Tighten • Cover must be installed with both gates closed
for proper alignment.
• Endgate to handle bolts to 4 N-m (35 lb in). 7. Endgate trim panel. Refer to Trim Panel Replace
4. Latch assembly cover to the endgate. ment in this section.
• Cover must be installed with both gates closed
for proper alignment. ENDGATE LATCH STRIKER
5. Endgate trim panel. Refer to Trim Panel Replace ADJUSTMENT
0 Adiust
ENDGATE LATCH
ASSEMBLY REPLACEMENT • Loosen striker bolt and move assemblies up or
down, forward or backward, to obtain the proper
(RIGHT OR LEFT) close of the endgate. The endgate should seal
completely with minimum closing effort.
Tighten
• Open the endgate to the horizontal position.
1. Endgate trim panel. Refer to Trim Panel Replace • Striker assemblies to 63 N-m (47 lb ft).
2. Latch assembly cover. LIFT GLASS LATCH
3. Locking rod from the lock assembly.
4. Screws securing the bumper to the endgate.
REPLACEMENT
5. Bumper from the endgate.
6. Bolts securing the latch to the endgate.
7. Latch from the endgate.
-► 4- Install o r C onnect (Figure 9) this section.
2. Latch assembly cover to the endgate bolts.
1. Latch to the gate. 3. Latch assembly cover and seal.
2. Bolts securing the latch to the endgate. 4. Lock rods from the lock assembly.
• Mark the location of the latch assembly on the
Tighten endgate.
5. Latch assembly to the endgate bolts.
• Latch to the endgate bolts to 25 N-m (18 lb ft). 6. Latch assembly from the endgate.
3. Bumper to the endgate.
-► 4- Install o r C onnect (Figure 9)
1. Latch assembly and seal to the endgate.

• Align the assembly to the marks on the endgate
inner panel.
2. Latch assembly to the endgate bolts.
Tighten
• Latch assembly to the endgate bolts to 15 N-m

(11 lb ft).
3. Lock rods to the latch assembly.
4. Latch assembly cover.
• Cover must be installed with both gates closed
for proper alignment.
5. Latch assembly cover to endgate bolts.
Tighten
• Cover to endgate bolts to 15 N-m (11 lb ft).

6. Trim Panel. Refer to Trim Panel Replacement in
Figure 9—Endgate Latch Replacement this section.
10A7-6 ENDGATE
ENDGATE WINDOW MOLDING ENDGATE WINDOW
REPLACEMENT WEATHERSTRIP REPLACEMENT
Rem ove o r D isconnect (Figure 10) Rem ove or D isconnect (Figure 11)
1. Open the endgate. 1. Open the endgate.

2. Remove window molding retainers. 2. Remove the endgate window weatherstrip from the
3. Remove window molding. roof panel.
install or C onnect (Figure 10) Install or C onnect (Figure 11)
1. Install window molding to endgate window. 1. Install the endgate window weatherstrip to the roof
2. Install window molding retainers. panel.
2. Close the endgate.
• Push retainers in, five retainers for each upper
molding and three retainers for each lower ENDGATE BELT WEATHERSTRIP
molding.
REPLACEMENT
3. Close endgate.

this section.
2. Weatherstrip from the endgate flange.
1. Weatherstrip onto endgate flange.

A. Install ends of weatherstrip first by pressing fas
tener into the endgate hole.
B. Push center of weatherstrip onto center of end-
gate flange and work out to ends.
this section.
Figure 10— Endgate W indow M oldings
(1) Weatherstrip
(2) Door Frame Reinforcement Trim Edge
(3) Door Frame Reinforcement Trim Edge
Figure 11—Endgate Window Weatherstrip Figure 12—Endgate Belt Weatherstrip
ENDGATE 10A7-7
ENDGATE WINDOW STRIKER 3. Endgate window assembly from the vehicle.
4. Endgate window garnish molding.
REPLACEMENT 5. Hinge to endgate window assembly nuts.
6. Hinge from the endgate window.
• Open the endgate window.
1. Striker to the endgate window pin. 1. Hinge to the endgate window.
2. Striker to the endgate window bolt. 2. Hinge to endgate window assembly nuts.
3. Striker from the endgate window.
Tighten
• Hinge to endgate window assembly nuts to
1. Striker to the endgate window. 23 N-m (17 lb ft).
2. Striker to the gate window bolt. 3. Endgate window garnish molding.
4. Endgate window assembly to the vehicle.
Tighten 5. Hinge pins and the hinge pin retainers.
6. Endgate window supports. Refer to Endgate Win
• Striker to the endgate window bolt to 10 N-m dow Support Replacement in this section.
(89 lb in).
3. Striker to the endgate window pin. ENDGATE WINDOW SUPPORT
Tighten REPLACEMENT
• Striker to the endgate window pin to 10 N-m C AU TIO N: Do not attem pt to rem ove o r loos
(89 lb in). en gas su pport assem bly attachm ents with
glass in any position other than fu lly open as
ENDGATE WINDOW HINGE personal injury m ay result.
REPLACEMENT Do not intermix original quality gas supports with oth

er quality supports, since not all supports have the
Remove or Disconnect (Figure 13) same output level.
1. Endgate window supports. Refer to Endgate Win
dow Support Replacement in this section.
E3 Remove or Disconnect (Figure 14)
2. Hinge pin retainers and the hinge pins. 1. Rear window defogger wires attached to the gas
supports (if equipped).
Legend
(1) Hinge
(2) Endgate Window Frame
(3) Striker (1) Endgate Window Assembly
(4) Pin
(2) Strut
(5) Bolt
(3) Stud
(6) Nut
(4) Stud
Figure 13—Endgate Window Striker and Hinge Figure 14— Endgate Window Struts
10A7-8 ENDGATE
2. Ball sockets from the glass side. Install or Connect (Figure 14)
• Support the rear window glass.
• Carefully pry the gas support ball socket from 1. Gas support ball socket to the body and glass
the ball. Insert a small screwdriver between the sides.
ball and the ball socket and pull the gas support • Push the ball socket onto the ball.
from the window. 2. R ear window defogger wires to the gas supports (if
3. Ball sockets from the body side. equipped).
SPECIFICATIONS
Body Side Hinge Bolts (Pickup) 27 20 —
Endgate Bumper to Endgate Screws (Utility) 3 — 27

Endgate Latch to Endgate Bolts (Utility) 10 — 89
Endgate Side Hinge Bolts (Pickup) 27 20 —
Endgate Striker Bolts (Pickup) 30 22 —
Endgate Window Assembly Hinge Nuts (Utility) 23 17 —
Endgate Window Assembly Striker Bolts (Utility) 10 — 89

Latch Operating Handle Bolts (Pickup) 25 18 —
Latch Operating Handle to Endgate Bolts (Utility) 4 — 35

Latch to Endgate Bolts (Pickup) 30 22 —
Latch Assembly Cover to Endgate Bolts (Utility) 15 11 —
Latch Assembly to Endgate Bolts (Utility) 15 11 —

Support Cable to Body Bolts (Utility) 29 21 —
Support Cable to Endgate Bolts (Utility) 3 — 27

Striker to Body Bolts (Utility) 63 47 —
Strut Stud to Body (Utility) 17 13 —
Strut Stud to Endgate Window Assembly (Utility) 17 13 —
Torque Rod Bracket Bolts (Utility) 15 11 —
Trim Panel to Endgate Screws (Utility) 2 — 18

CAB AND BODY MAINTENANCE 10B-1
SECTION 10B
CAB AND BODY MAINTENANCE

ON-VEHICLE SERVICE
CLEANING AGENTS 3. Use solvent-type cleaners only in a well ventilated
area. Do not saturate the stained area.
CAUTION: Follow the manufacturer’s advice 4. If a ring forms after spot cleaning, clean the entire
when cleaning agents or other chemicals are area immediately.
used inside or outside the vehicle. Some 5. Follow manufacturer’s instructions for all cleaning
cleaners may be poisonous or flammable, agents.
and improper use may cause personal injury
G e n e ra l C le a n in g o f F a b ric T rim
or damage. When cleaning the interior or
exterior of the vehicle, do not use the follow Use Multi-Purpose Powdered Cleaner GM P/N
ing cleaners except as specifically directed in 1050429 or equivalent for this type of cleaning and for
the fabric cleaning procedures contained in cleaning panel sections where small cleaning rings may
this manual: be left from spot cleaning.
• acetone Vacuum and brush the area to remove any loose dirt
• lacquer thinners and mask surrounding trim along stitch or welt lines.
• enamel reducers Clean a whole trim panel or section. Mix the cleaner
• nail polish removers following the directions on the container label. Mix in
• laundry soaps proportion for smaller quantities. Use suds on a clean
• bleaches sponge. Do not saturate the material or rub it harshly.
• reducing agents Wipe off remaining residue with a slightly damp absor
Never use carbon tetrachloride, gasoline, bent towel or cloth. Dry the material with an air hose. A
benzene, or naphtha for any cleaning pur heat dryer or heat lamp may be used. Use care with a
pose. heat dryer or lamp to prevent fabric damage.
Open all vehicle doors for ventilation when
any cleaning agents or other chemicals are S p o t C le a n in g F a b ric T rim
used inside the vehicle. Overexposure to
some vapors, which is more likely to occur in Before trying to remove a spot or stain from fabric, try
small, unventilated spaces, may result in a to determine the type and age of the spot or stain.
health problem. Some spots or stains can be removed with water or a
mild soap solution. Remove spots or stains as soon as
NOTICE: To avoid possible permanent dis possible.
coloration o f light colored seats, do not let Some types of stains or soilage, such as lipstick, inks
materials with non-fast colors come In con and grease, are very difficult (sometimes impossible) to
tact with seat trim materials until these mate remove completely. When cleaning this type of stain, do
rials are totally dry. This Includes certain not enlarge the soiled area. Use Multi-Purpose Pow
types o f clothing, such as colored denim, dered Cleaner GM P/N 1050429 or equivalent for
corduroy, leather, and suede. spot-cleaning grease, oil, or fat stains.
Gently scrape excess stain from the trim material with
Use the proper cleaning techniques and cleaners on
a clean dull knife or scraper. Use very little cleaner, light
the first cleaning to avoid water spots, spot rings, or
pressure, and clean cloths, preferably cheesecloth. Start
setting of stains or soilage—all of which are more diffi
cleaning at the outside of the stain and feather towards
cult to remove in a second cleaning.
the center. Keep changing to a clean section of the
Remove dust and loose dirt often that collect on interi
or fabrics with a vacuum cleaner or soft bristle brush. cloth.
Wipe vinyl trim regularly with a clean damp cloth. After the stain has been removed, immediately dry the
area with an air hose, heat dryer, or heat lamp to help
INTERIOR CLEANING prevent a cleaning ring. Use caution when using a heat
dryer or lamp to help prevent fabric damage.
Basic Steps Before Cleaning If a ring forms, immediately repeat the cleaning opera
1. Remove stains as quickly as possible before they tion over a slightly larger area with emphasis on feath
set. ering towards its center. If a ring still remains, mask off
2. Use a clean cloth or sponge, and change to a the surrounding trim sections and clean the entire area
clean area often. A soft brush may be used if with Multi-Purpose Powdered Cleaner GM P/N 1050429
stains persist. or equivalent as described earlier in this section.
10B-2 CAB AND BODY MAINTENANCE
Removal of Specific Stains A nonabrasive cleaner may be used on the outside of
Grease or Oily Stains the windshield. Clean wiper blades with a cloth soaked
The following applies to stains caused by such sub in a solution of one-half water and one-half Opticlean®
stances as grease, oil, butter, margarine, shoe polish, GM P/N 1051515 or equivalent. A solution of one-half
coffee with cream, chewing gum, cosmetic creams, veg water and one-half methanol alcohol may also be used.
etable oils, wax crayon, tar, and asphalt. Then rinse the blade with water.
• Carefully scrape off excess matter, then use
Multi-Purpose Powdered Cleaner GM P/N 1050429
EXTERIOR CLEANING
or equivalent as explained earlier in this section. W a s h in g a n d W a x in g
• Shoe polish, wax crayons, tar, and asphalt will stain Wash the vehicle in lukewarm or cold water. Do not
if left on trim; remove them as soon as possible. use hot water or wash the vehicle in the direct rays of
Use care since the cleaner may cause the stains to the sun. Do not use strong soap or chemical deter
bleed as it dissolves them. gents. All cleaning agents should be promptly flushed
Non-Greasy Stains from the surface and not allowed to dry on the finish.
This includes stains from catsup, black coffee, egg, Painted body surfaces and chrome plating should be
fruit, fruit juice, milk, soft drinks, wine, vomit, blood, and protected by a coating of wax. Any good body wax can
urine. be used for both painted and chrome surfaces. Apply
wax immediately after the vehicle has been cleaned.
• Carefully scrape off excess matter, then sponge the Periods between applications should be short enough to
stain with cool water. ensure continuous protection of the finish.
• If a stain remains, use Multi-Purpose Powdered
Cleaner GM P/N 1050429 or equivalent as F o re ig n M a te ria l D e p o s its
explained earlier in this section. Calcium chloride and other salts, ice melting agents,
• If an odor lingers after cleaning vomit or urine, treat road oil and tar, tree sap, bird droppings, chemicals
the area with a water/baking soda solution of from industrial chimneys, and other foreign matter may
5 milliliters (1 teaspoon) of baking soda to 250 milli damage vehicle finishes if left on painted surfaces. Use
liters (1 cup) of lukewarm water. cleaners that are marked safe for painted surfaces for
• Finally, if needed, clean lightly with Multi-Purpose these deposits.
Powered Cleaner GM P/N 1050429 or equivalent.
C le a n in g B r ig h t M e ta l P a rts
Com bination Stains
This includes stains from candy, ice cream, mayon Clean bright metal parts regularly. Washing with water
naise, chili sauce, and stains of unknown origin. is all that is usually needed. Use Chrome Cleaner and
Polish GM P/N 1050173 or equivalent on chrome or
• Carefully scrape off excess matter. Clean with cold stainless steel trim, if necessary.
water and allow to dry. Use special care with aluminum trim. Do not use auto
• If a stain remains, clean it with Multi-Purpose Pow or chrome polish, steam, or caustic soap to clean alumi
ered Cleaner GM P/N 1050429 or equivalent. num. A coating of wax, rubbed to a high polish, is
recommended for all bright metal parts.
Cleaning Vinyl Trim
Ordinarily soilage can be removed from vinyl with W e a th e r s tr ip L u b ric a tio n
warm water and mild soap. Use silicone grease to lengthen weatherstrip life, to
Apply a small amount of soap solution and let it soak help sealing, and to help eliminate squeaks. Use a
for a few minutes to loosen the dirt; then rub briskly with clean cloth to apply a thin film of silicone grease to all
a clean damp cloth to remove dirt and traces of soap. weatherstrips.
This may be repeated several times, if needed.
Soilage from such things as tars, asphalt, shoe polish, WATER LEAKS
etc. will stain if left on trim. Wipe off these compounds
If water has leaked into the interior, test for leak
as quickly as possible and clean the area with a clean
points. Refer to Water Leak Tests in Doors. Mark the
cloth dampened with Vinyl and Leather Cleaner GM
location(s) of any leaks.
P/N 1050214 or equivalent. Water which appears at a certain place inside the
Seat Belt Care body may actually be entering from another point. It
may be necessary to remove the floor mat, insulation,
C A U TIO N : Do not bleach or dye seat belts instrument panel, etc. in order to backtrack the path of
sin ce this m ay severely w eaken them . Dam the water to the point of entry. If it is still not possible to
aged seat belts are a safety hazard. locate the point of entry, do the following:
• Keep the belts clean and dry. 1. Close all windows and vents.
• Clean seat belts only with mild soap and 2. Cover the air pressure relief valves.
lukewarm water. 3. Place the air lever in position to use outside air.
4. Turn the fan lever to the HI position.
5. Close the doors.
GLASS SURFACES 6. Run a small stream of water over the area suspect
Glass surfaces should be cleaned on a regular basis. ed of leaking.
Use Glass Cleaner GM P/N 1050427 or equivalent to 7. Check for pressure bubbles that indicate air is
remove normal tobacco smoke and dust films. escaping from the interior.
CAB AND BODY MAINTENANCE 10B-3
Corrective Measures To determine the location of dust leaks:
If the leak is between body panels, use an air drying 1. Remove the mats and insulation from the floor and
body sealing compound. toe panel.
If the leak is around a door, it may be because the 2. Drive the vehicle on a dusty road.
door is not properly aligned. Refer to Doors and align 3. Examine the interior. Dust in the shape of a small
the door. If the door is contacting the weatherstrip cor cone or slit will usually be found at the point of
rectly, make sure the weatherstrip is not damaged and leakage.
is properly seated on the opening flange. If the weather 4. Mark the points of leakage.
strip is damaged, replace it. 5. With the interior of the vehicle darkened, shine
bright lamps on the underside of the floor and cowl,
DUST LEAKS and have an assistant check inside for any points
where the light shines through. Mark the leakage
Dust will leak into the vehicle where water will not, points. Check weld joints and body mounts.
particularly in the lower portion of the interior. Forward
Sealing of leaks should be done with an air-drying
motion of the vehicle can create a slight vacuum which
body-sealing compound.
pulls air and dust inside.
10B-4 CAB AND BODY MAINTENANCE
BLANK
INDEX 1
Air Cleaner (cont.)

A Assembly Replacement (7.4L)....................... 6-3192
Abbreviations and Their Meanings.........................0-29 Element Replacement (4.3L)........................6-1595
ABS Handling..................................................................3 Element Replacement(5.0L, 5.7L).................. 6-2227
ABS/Traction Control Element Replacement (6.5L)........................6-2653
Bleed Procedure................................................. 5-250 Element Replacement (7.4L)........................6-3192
Component Locations........................................ 5-173 Intake Duct Replacement (4.3L).................... 6-1598
Component Views...............................................5-175 Intake Duct Replacement (5.0L, 5.7L).......... 6-2230
Connector End Views........................................ 5-177 Intake Duct Replacement (7.4L).................... 6-3194
Description Air Conditioning
Abbreviations and Definitions.......................5-260 Compressor Control Circuit
ABS System................................................... 5-261 Diagnosis (7.4L)...........................................6-3059
ABS System Operation................................. 5-261 Diagnosis
Antilock Brakes System Introduction........... 5-260 Compressor Control Circuit (4.3L)............. 6-1478
Basic Knowledge Required...........................5-260 Aluminum Wheel
Service Precautions...................................... 5-260 Clearcoat Damage.............................................. 3-118
Diagnosis Hub Cap Replacement.......................................3-117
ABS Indicator Off No DTC S e t................... 5-245 Porosity Repair................................................... 3-117
ABS Indicator On No DTC S e t................... 5-248 Recoating Procedure..........................................3-118
Diagnostic System Check.............................5-179 Refinishing...........................................................3-117
Displaying Diagnostic Trouble Codes.......... 5-178 Automatic Transmission 4L60-E
Intermittents and Poor Connections............ 5-178 2-4 Servo.............................................................7-182
Scan Tool Diagnostics................................... 5-178 Component Location..........................................7-239
Self-Diagnostics..............................................5-178 Component Location Table................................. 7-60
Schematic Description
ABS Schematic..............................................5-169 Diagnosis........................................................ 7-232
ABS Schematic Icons................................... 5-169
Electronic Component................................... 7-233
ABS Schematic References..........................5-168
Fluid Checking Procedure............................7-232
BPMV Hydraulic Flow Chart.........................5-164
Transmission ID Information.........................7-229
Specification
Diagnosis
Fastener Tightening....................................... 5-163
2nd Gear S tart...............................................7-158
GM SPO Group Numbers.............................5-163
3-2 Flare or Tie-Up....................................... 7-154
ABS/T ractionControl
Component Resistance................................. 7-145
Diagnosis
Delay in Drive and Reverse.........................7-159
Clearing Diagnostic Trouble Codes............. 5-178
Accelerator Controls Drives in Neutral............................................7-158
Cable Replacement (4.3L)..............................6-1525 Electronic Component Malfunctions............ 7-149
Cable Replacement (5.0L, 5.7L).................... 6-2140 Fluid Leak....................................................... 7-160
Cable Replacement (7.4L)..............................6-3109 Front Oil Leak................................................ 7-159
Pedal Replacement (4.3L)..............................6-1529 Functional Test Procedure..............................7-52
Pedal Replacement (5.0L, 5.7L).................... 6-2143 Harsh Garage S hift........................................7-156
Pedal Replacement (7.4L)............................... 6-3112 Harsh Shifts.................................................... 7-151
Accelerator Pedal Position Inaccurate Shift Points.................................. 7-151
Module Description (6.5L)............................... 6-2666 Line Pressure Check Procedure................. 7-137
Module Replacement (6.5L)............................6-2589 No Drive in All Ranges................................. 7-159
Accessory Removal No Drive in Drive Range.............................. 7-159
(Engine Mechanical - 6.5L)............................... 6-590 Noise and Vibration Analysis........................7-139
Accumulator and 2-1 Manual No P ark...........................................................7-158
Servo Replacement (Automatic 4L80-E)........7-518 Oil Out the Vent.............................................7-158
Accumulator Assembly (Automatic 4L60-E)......... 7-217 Oil Pressure High or Low............................. 7-150
Accumulator Housing Replacement Ratcheting Noise............................................7-159
(Automatic 4L80-E).............................................7-517 Road Test Procedure.................................... 7-138
Adapter Replacement Slipping or Rough 1-2 Shift..........................7-153
Transfer Case..................................................... 4-291 Slips in 1st G ear............................................7-152
AFWD Speed Sensor Replacemen......... 4-296, 4-297 Third Gear O nly.............................................7-154
AFWD Speed Sensor Replacement..................... 4-297 Torque Converter Clutch............................... 7-142
AIR Electronic Component View s.............................. 7-63
Check Valve/Pipe Replacement - Fluid/Filter Changing..........................................7-171
Bankl (7.4L)................................................. 6-3188 General Information............................................7-230
Air Cleaner Inline Harness Connector End V iew ................. 7-64
Assembly Replacement (4.3L)........................6-1596 Internal Connector End Views............................ 7-65
Assembly Replacement (5.0L, 5.7L).............. 6-2228 Oil Cooler Line Replacement............................ 7-174
Assembly Replacement (6.5L)........................6-2656 Oil Cooler Replacement.................................... 7-182
2 INDEX
Automatic Transmission 4L60-E (cont.) Automatic Transmission - 4L80-E (cont.)

Schematic Noise................................................................7-490
Controls Schematic Diagrams....................... 7-53 No P ark.......................................................... 7-481
Schematic Reference Table............................7-53 No Reverse.................................................... 7-481
Special Tools....................................................... 7-268 No Second Gear - D 1 .................................. 7-482
Specifications............... 7-39, 7-40, 7-41, 7-45, 7-49 No Second Gear - D 2 .................................. 7-483
Fluid Capacity................................................... 7-48 No Second Gear - D 3 .................................. 7-484
Range Reference Table.................................. 7-48 No Second Gear - D 4 .................................. 7-486
Scan Tool Data Definitions.............................7-43 No TCC Apply................................................ 7-488
Shift Speed Table.............................................7-50 No Third Gear - D 3 .......................................7-484
Temperature vs Resistance............................7-39 No Third Gear - D 4 .......................................7-487
Automatic Transmission - 4L80-E No Torque in Second G ear.......................... 7-491
Component Location......................................... 7-555 No Torque Multiplication............................... 7-490
Component Location Table..............................7-294 Oil Cooler Flow Test..................................... 7-472
Description Oil Out the Vent T ube.................................. 7-491
Adapt Function..............................................7-550 Overheating.................................................... 7-478
Component and System ..............................7-549 Overheating at W OT......................................7-478
Electronic Component.................................. 7-550 Remains in Park............................................. 7-481
General Description...................................... 7-549 Road Test Procedure.....................................7-463
General Service Information....................... 7-547 Second Gear Only - D4................................ 7-485
Identification Information..............................7-549 Second Gear Starts.......................................7-491
Diagnosis Slipping TC C .................................................. 7-489
Clutch Plate...................................................7-472 Soft Shift 2 to 1 ............................................. 7-495
Converter Ballooning.................................... 7-490 Soft Shift 2 to 3 ............................................. 7-495
Delayed Shift 1 to 2 ..................................... 7-496 Soft Shift 3 to 2 ............................................. 7-496
Does Not Stay in Park.................................7-481 Soft Shift D3 to D 2........................................7-496
Engine Coolant in Transmission................. 7-472 Soft Shift into R ............................................. 7-495
Engine S ta ll...................................................7-490 Soft Shift R to D ............................................ 7-495
Engine Stall in Neutral.................................7-477 Soft Shifts........................................................7-495
Engine Starts in G ear..................................7-479 Soft TCC Apply.............................................. 7-488
TCC Stuck O n................................................ 7-489
Erratic Shift Q uality...................................... 7-492
Third Gear S tarts........................................... 7-492
First Gear Only - D4.................................... 7-485
Torque Converter Clutc................................. 7-465
Fluid Foaming................................................7-490
Torque Converter Evaluation........................ 7-466
Fluid Leak
Transmission Seized......................................7-492
At Case Extension...................................7-497
Transmission S lips.........................................7-492
At Fill Tube................................................7-497
Vibration...........................................................7-491
At Oil Pan..................................................7-496
Electronic Component Views............................ 7-295
Forward Motion in Neutral.......................... 7-477
Fluid/Filter Changing..........................................7-507
Fourth Gear Starts....................................... 7-492 Internal Connector End Views.......................... 7-296
Functional Test Procedure.......................... 7-286 Schematic
Harsh Shift 3 to 4 ........................................ 7-494 Icon Table........................................................7-287
Harsh Shift 4 to 3 ........................................ 7-494 Special Tools...................................................... 7-590
Harsh Shift D to R ........................................ 7-494 Specifcations
Harsh Shifts...................................................7-494 Component Resistance................................. 7-285
High Line Pressure......................................7-476 Specifications
Inaccurate Shift Points.................................7-493 Fastener Tightening..........................7-269, 7-270
Inadequate Lubrication.................................7-477 Fluid Capacity................................................. 7-282
Line Pressure Check Procedure................7-463 General............................................................7-284
Loss of Drive................................................ 7-479 Line Pressure Table.......................................7-285
Loss of Power.............................................. 7-477 Range Signal............................................. 7-284
Low Line Pressure........................................ 7-478 Shift Speed Table........................................... 7-283
No D2 to D1................................................... 7-496 Temperature vs Resistance.......................... 7-269
No D3 to D2................................................... 7-496 Auxiliary
No Engine Braking - D 1 ............................. 7-482 Cooling Fan and Motor Replacement
No Engine Braking - D 2 ............................. 7-483 (Engine Cooling)............................................. 6-961
No Engine Braking - D 3 ............................. 7-484 Cooling Fan Relay Replacement
No First Gear - D1.......................................7-482 (Engine Cooling)............................................. 6-963
No First Gear - D2...................................... 7-483 Axle
No First Gear - D3...................................... 7-484 Shaft and Seal Replacement
No First Gear - D4...................................... 7-485 Front Drive A xle............................................... 4-60
No Fourth Gear - D 4 .................................. 7-487 Axle Replacement
No Gear Selection..........................................7-479 Rear Drive Axle 4-147, 4-148, 4-150
INDEX 3
B rake Pedal
B Diagnosis
Backlash Adjustment Travel (Hydraulic B ra k e s ).....................................5 -3 9
Rear Drive A xle.................................................. 4-143 R ep lacem en t (Hydraulic B r a k e s )............................ 5 -5 9
Backlash Inspection and Adjustment Brake Rotor
Front Drive Axle.................................................... 4-90 Refinishing (Disc B ra k e s )......................................... 5-119
Balance Shaft R eplacem ent (Disc B ra k e s )..................... 5 -116, 5-117
Clean and Inspect B rake S hoe
(Engine Mechanical - 4.3L)...........................6-169 Inspection (Drum B ra k e s )........................................5 -1 2 5
Installation (Engine Mechanical - 4.3L)........... 6-204 Brake W arning
Removal (Engine Mechanical - 4.3L).............. 6-136 Description
Replacement (Engine Mechanical - 4.3L).........6-90 B rake W am ing/lndicator Lam p
Ball Joint (Hydraulic B r a k e s )..............................................5 -8 6
Lower Ball Joint Replacement Brake W arning/lndicator Lam p O peration
Front Suspension................................... 3-53, 3-55 (Hydraulic B r a k e s )..............................................5 -8 6
Upper Ball Joint Replacement Diagnosis
Front Suspension................................... 3-48, 3-50 Indicator Always O n (Hydraulic B ra k e s )........ 5 -2 4
Battery Indicator Inoperative (Hydraulic B ra k e s )........ 5 -2 6
Cable (Engine Electrical)................................. 6-1044 Burnishing Pads and Rotors
Charging (EngineElectrical).............................6-1039 R ep lacem en t (Disc B ra k e s )....................................5-101
Replacement (Engine Electrical).................... 6-1043
Tray Replacement
(Engine Electrical)........................ 6-1045, 6-1047
Battery Disconnect.................................................. ,......3
c
Camshaft
Bearing Cup Replacement
Bearing Installation
Rear Drive A xle.....................................4-154, 4-156 (Engine Mechanical - 4 .3 L )......................... 6-167
Bearings Inspection Bearing Installation
Front Drive Axle................................ ..4-82 (Engine Mechanical - 7 .4L)......................... 6-865
Rear Drive A xle .................................................. 4-134 Bearing Removal
Boost Sensor Replacement (6.5L)......................6-2651 (Engine Mechanical - 4 .3L).............6-162, 6-164
Brake Backing Plate Replacement Bearing Removal
(Drum Brakes)........................................5-135, 5-136 (Engine Mechanical - 5.0L, 5.7L)................ 6-390
Brake Bluid Bearing Removal
Diagnosis (Engine Mechanical - 7 .4 L ).......................... 6-862
Leaks (Hydraulic Brakes)................................ 5-39 Installation (Engine Mechanical - 4.3L)........... 6-203
Brake Booster Installation
Push Rod Gauging Procedure (Engine Mechanical - 5.0L, 5.7L)................ 6-424
(Hydraulic Brakes)............................................5-81 Installation (Engine Mechanical - 6.5L)........... 6-656
Brake Caliper Installation (Engine Mechanical - 7.4L)........... 6-900
Bracket Replacement (Disc Brakes).................5-116 Position Sensor Replacement (4.3L)............. 6-1591
Caliper and Anchor Plate Wear Position Sensor
Adjustment (Disc Brakes)............................. 5-108 Replacement (5.0L, 5.7L)........................... 6-2220
Inspection (Disc Brakes)....................................5-110 Position Sensor Replacement (7.4L)............. 6-3183
Overhaul (Disc Brakes)........................5-110, 5-113 Removal (Engine Mechanical - 4.3L).............. 6-138
Replacement (Disc Brakes)..... 5-101, 5-104, 5-106 Removal (Engine Mechanical - 5.0L, 5.7L) ....6-365
Brake Drum Removal (Engine Mechanical - 6.5L).............. 6-610
Inspection (Drum Brakes).................................. 5-124 Removal (Engine Mechanical - 7.4L).............. 6-836
Replacement (Drum Brakes)............................. 5-124 Replacement (Engine Mechanical - 4.3L)......... 6-95
Brake D ust...................................................................... 3 Replacement
Brake Fluid...................................................................... 4 (Engine Mechanical - 5.0L, 5.7L)................ 6-317
Description Replacement (Engine Mechanical - 6.5L).......6-560
Brake Fluid and Brake Fluid Replacement (Engine Mechanical - 7.4L)....... 6-785
Handling (Hydraulic Brakes)...................... 5-83 CDR Valve and Hoses Replacement (6.5L)......6-2652
Brake Hose Center Bearing Replacement
Front Brake Hose Replacement Propeller Shaft.......................................................4-17
(Hydraulic Brakes).................................5-62, 5-63 Cleaning Carrier Components
Brake Lining Front Drive A x le ................................................... 4-82
Replacement (Drum Brakes)............... 5-126, 5-131 Clutch
Brake Modulator Assembly.............................................................. 7-606
Pressure Modulator Valve Concentric Slave Cylinder................................. 7-608
Replacement (ABS)........................................5-251 Description
Brake Pads Clutch Driven Members................................ 7-610
Inspection (Disc Brakes)......................................5-92 Clutch Driving Members.................................7-610
Replacement (Disc Brakes)............5-93, 5-95, 5-98 Clutch Operating Members........................... 7-610
4 INDEX
Clutch (cont.) Crankshaft
Diagnosis Balancer Installation
Actuator Fluid Leaks..................................... 7-600 (Engine Mechanical - 4.3L)..........................6-218
Does Not Disengage..................................... 7-594 Balancer Installation
Grabbing (Chattering).................................... 7-595 (Engine Mechanical - 6.5L), 6-663
Master Cylinder Fluid Leaks.........................7-600 Balancer Installation
Noisy................................................................7-597 (Engine Mechanical - 7 .4 L )..........................6-913
Pedal Hard to Push...................................... 7-598 Balancer Removal
Pedal Spongy................................................. 7-600 (Engine Mechanical - 4 .3L)..........................6-126
Pedal Stays on Floor Balancer Removal
(Clutch Disengaged)................................. 7-597 (Engine Mechanical - 5.0L, 5.7L)................ 6-354
Pedal Sticks or Binds.................................... 7-601 Balancer Removal
Pedal Travels to Floor (Engine Mechanical - 6 .5L)..........................6-604
(Fluid in Master Cylinder).........................7-599 Balancer Removal
Preliminary Checking Procedure................. 7-594 (Engine Mechanical - 7 .4L)..........................6-825
Rattle (Trans C lick)....................................... 7-596 Balancer Replacement
Release Bearing Noisy (Engine Mechanical - 4 .3 L ).......................... 6-80
w/Clutch Engaged..................................... 7-597 Balancer Replacement
Slipping........................................................... 7-595 (Engine Mechanical - 6 .5 L )..........................6-538
Spin Down Time.............................................7-594 Balancer Replacement
Unable to Select G ears................................ 7-601 (Engine Mechanical - 7.4L)..........................6-764
Hydraulic Clutch Bleeding................................. 7-605 CKP System Variation
Master Cylinder Replacement...........................7-603 Learn Procedure (4.3L)............................... 6-1513
Pedal Replacement............................................7-602 Position Sensor Replacement (4.3L)........ ..6-1588
Special Tools........................................................7-611 Position Sensor
Specifications Replacement (5.0L, 5.7L)...........................6-2218
Fastener Tightening........................................7-593 Position Sensor Replacement (6.5L).......... 6-2639
Start Switch..........................................................7-605 Position Sensor Replacement (7.4L).......... 6-3181
Clutch Dust.................................. 4 System Variation Learn Procedure (7.4L).... 6-3099
Coding Keys and Lock Cylinders............................0-34 Cylinder
Colors Boring and Honing
Exterior and Interior..............................................0-22 (Engine Mechanical - 4.3L)........................ 6-146
Combination Valve Boring and Honing
Replacement (Hydraulic Brakes).........................5-61 (Engine Mechanical - 5.0L, 5.7L)......... 6-373
Control and Shift Solenoids Boring and Honing
Replacement (Automatic 4L60-E).....................7-202 (Engine Mechanical - 6 .5 L )........................ 6-618
Control Arm Boring and Honing
Lower Control Arm Replacement (Engine Mechanical - 7 .4L)........................ 6-844
Front Suspension..................................3-63, 3-64 Head Assemble
Upper Control Arm Replacement (Engine Mechanical - 4 .3L)........................ 6-178
Front Suspension..................................3-60, 3-62 Head Assemble
Control Module Replacement (Engine Mechanical - 5.0L, 5.7L)......... 6-403
Transfer C ase..................................................... 4-295 Head Assemble
Control Valve (Engine Mechanical - 6 .5 L )..........................6-640
Assembly (Automatic 4L60-E)........................... 7-212 Head Assemble
Control Valve Body (Engine Mechanical - 7.4L)..........................6-875
Replacement (Automatic 4L80-E).....................7-535 Head Clean and Inspect
Conversion Table (Engine Mechanical - 4 .3 L )..........................6-174
English/Metric...........................................................0-3 Head Clean and Inspect
Coolant (Engine Mechanical - 6.5L).......................... 6-637
Recovery Reservoir Replacement Head Clean and Inspect
(Engine Cooling).............................................6-948 (Engine Mechanical - 7 .4 L ).......................... 6-870
Recovery System Description........................... 6-986 Head Disassemble
Cooler Lines (Engine Mechanical - 4 .3L).......................... 6-173
Engine Oil Cooler Line Replacement Head Disassemble
(Engine Cooling).............................................6-952 (Engine Mechanical - 5.0L, 5.7L)................ 6-396
Crankcase Head Disassemble
Description (Engine Mechanical - 6 .5L)..........................6-636
Ventilation System (4.3L)........................ 6-1637 Head Disassemble
Ventilation System (5.0L, 5 .7 L )................... 6-2274 (Engine Mechanical - 7.4L)..........................6-869
Ventilation System (7.4L)........................ 6-3235 Head Installation
Diagnosis (Engine Mechanical - 4 .3 L ).......................... 6-212
Ventilation System (4.3L)........................ 6-1506 Head Installation
Ventilation System Description(6.5L)..............6-2673 (Engine Mechanical - 5.0L, 5 .7 L )....6-430, 6-431
INDEX 5
Cylinder (cont.) Distributor
Head Installation Inspection (Engine Electrical)..........................6-1076
(Engine Mechanical - 6.5L).......................... 6-658 Installation (Engine Mechanical - 4.3L)........... 6-219
Head Installation Installation
(Engine Mechanical - 7.4L)..............6-905, 6-906 (Engine Mechanical - 5.0L, 5.7L)................ 6-438
Head Removal Installation (Engine Mechanical - 7.4L)........... 6-910
(Engine Mechanical - 4.3L)..........................6-131 Overhaul (Engine Electrical)........................... 6-1068
Head Removal Removal (Engine Mechanical - 4.3L).............. 6-129
(Engine Mechanical - 5.0L,5.7L)................. 6-359 Removal (Engine Mechanical - 5.0L, 5.7L) ....6-356
Head Removal Removal (Engine Mechanical - 7.4L).............. 6-827
(Engine Mechanical - 6.5L)..........................6-608 Replacement (Engine Electrical)..... 6-1060, 6-1066
Head Removal Drain Cock
(Engine Mechanical - 7.4L)..........................6-831 Replacement (Engine Cooling)......................... 6-974
Head Replacement Draining and Filling Cooling System
(Engine Mechanical - 4.3L)............................6-76 (Engine Cooling)................................................. 6-945
Head Replacement Drive Axle
(Engine Mechanical - 5.0L,5.7L)................. 6-301 Disassemble
Head Replacement Rear Drive Axle.............................................. 4-129
(Engine Mechanical - 6.5L).......................... 6-517 Final Assembly
Head Replacement Rear Drive Axle.............................................. 4-147
(Engine Mechanical - 7.4L)..........................6-757 Drive Belt
Diagnosis (Engine Mechanical - 7.4L)............ 6-702
Replacement
D (Engine Mechanical - 5.0L, 5.7L)................ 6-263
Decimal and Metric Equivalents................................0-3 Replacement (Engine Mechanical - 4.3L)......... 6-47
Defective Scan Tool....................................................... 6 Replacement (Engine Mechanical - 7.4L)....... 6-711
Definition of Caution, Notice, andImportant................ 3 Tensioner Diagnosis
Diagnosis (Engine Mechanical - 7 .4L).............6-470, 6-706
Valve Train............................................................ 6-32 Tensioner Replacement
Diagnostic Work Sheets.............................................0-6 (Engine Mechanical - 4 .3L)............................ 6-48
Differential Tensioner Replacement
Case Assembly (Engine Mechanical - 7 .4L)..........................6-712
Rear Drive Axle............................................ 4-137 Drum Brake Adjustment.........................................5-142
Differential to Axle Housing Assemble Drum Brakes
Rear Drive Axle............................................ 4-141 Specifications
Inspection Component..................................................... 5-123
Rear Drive Axle............................................ 4-134 Fastener Tightening.......................................5-123
Differential Carrier GM SPO Group Numbers............................ 5-123
Assembly Replacement System Description............................................. 5-143
Front Drive A xle ..............................................4-65 DTC B1015.............................................................. 9J-72
Bushing Replacement DTC B1016.............................................................. 9J-76
Front Drive A xle ...............................................4-64 DTC B1017.............................................................. 9J-80
Final Assembly DTC B1018.............................................................. 9J-84
Overhaul DTC B1021.............................................................. 9J-90
Differential Case Assembly DTC B1024.............................................................. 9J-98
Assemble DTC B1025............................................................ 9J-101
Front Drive A xle ...............................................4-87 DTC B1026............................................................ 9J-104
Differential Pilot DTC B1035............................................................ 9J-108
Bearing Replacement DTC B1036............................................................ 9J-110
Front Drive A xle ...............................................4-61 DTC B1051............................................................ 9J-113
Disc Brakes DTC B1053............................................................ 9J-114
Description.......................................................... 5-120 DTC B1054........................................... 9J-115
Diagnosis DTC B1061............................................................ 9J-122
Brake Rotor Lateral Runout Check............... 5-91 DTC B1071............................................................ 9J-124
Brake Rotor Thickness Variation Check...... 5-91 DTC P0101 ................ 6-1177, 6-1743, 6-2346, 6-2759
Brake Rotor Tolerance.................................... 5-91 DTC P0102................. 6-1182, 6-1748, 6-2349, 6-2763
Special Tools....................................................... 5-121 DTC P0103................. 6-1186, 6-1752, 6-2353, 6-2767
Specifications DTC P0106............................................ 6-1189, 6-1755
Caliper Wear Shim...........................................5-89 DTC P0107..............................6-1192, 6-1758, 6-2770
Component....................................................... 5-89 DTC P0108..............................6-1196, 6-1761, 6-2773
Fastener Tightening..........................................5-89 DTC P0112................. 6-1200, 6-1765, 6-2356, 6-2777
GM SPO Group Numbers............................... 5-89 DTC P0113................. 6-1203, 6-1767, 6-2359, 6-2779
6 INDEX
DTC P0117.................. 6-1206, 6-1770, 6-2362, 6-2782 DTC P0304........................................................... 6-2458
DTC P0118..................6-1208, 6-1773, 6-2365, 6-2785 DTC P0305........................................................... 6-2460
DTC P0121 ................ 6-1211, 6-1776, 6-2368, 6-2788 DTC P0306........................................................... 6-2462
DTC P0122.................6-1214, 6-1778, 6-2371, 6-2790 DTC P0307........................................................... 6-2464
DTC P0123................. 6-1217, 6-1781, 6-2374, 6-2793 DTC P0308........................................................... 6-2466
DTC P0125................................6-1220, 6-1784,6-2796
DTC P0325............................... 6-1283, 6-1877, 6-2874
DTC P0126........................................................... 6-2377 DTC P0327............................... 6-1286, 6-1880, 6-2877
DTC P0131 .............................. 6-1222, 6-1786,6-2798DTC P0335........................................................... 6-2468
DTC P0132................................6-1225, 6-1789,6-2801DTC P0336............................... 6-1290, 6-1884, 6-2881
DTC P0133................................6-1228, 6-1792,6-2804
DTC P0337............................... 6-1293, 6-1887, 6-2884
DTC P0134................................6-1231, 6-1795,6-2807DTC P0338............................... 6-1296, 6-1890, 6-2887
DTC P0135................................6-1234, 6-1798,6-2810
DTC P0339............................... 6-1299, 6-1893, 6-2890
DTC P0137...........................................................6-1801,6-2813 DTC P0340............................... 6-1302, 6-1896, 6-2893
DTC P0138.......................................................... 6-1805,6-2817 DTC P0341 ...............................6-1305, 6-1899, 6-2896
DTC P0140.......................................................... 6-1808,6-2820 DTC P0370............................................................6-2471
DTC P0141 ............................................. 6-1811, 6-2823 DTC P0380............................................................6-2475
DTC P0143...........................................................6-1237,6-1815 DTC P0400............................................................6-2478
DTC P0144..... 6-1240, 6-1819 DTC P0401...............6-1307, 6-1901, 6-2481, 6-2898
DTC P0146.......................................................... 6-1243,6-1822 DTC P0402............................................................6-2483
DTC P0147...........................................................6-1246,6-1826 DTC P0404................. 6-1311, 6-1905, 6-2485, 6-2902
DTC P0151 .............................. 6-1249, 6-1830,6-2827DTC P0405................ 6-1315, 6-1909, 6-2487, 6-2906
DTC P0152................................6-1252, 6-1833,6-2830DTC P0406............................................................6-2490
DTC P0153................................6-1255, 6-1836,6-2833DTC P0410.............................................. 6-1912, 6-2909
DTC P0154................................6-1258, 6-1839,6-2836DTC P0420............................... 6-1319, 6-1917, 6-2913
DTC P0155................................6-1261, 6-1842,6-2839DTC P0430.............................................. 6-1921, 6-2917
DTC P0157.......................................................... 6-1845,6-2842 DTC P0440............................... 6-1323, 6-1924, 6-2920
DTC P0158.......................................................... 6-1848,6-2845 DTC P0442............................... 6-1328, 6-1929, 6-2925
DTC P0160.......................................................... 6-1851,6-2848 DTC P0446............................... 6-1332, 6-1933, 6-2929
DTC P0161 ............................................. 6-1854, 6-2851 DTC P0452............................... 6-1336, 6-1937, 6-2933
DTC P0171 ...............................6-1264, 6-1858,6-2855DTC P0453................................6-1340, 6-1940, 6-2937
DTC P0172................................ 6-1268, 6-1862,6-2859DTC P0461................ 6-1343, 6-1943, 6-1945, 6-2940
DTC P0174................................6-1272, 6-1866,6-2863DTC P0462................ 6-1346, 6-1947, 6-1949, 6-2943
DTC P0175................................6-1276, 6-1870,6-2867DTC P0463................ 6-1349, 6-1952, 6-1955, 6-2946
DTC P0182............................................................6-2380 DTC P0500................................6-1352, 6-1958, 6-2949
DTC P0183............................................................6-2383 DTC P0501 ............................................................6-2493
DTC P0215........................................................... 6-2386 DTC P0502.................................................... 7-69, 7-304
DTC P0216............................................................6-2389 DTC P0503.................................................... 7-72, 7-308
DTC P0218...................................... 7-67, 7-298, 7-301 DTC P0506................................6-1355, 6-1961, 6-2952
DTC P0219............................................................6-2393 DTC P0507................................6-1357, 6-1963, 6-2954
DTC P0220............................................................6-2395 DTC P0560.................................................. 7-312, 7-315
DTC P0221 ............................................................6-2397 DTC P0567............................................................6-2496
DTC P0222............................................................6-2400 DTC P0568............................................................6-2498
DTC P0223............................................................6-2403 DTC P0571 ............................................................6-2501
DTC P0225............................................................6-2406 DTC P0601 ............................................. 6-2504, 6-2956
DTC P0226.............. 6-2408 DTC P0602.............................................. 6-2505, 6-2957
DTC P0227............................................................6-2411 DTC P0603............................................................6-2959
DTC P0228........................................................... 6-2414 DTC P0604.............................................. 6-2506, 6-2960
DTC P0231 ............................................................6-2417 DTC P0605............................................................6-2961
DTC P0236............................................................6-2420 DTC P0606............................................................6-2507
DTC P0237............................................................6-2423 DTC P0704................................6-1369, 6-1975, 6-2962
DTC P0238............................................................6-2426 DTC P0711 ....................................... 7-75, 7-318, 7-322
DTC P0251 ............................................................6-2429 DTC P0712........................................ 7-79, 7-326, 7-329
DTC P0263............................................................6-2433 DTC P0713........................................ 7-83, 7-332, 7-336
DTC P0266............................................................6-2435 DTC P0716.................................................. 7-340, 7-343
DTC P0269............................................................6-2437 DTC P0717.................................................. 7-347, 7-350
DTC P0272............................................................6-2439 DTC P0719........................................ 7-87, 7-353, 7-357
DTC P0275............................................................6-2441 DTC P0722.............................................................. 7-360
DTC P0278............................................................6-2443 DTC P0723.............................................................. 7-365
DTC P0281 ............................................................6-2445 DTC P0724........................................ 7-90, 7-370, 7-373
DTC P0284............................................................6-2447 DTC P0730.................................................. 7-375, 7-378
DTC P0300............... 6-1280, 6-1874, 6-2449, 6-2871 DTC P0740................................................................ 7-92
DTC P0301 ............................................................6-2452 DTC P0741 .................................................7-381, 7-384
DTC P0302............................................................6-2454 DTC P0742........................................ 7-95, 7-387, 7-390
DTC P0303............................................................6-2456 DTC P0748............................. 7-98, 7-393, 7-397
INDEX 7
DTC P0751 ............................................................. 7-102 EGR (cont.)
DTC P0753..................................... 7-105, 7-407, 7-411 System Description (4.3L)...............................6-1636
DTC P0756................................................ 7-109, 7-415,7-418 System Description (6.5L)............................... 6-2673
DTC P0758................................................ 7-112, 7-421,7-425 System Description (7.4L)............................... 6-3233
DTC P0785..............................................................7-116 Valve Replacement (4.3L)............................... 6-1593
DTC P1106................................ 6-1372, 6-1978, 6-2965 Valve Replacement (5.0L, 5.7L).....................6-2225
DTC P1107................................ 6-1376, 6-1981, 6-2968 Valve Replacement (6.5L)............................... 6-2647
DTC P1111 ................................6-1379, 6-1984, 6-2971 Valve Replacement (7.4L)............................... 6-3191
DTC P1112................................ 6-1382, 6-1987, 6-2974 Vent Solenoid Replacement (6.5L)................ 6-2649
DTC P1114................................ 6-1385, 6-1989, 6-2976 Electrical Connector Replacement
DTC P1115................................ 6-1388, 6-1991, 6-2979 Transfer Case..................................................... 4-298
DTC P1121................................ 6-1391, 6-1994, 6-2982 Electric Coolant Fan...................................................... 4
DTC P1122................................ 6-1394, 6-1997, 6-2985 Electric Motor Replacement
DTC P1125............................................................ 6-2508 Transfer Case........................................4-291, 4-293
DTC P1133................................ 6-1397, 6-2000, 6-2988 Electronic Brake Control
DTC P1134................................ 6-1400, 6-2003, 6-2991 Module Replacement (ABS).............................. 5-250
DTC P1153................................ 6-1403, 6-2006, 6-2994 Engine Block
DTC P1154................................ 6-1406, 6-2009, 6-2997 Clean and Inspect
DTC P1191............................................................ 6-2510 (Engine Mechanical - 4.3L)..........................6-145
DTC P1214........................................................... 6-2512 Clean and Inspect
DTC P1216........................................................... 6-2514 (Engine Mechanical - 6.5L)..........................6-617
DTC P1217........................................................... 6-2517 Clean and Inspect
DTC P1218........................................................... 6-2520 (Engine Mechanical - 7.4L)..........................6-843
DTC P1336............................... 6-1409, 6-2012, 6-3000
Plug Installation
DTC P1345............................... 6-1413, 6-2015, 6-3003
(Engine Mechanical - 4.3L)..........................6-196
DTC P1351 ..... 6-1415, 6-2018, 6-3005
Plug Installation
DTC P1361 .............................. 6-1418, 6-2021, 6-3009
DTC P1380............................... 6-1421, 6-2024, 6-3012 (Engine Mechanical - 7.4L)..........................6-892
DTC P1381 .............................. 6-1423, 6-2026, 6-3014 Plug Removal
DTC P1404............................... 6-1425, 6-2028, 6-3016 (Engine Mechanical - 4 .3L)..........................6-142
DTC P1406........................................................... 6-2522 Plug Removal
DTC P1409............................................................6-2524 (Engine Mechanical - 5.0L, 5.7L)................ 6-369
DTC P1415...........................................................6-2031,6-3019 Plug Removal (Engine Mechanical - 7.4L).....6-840
DTC P1416..........................................................6-2034,6-3021Engine Controls - 4.3L
DTC P1441 .............................. 6-1428, 6-2037, 6-3023 Connector End Views.......................................6-1148
DTC P1508...............................6-1432, 6-2040, 6-3026 Engine Controls - 4.3L
DTC P1509...............................6-1435, 6-2043, 6-3030 Component Location Table............................. 6-1128
DTC P1621 ........................................................... 6-2527 Component Views............................................. 6-1133
DTC P1626...............6-1440, 6-2048, 6-2528, 6-3034 Description
DTC P1627........................................................... 6-2530 Air Intake System.........................................6-1637
DTC P1630.......................................................... 6-2531,6-3036 Long Term Fuel T rim .................................. 6-1628
DTC P1631...............6-1445, 6-2053, 6-2532, 6-3037 Serial Data Communications......................6-1611
DTC P1635........................................................... 6-2536 Short Term Fuel Trim.................................. 6-1627
DTC P1641 ........................................................... 6-2539 Speed Density System ............................... 6-1628
DTC P1643............................................................6-2541 Diagnosis
DTC P1653............................................................6-2543 Alcohol-in-Fuel..............................................6-1494
DTC P1654............................................................6-2547 Backfire......................................................... 6-1474
DTC P1655........................................................... 6-2549 Cuts Out, Misses..........................................6-1469
DTC P1656........................................................... 6-2553 Detonation/Spark Knock.................. 6-1467
DTC P1810................................................ 7-120, 7-429,7-433 Dieseling, Run-On....................................... 6-1474
DTC P1811.............................................................. 7-437 EGR System.................................................6-1503
DTC P1860................................................ 7-124, 7-440,7-444 Hard Start..................................................... 6-1464
DTC P 1870................................................7-128, 7-448,7-452 Hesitation, Sag, Stumble............................ 6-1468
DTC P 1875................................................ 7-133, 7-456,7-459 Idle Air Control System............................... 6-1507
Poor Fuel Economy.................................... 6-1470
Powertrain OBD System Check.................6-1153
E Surges/Chuggles..........................................6-1465
EGR Symptoms..................................................... 6-1461
Control Pressure Password Learn Procedure............................. 6-1513
Sensor Replacement (6.5L)........................6-2650 Schematic
Description Engine Controls............................................ 6-1115
System Description (5.0L, 5.7L)................ 6-2273 Icon Table......................................................6-1114
Solenoid Filter Replacement (6.5L)............... 6-2649 Reference Table........................................... 6-1114
Solenoid Replacement (6.5L)..........................6-2648 Special Tools.................................................... 6-1639
8 INDEX
Engine Controls - 4.3L (cont.) Engine Controls - 6.5L....................................... (cont.)
Specifications CDR Valve Test............................................6-2580
DTC Type..................................................... 6-1108 Contamination Testing................................. 6-2569
Fastener Tightening..................................... 6-1089 Cruise Control.............................................. 6-2566
GM SPO Group Numbers........................... 6-1112 Cuts Out, Misses..........................................6-2563
Scan Tool Data Definitions.........................6-1096 Data Link Connector................................... 6-2338
Scan Tool Data List..................................... 6-1090 Excessive Smoke.........................................6-2564
Temperature vs Resistance........................6-1089 Fuel Heater Functional............................... 6-2573
Engine Controls - 5.0L, 5.7 Fuel Injection System ................................. 6-2577
Specifications Fuel Knock/Combustion N oise.................. 6-2562
Scan Tool Data Definitions.........................6-1651 Fuel Manager/Filter..................................... 6-2572
Engine Controls - 5.0L, 5.7L Fuel Pump Relay Circuit............................. 6-2343
Diagnosis Fuel Quality.................................................. 6-2570
Backfire......................................................... 6-2080 Fuel Return System.....................................6-2578
Electric Cooling Fan.................................... 6-2088 Fuel Sender................................................ ..6-2570
Engine Controls - 5.0L, 5.7L Fuel Supply System Check........................ 6-2571
Component Location Table.............................6-1691 Fuel Tank Leak Check................................ 6-2569
Component Views.............................................6-1696 Glow Plug System Check........................... 6-2578
Connector End Views...................................... 6-1713 Hard Start..................................................... 6-2560
Description Hesitation, Sag, Stumble............................ 6-2563
Air Intake System........................................ 6-2274 Injection Nozzle(s)........................................6-2577
Long Term Fuel Trim................................... 6-2264 Poor Fuel Economy.....................................6-2563
Diagnosis........................................... 6-2084, 6-2113 Powertrain OBD System Check................ 6-2333
Cuts Out, Misses..........................................6-2075 Specific Gravity Testing.............................. 6-2570
Data Link Connector................................... 6-1725 Surges/Chuggles..........................................6-2561
Detonation/Spark Knock..............................6-2074 Symptoms..................................................... 6-2559
Dieseling, Run-On....................................... 6-2080 Water-in-Fuel Lamp Circuit.........................6-2575
EGR System................................................. 6-2117 Password Learn Procedure............................. 6-2583
EVAP Control System................................. 6-2105 Schematic
Fuel Injector Balance Test..........................6-2093 Schematic Diagrams....................................6-2292
Fuel Injector Circuit..................................... 6-2099 Schematic Icon Table.................................. 6-2292
Fuel Injector Coil Test................................. 6-2097 Schematic Reference Table........................6-2291
Fuel System ................................................. 6-1733 Special Tools.................................................... 6-2675
Fuel Tank Pressure Sensor........................6-2101 Specificaitons
Hard Start..................................................... 6-2070 DTC Type..................................................... 6-2287
Poor Fuel Economy.................................... 6-2077 Specifications
Surges/Chuggles..........................................6-2072 Fastener Tightening.....................................6-2280
Symptoms..................................................... 6-2068 Fuel System................................................. 6-2290
Vehicle Control Module............................... 6-2083 GM SPO Group Number............................ 6-2290
Password Learn Procedure............................. 6-2128 Scan Tool Data Definitions......................... 6-2284
Schematic Scan Tool Data L is t.....................................6-2281
Icon Table..................................................... 6-1673 Temperature vs Resistance........................ 6-2279
Reference Table...........................................6-1673 Engine Controls - 7.4L
Special Tools..................................................... 6-2276 Component Location Table............................. 6-2714
Specifications Component Views............................................. 6-2719
DTC Type..................................................... 6-1662 Connector End Views.......................................6-2734
Fastener Tightening..................................... 6-1643 Description
GM SPO Group Numbers...........................6-1671 Air Intake System.........................................6-3235
Scan Tool Data List..................................... 6-1644 Enhanced Ignition System.......................... 6-3230
Temperature vs Resistance........................6-1643 Fuel Supply Component............................. 6-3222
Engine Controls - 6.4L Long Term Fuel T rim .................................. 6-3229
Diagnosis Serial Data Communications......................6-3209
Surges/Chuggles..........................................6-3044 Short Term Fuel Trim...................................6-3229
Engine Controls - 6 .5 L .........................................6-2325 Speed Density System ............................... 6-3229
Component Location Table............................. 6-2305 Diagnosis...........................................................6-3059
Component Views.............................................6-2309 Backfire..........................................................6-3052
Connector End Views...................................... 6-2331 Crankcase Ventilation System....................6-3091
Description Cuts Out, Misses..........................................6-3047
Air Intake System.........................................6-2674 Data Link Connector................................... 6-2742
Fuel Supply Component.............................6-2670 Detonation/Spark Knock............................. 6-3046
Serial Data Communications......................6-2659 Dieseling, Run-On........................................6-3052
Diagnosis EGR System................................................. 6-3088
Air Cleaner.................................................... 6-2580 Electric Cooling Fan.....................................6-3062
Air Conditioning Request Circuit................ 6-2565 Enhanced Ignition System.......................... 6-3081
INDEX 9
Engine Controls - 7.4L (cont.) Engine Diagnosis - 4.3L

EVAP Control System................................. 6-3078 Diagnosis
Fuel Injector Balance Test..........................6-3067 Cranks but Does Not Run.......................... 6-1162
Fuel Injector Circuit..................................... 6-3073 Fuel Pump Relay Circuit............................. 6-1164
Fuel Injector Coil Test................................. 6-3071 Fuel System ................................................. 6-1167
Fuel Pump Relay Circuit............................. 6-2746 Engine Diagnosis - 4.3L
Fuel System ................................................. 6-2749 Diagnosis
Fuel Tank Pressure Sensor........................6-3075 Data Link Connector....................................6-1159
Hard Start..................................................... 6-3042 Engine Electircal
Hesitation, Sag, Stumble............................6-3047 Starting and Charging
Idle Air Control System............................... 6-3092 Connector End Views................................. 6-1002
Knock Sensor System................................. 6-3085 Engine Electric
Poor Fuel Economy.................................... 6-3049 Specifications
Powertrain OBD System C heck................ 6-2737 Fastener Tightening...................................... 6-991
Secondary Air Injection System ................ 6-3085 Engine Electrical
Symptoms..................................................... 6-3040 •.Schematic
Vehicle Control Module............................... 6-3055 Starting and Charging Icons......................... 6-993
Vehicle Control Module Outputs................ 6-3056
Starting and Charging
Fuel Pressure Relief Procedure......................6-3117
Component Views........................................6-1000
Password Learn Procedure............................. 6-3099
Schematic Component Locations.........................................6-998
Schematic Diagrams................................... 6-2701 Description
Schematic Icons...........................................6-2700 Battery............................................. 6-1079, 6-1080
Schematic References................................ 6-2700 Battery Operation........................... 6-1082, 6-1084
Special Tools..................................................... 6-3236 Charging System..........................................6-1084
Specifications Charging System Operation.......................6-1085
DTC Type..................................................... 6-2695 Ignition System.............................................6-1086
Fastener Tightening..................................... 6-2677 Starting System Circuit............................... 6-1079
GM SPO Group Numbers...........................6-2698 Starting System Operation.......................... 6-1079
Scan Tool Data List..................................... 6-2678 Diagnosis
Temperature vs Resistance........................6-2677 Battery Load Test.........................................6-1012
Engine Controls - 7.4LSpecification Charge Indicator Always On.......................6-1014
Scan Tool Data Definitions.............................. 6-2684 Charge Indicator Inoperative......................6-1014
Engine Coolant Temperature Charging System Check............................. 6-1005
Sensor Replacement (4.3L)............................6-1515 Generator Assembly
Sensor Replacement (5.0L, 5.7L).................. 6-2130 Bench Check...................................6-1017, 6-1018
Sensor Replacement (6.5L)............................6-2584
Generator Electrical Test............................ 6-1016
Sensor Replacement (7.4L)............................6-3100
Ignition Coil Test...........................................6-1018
Engine Cooling
Component Views............................................... 6-931 Noisy Generator...........................................6-1016
Connector End Views.........................................6-932 Parasitic Load Test......................................6-1012
Description Spark Plug Visual.........................................6-1019
Coolant Recovery System ............................6-986 Spark Plug Wire Harness........................... 6-1021
Cooling System ..............................................6-985 Starter Motor Noise........................ 6-1008, 6-1010
Electric Engine Cooling Fan.........................6-988 Starter No Load Test.................................. 6-1010
Radiator Assembly.........................................6-986 Starter Solenoid Does Not C lick............... 6-1005
Radiator Filler Cap Assembly.......................6-987 Starting System Check............................... 6-1004
Thermostat...................................................... 6-989 Voltmeter Reading High/Low......................6-1015
Water Pump.................................................... 6-989 Schematic
Diagnosis Starting and Charging................................... 6-993
Coolant Concentration Testing..................... 6-941 Starting and Charging References.............. 6-993
Cooling System Special Tools.................................................... 6-1087
Leak Testing......................... 6-942, 6-943, 6-944 Specifications...................................................... 6-992
Fan Clutch...................................................... 6-940 Battery Usage Table......................................6-991
Loss of Coolant..............................................6-936 Starter Motor Usage Table........................... 6-992
Overheating.................................................... 6-934
Engine Exhaust
Thermostat......................................... 6-938, 6-939
Catalytic Converter
Schematic
Replacement..... 6-3262, 6-3264, 6-3266, 6-3268
Cooling Fan.................................................... 6-929
Cooling Fan Icons..........................................6-929 Description
Cooling Fan References............................... 6-929 Exhaust System...........................................6-3270
Special Tools....................................................... 6-990 Diagnosis
Specifications Exhaust Leakage (Not OBD II)..................6-3260
Fastener Tightening........................................6-927 Restricted Exhaust.......................................6-3260
GM SPO Group Numbers............................. 6-927 Vibration or Rattling.................................... 6-3260
10 INDEX
Engine Exhaust (cont.) Engine Mechanical - 4 .3 L .................................. (cont.)
Specifications Disassembled V iew .............................................. 6-42
Fastener Tightening..................................... 6-3259 Service Prior to Assembly................................. 6-196
GM SPO Group Numbers...... ....................6-3259 Specifications............................................. 6-25, 6-29
System Inspection........................................... 6-3262 Fastener Tightening.........................................6-23
Engine Flywheel GM SPO Group Numbers.............................. 6-27
Clean and Inspect Engine Mechanical - 5.0L, 5.7L
(Engine Mechanical - 4.3L)...........................6-155 Description
Clean and Inspect Engine Components.......................................6-444
(Engine Mechanical - 7.4L)...........................6-855 Lubrication...................................................... 6-446
Installation (Engine Mechanical - 4.3L)........... 6-223 Separating Parts............................................. 6-449
Installation Thread Repair................................................ 6-447
(Engine Mechanical - 5.0L, 5.7L)................ 6-441 Diagnosis
Installation (Engine Mechanical - 6.5L)........... 6-676 Base Engine Misfire.......................................6-246
Installation (Engine Mechanical - 7.4L)........... 6-917 Drive Belt........................................................ 6-253
Removal (Engine Mechanical - 4.3L).............. 6-124 Drive Belt Tensioner.......................................6-257
Removal (Engine Mechanical - 5.0L, 5.7L).... 6-352 Engine Noise.................................................. 6-248
Removal (Engine Mechanical - 6.5L).............. 6-591 Oil Consumption............................................. 6-251
Removal (Engine Mechanical - 7.4L).............. 6-821 Oil Leak...........................................................6-251
Replacement (Engine Mechanical - 4.3L)...... 6-111 Valve Train...................................................... 6-248
Replacement Disassembled V iew ............................................ 6-258
(Engine Mechanical - 5.0L, 5.7L)....6-339, 6-340 Service Prior to Assembly..................................6-417
Replacement (Engine Mechanical - 6.5L)...... 6-570 Specifications.......................................................6-245
Replacement (Engine Mechanical - 7.4L).......6-809 Engine Mechanical........................... 6-239, 6-241
Engine Front Cover Installation Fastener Tightening.......................................6-237
(Engine Mechanical - 4.3L)............................... 6-208 GM SPO Group Numbers............................ 6-243
Engine Front Cover Installation Engine Mechanical - 6.5L
(Engine Mechanical - 6.5L)............................... 6-662 Description
Engine Front Cover Installation Cleanliness and C a re ................................... 6-681
(Engine Mechanical - 7.4L)............................... 6-902 Engine Components.......................................6-679
Engine Front Cover Removal Lubrication...................................................... 6-680
(Engine Mechanical - 4.3L)............................... 6-135 Replacing Engine G askets........................... 6-681
Engine Front Cover Removal Separating Parts............................................. 6-682
(Engine Mechanical - 5.0L, 5.7L).................... 6-363 Tools and Equipment.....................................6-683
Engine Front Cover Removal Diagnosis
(Engine Mechanical - 6.5L)............................... 6-605 Drive Belt.........................................................6-466
Engine Front Cover Removal Engine Compression Test............................. 6-462
(Engine Mechanical - 7.4L)............................... 6-834 Engine Noise.................................................. 6-462
Engine Front Cover Replacement Oil Leak...........................................................6-464
(Engine Mechanical - 4.3L)................................. 6-82 Valve Train...................................................... 6-463
Engine Front Cover Replacement Disassembled V iew ............................................ 6-471
(Engine Mechanical - 6.5L)............................... 6-545 Special Tools...................................................... 6-684
Engine Front Cover Replacement Specifications......................................... 6-456, 6-461
(Engine Mechanical - 7.4L)...............................6-771 Fastener Tightening.......................................6-455
Engine ID and Partial VIN Location.......................0-12 GM SPO Group Numbers............................ 6-459
Engine Mechanical - 4.3L.........................................6-32 Engine Mechanical - 7.4L
Description Description
Cleanliness and Care.................................... 6-230 Cleanliness and C a re ....................................6-922
Identification.................................................... 6-227 Engine Comonents.........................................6-919
Lubrication...................................................... 6-229 Lubrication...................................................... 6-922
Replacing Engine Gaskets............................6-230 Replacing Engine G askets........................... 6-923
Separating Parts.............................................6-231 Thread Repair................................................ 6-922
Thread R epair................................................ 6-229 Tools and Equipment.....................................6-924
Tools'and Equipment.................................... 6-232 Desription
Desription Separating Parts............................................. 6-924
Engine Components...................................... 6-226 Diagnosis
Diagnosis Base Engine Misfire.......................................6-693
Base Engine Misfire.........................................6-30 Engine Noise.................................................. 6-695
Drive Belt...........................................................6-37 Oil Consumption............................................. 6-700
Drive Belt Tensioner.........................................6-41 Oil Leak...........................................................6-700
Engine Compression Test............................... 6-32 Valve Train.......................................................6-698
Engine Noise.................................................... 6-32 Disassembled V iew ............................................ 6-707
Oil Consumption............................................... 6-35 Identification.........................................................6-921
Oil Leak.............................................................6-35 Service Prior to Assembly................................. 6-892
INDEX 11
Engine Mechanical - 7.4L (cont.) Exhaust Manifold (cont.)
Specifications......................................... 6-688, 6-692 Clean and Inspect
Fastener Tightening....................................... 6-687 (Engine Mechanical - 6.5L)..........................6-646
Engine Mount Clean and Inspect
Inspection (Engine Mechanical - 4.3L).............6-50 (Engine Mechanical - 7.4L)..........................6-889
Inspection Installation
(Engine Mechanical - 5.0L, 5.7L)................ 6-266 (Engine Mechanical - 4.3L).............6-222, 6-223
Inspection (Engine Mechanical - 6.5L)...........6-481 Installation (Engine Mechanical - 6.5L)...........6-667
Inspection (Engine Mechanical - 7.4L)...........6-715 Installation
Replacement (Engine Mechanical - 7.4L).............6-914, 6-916
(Engine Mechanical - 4.3L)....... 6-51, 6-53, 6-55 Removal (Engine Mechanical - 4.3L).............. 6-125
Replacement Removal
(Engine Mechanical - (Engine Mechanical - 5.0L, 5.7L)....6-352, 6-353
5.0L, 5.7L)....................... 6-267, 6-268, 6-270, Removal (Engine Mechanical - 6.5L).............. 6-600
6-271, 6-272, 6-273 Removal
Replacement (Engine Mechanical - 7.4L).............6-822, 6-824
(Engine Mechanical - 6.5L)..............6-482, 6-484 Replacement (Engine Mechanical - 4.3L)........ 6-74
Replacement Replacement
(Engine Mechanical - 7.4L)..............6-716, 6-718 (Engine Mechanical - 5.0L, 5.7L)....6-297, 6-299
Engine Oil Pressure Sensor/Switch Replacement
(Engine Mechanical - 6.5L).............6-511, 6-514
Replacement (6.5L)......................................... 6-2639
Replacement
Engine Replacement
(Engine Mechanical - 7 .4L)..........................6-752
(Engine Mechanical -4.3L).............................. 6-112
Extension Housing Rear
Engine Replacement
Oil Seal (Automatic 4L60-E)............................. 7-216
(Engine Mechanical -5.0L, 5.7L)..................... 6-341
Exterior and Interior Colors...... ...............................0-22
Engine Replacement
(Engine Mechanical -6.5L).............................. 6-580
Engine Replacement
(Engine Mechanical -7.4L).............................. 6-811 F
Engine Set-Up and Testing Fan
(Engine Mechanical -4.3L).............................. 6-225 Clutch Replacement
Engine Set-Up and Testing (Engine Cooling)................................6-959, 6-960
(Engine Mechanical -5.0L, 5.7L)..................... 6-443 Electric Engine Cooling Fan Description........ 6-988
Engine Set-Up and Testing Shroud Replacement
(Engine Mechanical - 6.5L)............................... 6-678 (Engine Cooling)................................6-975, 6-978
Engine Set-Up and Testing Fastener Notice............................................................... 6
(Engine Mechanical - 7.4L)............................... 6-918 Filler Tube and Seal Replacement
English/Metric Conversion Table............................... 0-3 (Automatic 4L80-E).............................................7-510
EVAP Filler Tube Replacement (4.3L)............. 6-1559, 6-1560
Canister Purge Solenoid Filler Tube Replacement
Valve Replacement (4.3L)...........................6-1584 (5.0L, 5.7L)..........................................6-2185, 6-2187
Canister Purge Solenoid Valve Filler Tube Replacement (7.4L).............6-3154, 6-3156
Replacement (5.0L, 5 .7L)...........................6-2214 Filler Tube Replacement (Automatic 4L60-E).....7-188
Flushing (Engine Cooling)......................................6-947
Canister Purge Solenoid Valve
Flywheel to Torque Converter Bolts
Replacement (7.4L)..................................... 6-3179
(Automatic 4L60-E)............................................. 7-190
Canister Replacement (4.3L).........................6-1587
Forward Servo Replacement
Canister Replacement (5.0L, 5.7L)............... 6-2217 (Automatic 4L80-E)............................................. 7-521
Canister Replacement (7.4L)........................ 6-3180 Front Axle
Description Replacement
Control System (4.3L)................................. 6-1628 Front Suspension............................................. 3-85
Control System (5.0L, 5 .7 L ).......................6-2264 Front Coil Springs
Control System (7.4L)................................. 6-3229 Replacement
Diagnosis Front Suspension.............................................3-67
Control System (4.3L)................................. 6-1494 Front Drive Axle
System Cleaning (4.3L)................................... 6-1587 Assembly Replacement........................................4-67
System Hoses/Pipes Description.............................................................4-97
Replacement (5.0L, 5 .7L)...........................6-2217 Diagnosis...............................................................4-51
Vent Valve Replacement (4.3L)......................6-1586 Four Wheel Drive Diagnosis........................... 4-52
Vent Valve Replacement (5.0L, 5.7L)............ 6-2216 Noise Diagnosis............................................... 4-50
Vent Valve Replacement (7.4L)......................6-3180 Special Tools.........................................................4-98
Exhaust Manifold Specification
Clean and Inspect Fastener Tightening.........................................4-49
(Engine Mechanical - 4.3L)...........................6-194 GM SPO Group Numbers.............................. 4-49
12 INDEX
Front Drive Axle (cont.) Fuel Pipe Fitting..............................................................4
Lubrication........................................................ 4-49 Fuel Pressure..................................................................6
Front Suspension Connection Valve
Component Locations...........................................3-37 Replacement (5.0L, 5.7L)...........................6-2205
Description Connection Valve Replacement (7.4L).......... 6-3173
General Description......................................... 3-88 Regulator Replacement
Diagnosis (CSFI) (5.0L, 5.7L)...................................... 6-2206
Ball Joint Wear Check.................................... 3-42 Regulator Replacement (SFI) (7.4L)............. 6-3176
Special Tools......................................................... 3-90 Fuel Pressure Connection
Specifications Valve Replacement (4.3L)............................. 6-1575
Fastener Tightening......................................... 3-35 Fuel Pressure Regulator
GM SPO Group Number................................3-35 Replacement (CSFI) (4.3L)............................. 6-1576
Fuel and EVAP Pipe...................................................... 4 Fuel Pressure Relief Procedure (4.3L).............. 6-1533
Fuel Balance Pump Replacement (7.4L)...........6-3160 Fuel Pressure Relief Procedure
Fuel Feed and Fuel Return Pipe (5.0L, 5.7L)....................................................... 6-2148
Purge Procedure (6.5L)................................... 6-2632 Fuel Pump
Fuel Filter Relay Replacement (4.3L)............................. 6-1582
Element Replacement (4.3L)........................ 6-1540 Relay Replacement(5.0L, 5.7L)...................... 6-2212
Element Replacement(5.0L, 5.7L).................. 6-2155 Relay Replacement (6.5L)............................. 6-2638
Element Replacement (6.5L)........................ 6-2591 Relay Replacement (7.4L)............................. 6-3178
Element Replacement (7.4L)........................ 6-3124 Replacement (4.3L)..........................................6-1563
Fuel Heater Replacement (5.0L, 5.7L)................................ 6-2190
Replacement (6.5L)..........................................6-2601 Replacement (7.4L)..........................................6-3159
Fuel Hose/Pipes Fuel Pump and Engine Oil PRESS
Assembly Switch Replacement (7.4L)............................. 6-3178
Replacement (4.3L)....... 6-1568, 6-1569, 6-1571 Fuel Pump and Engine Oil PRESS
Assembly Replacement Sensor Replacement (4.3L)............................ 6-1583
(5.0L, 5.7L).................... 6-2196, 6-2197, 6-2198, Fuel Rail Assembly Replacement (7.4L)........... 6-3174
6-2199, 6-2201 Fuel Sender
Assembly Replacement (6.5L)........................6-2631 Assembly Replacement (4.3L)........................6-1562
Assembly Fuel Sender Assembly
Replacement (7.4L)..................... 6-3165, 6-3166, Replacement (5.0L, 5.7L)................................ 6-2188
6-3167, 6-3169 Replacement (6.5L)..........................................6-2627
Replacement Replacement (7.4L)..........................................6-3157
(Engine Compartment) (4.3L).................... 6-1565 Service (6.5L)................................................... 6-2629
Replacement Fuel Storage................................................................... 4
(Engine Compartment) (5.0L, 5.7L)...........6-2193 Fuel Supply Component
Description (4.3L).............................................6-1621
Replacement (Engine
Fuel System
Compartment) (7.4L)................................... 6-3162
Cleaning (4.3L)................................................. 6-1573
Fuel Injection
Cleaning (5.0L, 5.7L)........................................6-2203
Pump Installation
Cleaning (6.5L)................................................. 6-2631
(Engine Mechanical - 6.5L)...........................6-664
Description (6.5L)............................................. 6-2666
Pump Removal
Description - CSFI (4.3L)................................ 6-1619
Description - CSFI (5.0L, 5 .7 L )......................6-2254
Pump Replacement (6.5L)..............................6-2633
Description - SFI (7.4L)....................................6-3219
Fuel Injector
Balance Test (4.3L)..........................................6-1484 Fuel System Cleaning (7.4L).............................. 6-3171
Circuit Diagnosis (4.3L)................................... 6-1490 Fuel Tank
Draining Procedure (4.3L)............................... 6-1541
Coil Test (4.3L)................................................. 6-1488
Draining Procedure (5.0L, 5.7L).....................6-2156
Replacement (4.3L)..........................................6-1582
Replacement (CSFI) (5.0L, 5.7L)................... 6-2212
Replacement (SFI) (7.4L)................................ 6-3177
Pressure Sensor Diagnosis (4.3L)..................6-1492
Fuel Lift Pump Replacement (6.5L)................... 6-2629
Pressure Sensor Replacement (4.3L)........... 6-1558
Fuel Manager/Filter
Replacement (6.5L)..........................................6-2594 Pressure Sensor Replacement
Water Draining Procedure (6.5L)................... 6-2596 (5.0L, 5.7L)................................................... 6-2184
Fuel Metering Pressure Sensor Replacement (7.4L)........... 6-3153
Description Replacement (4.3L)......................... 6-1541, 6-1545,
System Components (5.0L, 5.7L).............. 6-2259 6-1550, 6-1555
System Component Description (4.3L)..........6-1623 Replacement (5.0L, 5.7L).... 6-2156, 6-2160, 6-2164,
System Component Description (7.4L)..........6-3225 6-2168, 6-2173,
6-2177, 6-2181
INDEX 13
Fuel Tank (cont.) Hydraulic Brakes (cont.)
Replacement (6.5L)......................... 6-2603, 6-2607, Diagnosis
6-2610, 6-2615, Accumulator Leak-Down Test.........................5-48
6-2620, 6-2623 Brake Hose and Pipe Diagnosis................... 5-40
Replacement (7.4L)...........6-3125, 6-3129, 6-3133, Brake System................................................... 5-30
6-3137, 6-3142, Brake System Testing..................................... 5-30
6-3146, 6-3150 External Conditions that Affect Brake
Performance................................................. 5-30
Hydraulic System Fluid Loss..........................5-40
Seal Leak......................................................... 5-49
G Pipe Replacement................................................5-62
Gasoline/Gasoline Vapors..............................................4 Scheamtic
Gear Tooth Brake Warning System Schematic Icons....... 5-7
Contact Pattern Check Schematic
Front Drive A xle ...............................................4-92 Brake Warning System..................................... 5-7
Rear Drive Axle..............................................4-144 Brake Warning System
General Information Schematic References.................................. 5-7
Special Tools Table...............................................0-40 Special Tools........................................................ 5-88
Generator Specification
Overhaul (Engine Electrical)............................6-1052 Brake System..................................................... 5-5
Replacement (Engine Electrical)..... 6-1049, 6-1051 Fastener Tightening...........................................5-5
Glow Plug GM SPO Group Numbers................................ 5-5
Relay Replacement (6.5L)............................... 6-2641 System Bleeding................................................... 5-65
Replacement (6.5L)......................................... 6-2644 System Flushing................................................... 5-68
System Description (6.5L)...............................6-2672
Ground Strap
Replacement (Engine Electrical).................... 6-1049 l
Identification
Vehicle...................................................................... 0-6
H Idle Air Control
Valve Replacement (4.3L)............................... 6-1523
Handling Electrostatic Discharge (ESD) Valve Replacement (5.0L, 5.7L).................... 6-2137
Sensitive Parts.................................................. 6 Valve Replacement (7.4L)............................... 6-3106
Handling Idle Air Control (IAC) Valve.......................... 7 Ignition OFF When Disconnecting Battery..................7
Heated Oxygen Sensor (H02S) Indicator Switch
Replacement (4.3L)......................................... 6-1518 Replacement
Replacement (5.0L, 5.7L)................................ 6-2133 Front Drive A xle............................................... 4-55
Replacement (7.4L)......................................... 6-3102 Injection Line(s) Replacement (6.5L)................. 6-2637
Heat Shield Replacement (Automatic 4L80-E)....... 7-533 Injection Nozzle(s) Replacement (6.5L)............. 6-2638
How to Obtain Replacement Labels.......................0-22 Injection Timing Adjustment (6.5L)......................6-2636
How to Use the Paper Version of the In-Line Fuel Filter
Service Manual....................................................... 0-4 Replacement (4.3L).......................... 6-1538, 6-1539
Hub and Drum Assembly Replacement In-Line Fuel Filter Replacement (5.0L, 5.7L) ....6-2154
Rear Drive A xle .................................................. 4-151 In-Line Fuel Filter Replacement (7.4L).............. 6-3123
Hub and Rotor Assembly Replacement Intake Air Resonator Replacement (4.3L)......... 6-1599
Rear Drive A xle .................................................. 4-153 Intake Air Resonator
Hub Cap Replacement (5.0L, 5.7L)................................ 6-2231
Aluminum Wheel Hub Cap Replacement....... 3-117 Intake Air Resonator Replacement (7.4L)......... 6-3196
Hydraulic Booster Intake Air Temperature
Diagnosis Sensor Replacement (4.3L)..........................6-1522
Functional Test (Hydraulic Brakes)................ 5-48 Sensor Replacement(5.0L, 5.7L).................... 6-2136
Noise (Hydraulic Brakes)................................ 5-46 Sensor Replacement (6.5L)..........................6-2588
Diagnosis (Hydraulic Brakes)........ 5-42, 5-43, 5-45 Sensor Replacement (7.4L)..........................6-3106
Hydraulic Brake Intake Manifold
Booster Replacement Assemble (Engine Mechanical - 4.3L)............ 6-190
(Hydraulic Brakes)............5-71, 5-73, 5-76, 5-78 Assemble (Engine
Hydraulic Brakes Mechanical - 5.0L, 5.7L)............................... 6-413
Brake Warning System Assemble (Engine Mechanical - 7 .4L)............ 6-886
Component Locations..................................... 5-10 Clean and Inspect
Brake Warning System Components View....... 5-11 (Engine Mechanical - 4 .3 L )..........................6-189
Brake Warning System Clean and Inspect
Connector End V iew s..................................... 5-19 (Engine Mechanical - 6 .5L)..........................6-646
Description Clean and Inspect
Booster Description..........................................5-84 (Engine Mechanical - 7 .4 L )..........................6-884
14 INDEX
Intake Manifold (cont.)
Disassemble (Engine Mechanical - 4.3L)....... 6-185 M
Disassemble Maintenance and Lubricant
(Engine Mechanical - 5.0L, 5.7L)................6-409 Periodic Maintenance Inspection.............0-83, 0-84
Disassemble (Engine Mechanical - 7.4L)....... 6-881 Maintenance and Lubrication
Installation Explanation of Scheduled Services....................0-76
(Engine Mechanical - 4.3L)..............6-214, 6-215 Inspections and Other Services.......................... 0-81
Installation Long Trip/Highway Maintenance
(Engine Mechanical - 5.0L, 5.7L)................6-434 Schedule.................................................. 0-66, 0-72
Installation Manitenance Schedule.........................................0-45
(Engine Mechanical - 6.5L).... 6-672, 6-673, 6-674 Owner Checks and Services.............................. 0-75
Installation (Engine Mechanical - 7.4L)........... 6-907 Short Trip/City Maintenance
Removal (Engine Mechanical - 4.3L).............. 6-130 Schedule.................................................. 0-46, 0-53
Removal (Engine Mechanical - 5.0L, 5.7L).....6-357 Specifications
Removal (Engine Mechanical - Drive Belt Tension............................................0-41
6.5L).......................................6-593, 6-594, 6-595 Fluid Capacities................................................0-41
Removal (Engine Mechanical - 7.4L).............. 6-829 Maintenance Items...........................................0-43
Replacement (Engine Recommended Fluids and Lubricants........... 0-42
Mechanical - 4 .3 L )................................6-57, 6-60 Tire Inflation Pressure..................................... 0-43
Replacement (Engine Manifold Absolute Pressure
Mechanical - 5.0L, 5.7L)...................6-274, 6-282 Sensor Replacement (5.0L, 5.7L)...................6-2132
Replacement (Engine Sensor Replacement (7.4L)............................ 6-3101
Mechanical - 6 .5 L )............................ 6-489, 6-492 Manifold Air Pressure
Sensor Replacement (4.3L)............................ 6-1517
Replacement (Engine
Manual Transmission - New Venture
Mechanical - 7 .4 L )............................ 6-723, 6-729
Backup Lamp Switch.................................. 7-19, 7-20
Diagnosis
Clutch Spin Down Time.....................................7-8
J Fluid Check..............................................................7-9
Jacking and Lifting....................................................0-37 Fluid Replacement.......................................7-11, 7-12
Shift Lever.............................................................7-14
Special Tools........................................................ 7-37
Specifications
K Fastener Tightening...........................................7-7
Key Coding and Lock Cylinders.............................0-34 Lubrication.......................................................... 7-7
Knock Sensor Transmission Replacement............7-22, 7-27, 7-31
Description Vehicle Speed Sensor................................7-15, 7-17
System Description (5.0L, 5.7L)................ 6-2271 Manual Transmission- New Venture
Replacement (4.3L)..........................................6-1592 Diagnosis
Replacement (5.0L, 5.7L)................................ 6-2221 Manual Transmission.........................................7-8
Replacement (7.4L)..........................................6-3184 Mass Air Flow
System Description (4.3L)............................... 6-1635 Sensor Replacement (4.3L)............................ 6-1516
System Description (7.4L)............................... 6-3232 Sensor Replacement (5.0L, 5.7L)...................6-2131
System Diagnosis (4.3L)................................. 6-1502 Sensor Replacement (6.5L)............................ 6-2585
Sensor Replacement (7.4L)............................ 6-3100
Master Cylinder
Bench Bleeding (Hydraulic Brakes)....................5-58
L Description (Hydraulic Brakes)............................ 5-83
Label Diagnosis (Hydraulic Brakes).............................. 5-39
Anti-Theft Labeling................................................0-17 Overhaul (Hydraulic Brakes)............................... 5-54
Service Parts ID ................................................... 0-17 Replacement
Labels, Replacement (Hydraulic Brakes)...................... 5-50, 5-51, 5-52
How to Obtain....................................................... 0-22 Reservoir Filling (Hydraulic Brakes)...................5-50
Latched DTC B1018, B1024 Notice Meanings of Abbreviations.......................................0-29
(SDN-RSD)..................................................................7 Moving Parts and Hot Surfaces....................................4
Leaf Springs Replacement MWheel Alignment
Front Suspension.................................................. 3-69 Measuring..............................................................3-23
Lifting and Jacking.................................................... 0-37
Lock Cylinders and Key C oding.............................0-34
Lower O-Ring Removal................................................. 4
Lubricant Change N
Front Drive Axle.................................................... 4-53 Nylon Fuel Lines............................................................. 7
INDEX 15
o On-Board Diagnostic (Level 2) (OBDII)

System Description.................................................... 7
Oil Cooler One-Piece Propeller Shaft Replacement............... 4-10
Flushing (Automatic 4L80-E).............................7-545 Ordering Information
Oil Cooler Flushing (Automatic 4L60-E).............. 7-227 Special Tools.......................................................... 0-6
Oil Cooler Line Replacement Output Shaft
(Automatic 4L80-E).............................................7-522 Shaft, Bearing, and Tube Replacement
Oil Pan Front Drive A xle...............................................4-58
Clean and Inspect Output Shaft Seal Replacement
(Engine Mechanical - 4.3L)...........................6-185 Transfer Case........................................4-278, 4-279
Clean and Inspect
(Engine Mechanical - 5.0L, 5.7L)............., 6-409
Clean and Inspect
P
Installation (Engine Mechanical - 4.3L)........... 6-209 Park Brake
Installation (Engine Brake Drum
Mechanical - 5.0L, 5.7L)...............................6-428 Replacement................................................... 5-157
Installation (Engine Mechanical - 6.5L)........... 6-656 Cable Replacement...... 5-151, 5-153, 5-154, 5-157
Installation (Engine Mechanical - 7.4L)........... 6-903 Cable Service/Adjustment................................. 5-159
Removal (Engine Mechanical - 4.3L).............. 6-133 Description
Removal (Engine Mechanical - 5.0L, 5.7L).....6-361 System............................................................ 5-161
Diagnosis
Removal (Engine Mechanical - 6.5L).............. 6-611
Removal (Engine Mechanical - 7.4L).............. 6-833 Hydraulic Park Brake.................................... 5-146
Lever Replacement............................................5-149
Replacement (Automatic 4L60-E).................... 7-191
Lubrication Procedure....................................... 5-149
Replacement (Engine Mechanical - 4.3L).......6-103
Shoe Replacement.............................................5-147
Replacement (Engine
Special Tools...................................................... 5-162
Mechanical - 5.0L, 5.7L)............................... 6-327
Specification
GM SPO Group Numbers............................5-145
Specifications
Oil Pan Replacement (Automatic 4L80-E)........... 7-509
Fastener Tightening...................................... 5-145
Oil Pump
Park Lock Pawl and Actuator
Assemble (Engine Mechanical - 4.3L)............. 6-182
Replacement (Automatic 4L80-E).................... 7-514
Assemble (Engine Mechanical -
Park/Neutral
5.0L, 5.7L)...................................................... 6-407
Back Up Switch Adjustment
Assemble (Engine Mechanical - 6.5L)............. 6-644
(Automatic 4L60-E)........................................7-171
Assemble (Engine Mechanical - 7.4L)............. 6-878 Back Up Switch Replacement
Clean and Inspect (Engine (Automatic 4L60-E)....................................... 7-170
Mechanical - 4 .3 L )........................................ 6-182 Park/Neutral Back Up Switch
Clean and Inspect (Engine Adjustment (Automatic 4L80-E)........................7-507
Mechanical - 5.0L, 5.7L)............................... 6-406 Replacement (Automatic 4L80-E).................... 7-506
Clean and Inspect (Engine Pinion
Mechanical - 6 .5 L )........................................ 6-643 Bearing Cup Installation
Clean and Inspect (Engine Front Drive A xle...............................................4-83
Mechanical - 7 .4 L )........................................ 6-878 Depth Adjustment
Disassemble (Engine Mechanical - 4.3L)........ 6-180 Front Drive A xle...............................................4-84
Disassemble (Engine Rear Drive Axle..............................................4-135
Mechanical - 5.0L, 5.7L)............................... 6-404 Installation
Disassemble (Engine Mechanical - 6.5L)........6-642 Front Drive A xle...............................................4-85
Disassemble (Engine Mechanical - 7.4L)........6-876 Rear Drive Axle..............................................4-139
Drive Installation (Engine Oil Seal Replacement
Mechanical - 6 .5 L )........................................ 6-668 Rear Drive Axle..................... 4-118, 4-121, 4-125
Drive Removal (Engine Mechanical - 6.5L) ....6-600 Pinion, Flange, and Dust Deflector
Drive Replacement (Engine Replacement
Mechanical - 6 .5 L )........................................ 6-496 Front Drive Shaft..............................................4-62
Installation (Engine Mechanical - 4.3L)........... 6-209 Pinion and Ring Gear Inspection
Installation (Engine Mechanical - 6.5L)........... 6-655 Rear Drive Axle..............................................4-134
Removal (Engine Mechanical - 4.3L).............. 6-134 Ring and Pinion Gear Inspection
Removal (Engine Mechanical - 6.5L)...............6-611 Front Drive A xle ...............................................4-82
Replacement (Engine Mechanical - 4.3L).......6-106 Piston and Connecting Rod Assemble
Replacement (Engine Mechanical - 6.5L).......6-578 (Engine Mechanical - 4.3L)............................... 6-161
Replacement (Engine Mechanical - 7.4L).......6-804 Piston and Connecting Rod Assemble
Oil Seal (Engine Mechanical - 6.5L)............................... 6-629
Oil Seal and/or Bearing Replaceme Piston and Connecting Rod Assemble
Rear Drive Axle.............................................. 4-113 (Engine Mechanical - 7.4L)............................... 6-861
16 INDEX
Piston Selection (Engine Mechanical - 4.3L)......6-160 Rear Drive Axle (cont.)
Piston Selection (Engine Mechanical - Specification
5.0L, 5.7L)........................................................... 6-388 GM SPO Group Numbers............................4-104
Piston Selection (Engine Mechanical - 6.5L)......6-629 Lubrication...................................................... 4-104
Piston Selection (Engine Mechanical - 7.4L)......6-860 Pinion Bearing and Differential
Powertrain Control Module Bearing Preload..............................................4-104
Connector End Views (6.5L)...........................6-2325 Specifications
Description Fastener Tightening.......................................4-103
General (6.5L)..............................................6-2658 Spacer and Shim ...........................................4-103
Replacement/Programming (6.5L).................. 6-2581 Rear Drive Axle - Locking/Limited Slip Rear Axle
Pressure Regulator Replacement Locking Differential Assemble........................... 4-179
(Automatic 4L80-E).............................................7-515 Rear Drive Axle - Locking/Limited Slip Rear Axle
Propeller Shaft Locking Differential Adjustment.........................4-178
Description.............................................................4-23 Locking Differential Cam Unit Assembly.........4-178
Center Bearing................................................. 4-26 Locking Differential Cam Unit Disassembly ....4-177
Phasing Description.........................................4-24 Locking Differential Cleaning and
Universal Joint.................................................. 4-25 Inspection....................................................... 4-178
Diagnosis Locking Differential Disassemble........ 4-170, 4-176
Knock or Clunk Noise........................................4-7 Special Tools...................................................... 4-180
Leak at Front Slip Yoke.................................... 4-6 Specification
Ping, Snap, or Click Noise............................... 4-6 Lubrication Specifications............................. 4-169
Roughness or Vibration.................................... 4-6 Reaction Block, 10 1/2 Inch Axle................ 4-169
Scraping Noise................................................... 4-7 Thrust Block Sizes (Locking)........................ 4-169
Shudder on Acceleration at Low Speed......... 4-7 Specifications
Squeak Noise..................................................... 4-7 Fastener Tightening.......................................4-169
Replacement...................................................4-8, 4-9 Rear Extension Housing Replacement
Special Tools......................................................... 4-27 Transfer Case..................................................... 4-281
Specifications Rear Suspension
Fastener Tightening............................................4-5 Component Locations...........................................3-94
GM SPO Group Numbers................................. 4-5 Description
Runout Specifications.........................................4-5 General Description........................................ 3-111
Proper Use of Torque Wrenches............................0-26 Specifications
Fastener Tightening.........................................3-93
GM SPO Group Numbers.............................. 3-93
Relieving Fuel Pressure................................................ 4
Q Reverse Servo Replacement
Quick Connect Fitting(s) Service (Automatic 4L80-E)............................................. 7-521
Metal Collar (4.3L)............................................6-1533 Road Test........................................................................ 4
Metal Collar (5.0L, 5.7L)................................. 6-2149
Metal Collar (7.4L)............................................ 6-3118
Plastic Collar (4.3L)..........................................6-1536
Plastic Collar (5.0L, 5 .7 L )............................... 6-2152
s
Plastic Collar (7.4L)..........................................6-3121 Safety Glasses and Compressed Air........................... 5
Safety Goggles and Fuel.............................................. 5
Schematic
Schematic Locations..........................................7-287
R Seat Belt
Radiator Child Seat Tether Outer Hardware K it............9J-39
Assembly Description.........................................6-986 Seat Belts
Filler Cap Assembly Description.......................6-987 Child Restraint Tether Anchor........................... 9J-40
Hose Replacement Description
(Engine Cooling)................... 6-949, 6-950, 6-951 System Operation........................................... 9J-46
Replacement (Engine Cooling).........................6-981 Emergency Locking Retractor Checks...............9J-2
Rear Drive Axle Front Seat Belt Height Adjuster
Description Replacement................................................... 9J-23
Rear Axle Description................................... 4-164 Front Seat Belt Replacement....... 9J-3, 9J-6, 9J-9,
Disassembled V ie w ............................................4-161 9J-11, 9J-14,
Rear Drive Axle 9J-17, 9J-20
Axle Housing Inspection.................................... 4-134 Intermediate Seat Belt Replacement................9J-25
Determining Total Shim Pack S ize.................. 4-138 Rear Seat Belt Replacement..... 9J-28, 9J-29, 9J-31,
Diagnosis 9J-33, 9J-35, 9J-37
Determining Type of Noise...........................4-106 Seat Belt Checks.................................................. 9J-2
Rear Axle Wheel Bearing W ear.................. 4-108 Seat Belt Service Precautions............................ 9J-2
Inspection Before Disassembly.........................4-129 Specifications
Special Tools....................................................... 4-166 Fastener Tightening......................................... 9J-1
INDEX 17
Secondary Air Injection SIR......................................................................... (cont.)

Description Inflatable Restraint Instrument Panel
System Description..................................... 6-2272 Inflator Module Replace.............................. 9J-130
Pump Replacement (5.0L, 5.7L).....................6-2221 Inflatable Restraint Sensing and
Pump Replacement (7.4L).............................. 6-3185 Diagnostic Module Replacement................9J-129
System Description (7.4L)............................... 6-3233 Inflatable Restraint Steering Wheel
System Diagnosis (5.0L, 5.7L)........................ 6-2113 Module Coil Replacement........................... 9J-134
Service Manual Inflatable Restraint Steering Wheel
Anti-Theft Labeling................................................0-17 Module Replacement.................. 9J-134
Description of Arrows andSymbols...................... 0-5 Inflator Module Handling, Shipping,
General Information and Scrapping.............................................. 9J-138
Fasteners.......................................................... 0-22 Repairs and Inspections Required
Thread Inserts.................................................. 0-26 After an Accident.........................................9J-136
How to Use the Paper Version............................. 0-4 Schematics
Introduction SIR Schematic Diagrams.............................. 9J-49
Tire Placard...................................................... 0-12 SIR Schematic Icons.....................................9J-49
RPO Code L is t..................................................... 0-17 SIR Schematic References........................... 9J-49
Service Parts ID Label.............................................0-17 SIR Component Locations................................ 9J-52
Shield Replacement SIR Component Views.......................................9J-53
Front Drive Axle.................................................... 4-54 SIR Connector End Views................... 9J-54, 9J-55
Transfer Case..................................................... 4-274 SIR Service Precautions................................. 9J-126
Shift Cable Special Tools.................................................... 9J-156
Adjustment (Automatic 4L60-E)........................7-166 Specifications
Adjustment (Automatic 4L80-E)........................7-499 Fastener Tightening.......................................9J-47
Replacement (Automatic 4L60-E).................... 7-163 GM SPO Group Numbers............................ 9J-48
Replacement (Automatic 4L80-E).................... 7-502 Scan Tool Data Definitions........................... 9J-48
Shift Cable Replacement Scan Tool Data L is t.......................................9J-47
Transfer C ase..................................................... 4-275 Wiring Repair.................................................... 9J-134
Shift Fork SIR Handling................................................................... 5
Replacement SIR Inflator Module Disposal........................................5
Front Drive A xle ............................................... 4-57 SIR Inflator Module Handling and Storage.................5
Shift Lever Replacement SIR Special Tool............................................................. 5
Transfer C ase..................................................... 4-276 Spare Tire
Shift Select Switch Replacement Carrier Replacement............................. 3-123, 3-124
Transfer C ase........................................4-294, 4-295 Spark Plug
Shims Inspection Replacement (Engine Electrical).....................6-1059
Rear Drive A xle .................................................. 4-134 Wire Harness Replacement
Shock Absorber (Engine Electrical)........................................6-1059
Replacement Special Tools
Front Suspension..................................3-83, 3-84 Clutch................................................................... 7-611
Rear Suspension.................................3-99, 3-100 Disc Brakes..........................................................5-121
ShopTowel Fuel L in k..................................................... 5 Engine Cooling................................................... 6-990
Single Cylinder Flooding................................................ 7 Front Drive A x le ................................................... 4-98
SIR.................................................................................... 5 Front Suspension................................................. 3-90
AIR BAG Warning Lamp Comes Hydraulic B rakes.................................................. 5-88
On Steady...................................................... 9J-63 Park Brake...........................................................5-162
AIR BAG Warning Lamp Replacement......... 9J-134 Propeller Shaft...................................................... 4-27
Description Rear Drive A xle.................................................. 4-166
Special Tools................................................ 9J-155 Rear Drive Axle - Locking/Limited
System Component Description Slip Rear A xle ................................................ 4-180
and Definitions.........................................9J-151 S IR ..................................................................... 9J-156
System Operation.........................................9J-150 Transfer Case..................................................... 4-305
Diagnosis Wheel Alignment.................................................. 3-33
AIR BAG Warning Lamp Does Not Wheel Drive Shafts..............................................4-47
Come O n.................................................... 9J-68 Special Tools Ordering Information...........................0-6
Intermittents and Poor Connections............ 9J-57 Specification
SDM Integrity Check......................................9J-61 Brake System
SIR Diagnostic System Check......................9J-58 Hydraulic Brakes................................................5-5
SIR General Diagnosis................................. 9J-57 Fastener Tightening
Disabling the SIR System............................... 9J-126 Front Drive A xle ...............................................4-49
Enabling the SIR System................................ 9J-127 Hydraulic Brakes................................................ 5-5
General Service Instructions........................... 9J-128 GM SPO Group Numbers
Inflatable Restraint Front End Front Drive A xle............................................... 4-49
Discriminating Sensor Replacement.......... 9J-131 Hydraulic Brakes................................................ 5-5
18 INDEX
Specification (cont.) Stabilizer Shaft (cont.)
Park Brake...................................................... 5-145 Replacement
Rear Drive Axle..............................................4-104
Lubrication
Front Drive A xle ...............................................4-49 Starter
Rear Drive Axle..............................................4-104 Motor Inspection
Pinion Bearing and Differential (Engine Electrical)........................6-1034, 6-1037
Bearing Preload Motor Overhaul
Rear Drive Axle.............................................4-104 (Engine Electrical)........................6-1023, 6-1026
Specifications Motor Replacement (Engine Electrical)......... 6-1022
4 .3 L ........................................................................ 6-25 Pinion Clearance Check
7 .4 L ...................................................................... 6-688 (Engine Electrical)........................................6-1038
Caliper Wear Shim Steering Knuckle
Disc Brakes...................................................... 5-89 Replacement
Component Front Suspension..................................3-57, 3-60
Drum Brakes................................................... 5-123 Stoplamp Switch
Components Description (Hydraulic Brakes)............................ 5-83
Disc Brakes...................................................... 5-89 Replacement (Hydraulic Brakes)........................ 5-81
Fastener Tightening Struts or Shock Absorbers
Automatic Transmission 4L60-E.........7-39, 7-40 Diagnosis
Disc Brakes...................................................... 5-89 Bench Test (Suspension)................................ 3-10
Drum Brakes................................................... 5-123 Struts or Shock Absorbers
Engine Cooling...............................................6-927 Diagnosis
Front Suspension.............................................3-35 Leak (Suspension)............................................. 3-9
Park Brake...................................................... 5-145 Noisy
Propeller Shaft.................................................... 4-5 (Suspension).................................................. 3-9
Rear Drive Axle..............................................4-103 Weak(Suspension).............................. 3-9
Rear Drive Axle - Locking/Limited Surge Tank
Slip Rear Axle............................................4-169 (Diesel) Replacement (Engine Cooling).......... 6-947
Rear Suspension..............................................3-93 Suspension
Seat Belts..........................................................9J-1 Diagnosis
Tires and W heels........................................... 3-113 Abnormal or Excessive Tire Wear..... 3-3, 3-4, 3-5
Wheel Alignment.............................................. 3-19 Excessive Road Shock......................................3-9
Wheel Drive Shafts , .........................................4-29 Front Wheel Shimmy.......................................3-10
GM SPO Group Number Hard Steering................................................... 3-10
Front Suspension.............................................3-35 Low or Uneven Trim Height........................... 3-15
GM SPO Group Numbers Noise In The Front End.....................................3-8
Tires and W heels........................................... 3-113 Noisy Front Suspension.....................................3-7
GM SPO Group Numbers Poor Directional Stability....................................3-7
Disc Brakes...................................................... 5-89 Tire Hop or Poor Handling............................... 3-8
Drum Brakes................................................... 5-123 Trim Height..........................................................3-5
Engine Cooling...............................................6-927 Vehicle Leads/Pulls............................................ 3-3
Propeller Shaft.................................................... 4-5 Wheel Bearings................................................ 3-11
Rear Suspension.............................................. 3-93 Wheel Tramp...................................................... 3-6
Wheel Alignment.............................................. 3-20
Runout Specifications
Propeller Shaft.................................................... 4-5 T
Sealers, Adhesives, and Lubricants TDC Offset Adjustment (6.5L)............................. 6-2636
4.3L....................................................................6-29 Thermostat
6.5L..................................................................6-461 Description...........................................................6-989
7.4L..................................................................6-692 Housing Crossover Replacement
Spacer and Shim (Engine Cooling)............................................. 6-967
Rear Drive Axle.............................................. 4-103 Replacement (Engine Cooling)............6-963, 6-965
Wheel Alignment....................................... 3-17, 3-18 Thread Repair (Engine Mechanical - 6.5L)......... 6-680
Spring Three-Piece Propeller Shaft Replacement............ 4-14
Bushing Replacement Throttle Body
Rear Suspension............................................3-101 Assembly Replacement (4.3L)........................6-1529
Leaf Spring Replacement Assembly Replacement (5.0L, 5 .7 L )............. 6-2143
Rear Suspension.................. 3-101, 3-103, 3-105 Assembly Replacement (7.4L)........................ 6-3113
Shackle Replacement Installation (Engine Mechanical - 4.3L)........... 6-217
Rear Suspension...............................3-107, 3-108 Installation (Engine Mechanical -
Stabilizer Shaft 5.0L, 5.7L)...................................................... 6-436
Link Bracket Replacement Installation (Engine Mechanical - 7.4L)........... 6-909
Rear Suspension.............................................. 3-98 Removal (Engine Mechanical - 4.3L).............. 6-129
INDEX 19
Throttle Body (cont.) Transcase Case (cont.)

Removal (Engine Mechanical - 5.0L,5.7L).... 6-356 DTC C0374.................................................... 4-259
Removal (Engine Mechanical - 7.4L).............6-828 DTC C0376.................................................... 4-260
Throttle Position DTC C0550.................................................... 4-262
Sensor Replacement (4.3L)............................6-1521 DTC C0611..................................................... 4-263
Sensor Replacement (5.0L, 5.7L).................. 6-2135 DTC C 895...................................................... 4-264
Sensor Replacement (7.4L)............................6-3104 Electronic Shift System................................. 4-222
Thrust Washers, Shims,and Adjuster Sleeves Front Axle.......................................................4-265,4-267
Front Drive Axle.................................................... 4-82 Functional Test............................................... 4-212
Timing Chain Functional Test Failed................................... 4-213
Wear Check (Engine Mechanical - 6.5L)........6-605 Indicator Lamps.............................................. 4-271
Tire Range/Mode Switch.......................................4-268
Chain Usage Description................................... 3-130 Shift Select
Hoist and Shaft Replacement..............3-126, 3-127 Buttons..... 4-214, 4-216, 4-217, 4-218, 4-219
Inflation Description............................................3-129 Slip in AWD M ode.........................................4-270
Mounting and Dismounting............................... 3-121 Transfer Case
Placard Description........................ 3-131 Clearing Memory................................................ 4-212
Repair................................................................... 3-121 Control Component Locations...........................4-190
Rotation................................................................3-122 Control Component V iew s..................... 4-193, 4-203
Tires and Wheels Control Connector EndViews............................4-205,4-206
Description Control Module Data Information......................4-304
All Seasons Tires Description.......................3-131 Control Module Description............................... 4-302
Aluminum W heels..........................................3-131 Data Memory Retention Check.........................4-302
Chain Usage................................................... 3-130 Description...........................................................4-299
General Description........................................3-129 Diagnosis
Inflation..... ......................................................3-129 System Diagnosis...........................................4-210
Metric Wheel Nuts and Bolts........................3-129 Transfer Case................................................. 4-222
P-Metric Sized Tires...................................... 3-131 Diagnostic Trouble Codes................................. 4-212
Replacement T ires.........................................3-130 Encoder Signal Check........................................4-303
Tire Placard.................................................... 3-131 Encoder Switch MonitorCheck.......................... 4-303
Wheel Repair.................................................. 3-131 Fluid Drain and Fill............................................. 4-274
Wheels.............................................................3-131 Mode Shifts..........................................................4-301
Diagnosis Motor and Relay Voltage Checks.....................4-303
Radial Tire Lead/Pull Correction...................3-115 Motor/Encode Circuit Operation........................4-303
Wheel Mounting Surface Check...................3-114 RAM/ROM Check............................................... 4-302
Specifications Range Shifts........................................................4-301
Fastener Tightening........................................3-113 Replacement..............................4-282, 4-285, 4-288
GM SPO Group Numbers............................. 3-113 Scan Tool Data Definitions............................... 4-304
Torque Converter Cover Replacement Schematic
(Automatic 4L60-E).............................................7-189 Control Schematic Diagrams........................4-182
Torque Wrenches Control Schematic Icons............................... 4-182
Proper Use.............................................................0-26 Control Schematic References.....................4-182
Torsion Bar Special Tools...................................................... 4-305
Bar and Support Assembly Replacement Specification
Front Suspension..................................3-77, 3-79 Fastener Tightening.......................................4-181
Transcase Case Fluid Capacities..............................................4-181
Diagnosis.............................................................4-220 System Descriptio..............................................4-300,4-301
4WD Does Not Disengage...........................4-220 Troubleshooting Hints.........................................4-209
4WD Does Not Engage................................ 4-220 Transmission
4WD Indicator................................................. 4-221 Replacement (Automatic 4L60-E).....................7-220
DTC B0768..................................................... 4-223 Replacement (Automatic 4L80-E).....................7-539
DTC B2725..................................................... 4-225 Transmission ID and Partial VIN Location............ 0-15
DTC C 0300.................................................... 4-228 Transmission Oil Cooler Replacement
DTC C 0305.................................................... 4-231 (Automatic 4L80-E).............................................7-533
DTC C 0308.................................................... 4-234 Tube Adapter
DTC C 0309.................................................... 4-236 Replacement (ABS)............................................5-259
DTC C 0310.................................................... 4-238 Turbocharger
DTC C 0315.................................................... 4-241 Description........................................................ 6-3251
DTC C 0323.................................................... 4-243 Diagnosis
DTC C 0324.................................................... 4-245 Blue Exhaust Smoke, Warm
DTC C 0327.................................................... 4-247 Engine O n ly ............................................. 6-3240
. DTC C 0357.................................................... 4-253 Lacks Power, Black Smoke at WOT......... 6-3240
DTC C 0362.................................................... 4-255 Lacks Power, No Black Smoke
DTC C 0367.................................................... 4-257 at WOT......................................................6-3240
20 INDEX
Turbocharger (cont.) Valve (cont.)
Noise..............................................................6-3240 Rocker Arm Cover Replacement
Turbocharger................................................6-3241 (Engine Mechanical - 7 .4 L ).......................... 6-733
Wastegate Actuator..................................... 6-3243 Valve Body (Automatic 4L60-E)............................ 7-195
Installation (Engine Mechanical - 6.5L)........... 6-668 Vehicle Certification Label.......................................0-11
Removal (Engine Mechanical - 6.5L).............. 6-598 Vehicle Control Module
Specifications Description
Fastener Tightening..................................... 6-3239 General (5.0L, 5.7L).................................... 6-2239
Turbocharger Replacement................................. 6-3244 General (7.4L)..............................................6-3204
Two-Piece Propeller Shaft Replacement............... 4-12 Description (4.3L).............................................6-1607
Diagnosis (4.3L)............................................... 6-1477
Replacement/Programming (4.3L).................. 6-1511
Universal Joints Replacement

u Replacement/Programming (5.0L, 5.7L)........ 6-2124
Replacement/Programming (7.4L)..................6-3096
Propeller Shaft........................................... 4-18, 4-20 Vehicle Identification................................................... 0-6
Vehicle Lifting.................................................................. 5
V Replacement (Automatic 4L60-E).....................7-219
Replacement (Automatic 4L80-E).....................7-513
Vacuum Booster Vehicle Speed Signal
Diagnosis (Hydraulic Brakes).............................. 5-41 Buffer Replacement (6.5L).............................. 6-2651
Vacuum Brake Vent Hose
Booster Hose Replacement Replacement
(Hydraulic Brake).............................................. 5-70 Front Drive A xle...............................................4-56
Booster Replacement (Hydraulic Brakes).......... 5-68 Rear Drive Axle..............................................4-126
Vacuum Brake Booster Vent Hose Replacement (Automatic 4L80-E)......7-534
Description (Hydraulic Brakes)............................5-84 Vibration
Vacuum Pump Balancing Tires and Wheels............................. 0-108
Diagnosis.......................................................... 6-3254 Correcting Driveline Vibration -
Specifications....................................................6-3253 RWD and 4 W D .............................................. 0-113
Vacuum Pump Replacement...............................6-3255 Correcting Non-Uniform Tires........................... 0-112
Valve Correcting Tire and Wheel Vibration............... 0-104
Lash Adjustment Description
(Engine Mechanical - 5.0L, 5.7L)................ 6-433 General Description........................................0-130
Lifter Installation Diagnosis...............................................................0-86
(Engine Mechanical - 4.3L).........................6-211 Classifying the Vibration................................. 0-89
Lifter Installation Driveline Vibration Analysis w/ EVA.............. 0-94
(Engine Mechanical- 5.0L, 5.7L).................. 6-430 Engine Related Vibration................................ 0-99
Lifter Installation Road Test..........................................................0-87
(Engine Mechanical - 6.5L).........................6-657 Tire and Wheel Vibration................................ 0-92
Lifter Installation Wheel Runout Measurement.......................... 0-92
(Engine Mechanical - 7.4L).........................6-904 General Service Precautions............................ 0-104
Lifter Removal (Engine Mechanical - 4.3L).....6-132 Special Tools...................................................... 0-142
Lifter Removal Specifications
(Engine Mechanical -5.0L, 5.7L)............... , 6-360 Vibration Diagnosis..........................................0-85
Lifter Removal (Engine Mechanical - 6.5L).....6-609 VIN
Lifter Removal (Engine Mechanical - 7.4L).....6-832 Engine ID and Partial VIN Location...................0-12
Lifter Replacement Transmission ID and Partial VIN Location....... 0-15
(Engine Mechanical - 4.3L)...........................6-72 VIN Derivative....................................................... 0-10
Lifter Replacement
(Engine Mechanical -5.0L, 5.7L).................. 6-294
Lifter Replacement
(Engine Mechanical - 6.5L).........................6-533 w
Lifter Replacement Wastegate Actuator (Turbocharger)....................6-3249
(Engine Mechanical - 7.4L).........................6-744 Wastegate Solenoid Replacement (6.5L).......... 6-2652
Rocker Arm Cover Removal Water-in-Fuel Sensor Replacement (6.5L)........ 6-2597
(Engine Mechanical - 4.3L).........................6-128 Water Pump
Rocker Arm Cover Removal Clean and Inspect
(Engine Mechanical - 6.5L).........................6-607 (Engine Mechanical - 4 .3L).......................... 6-195
Rocker Arm Cover Removal Clean and Inspect
(Engine Mechanical - 7.4L)..............6-826, 6-827 (Engine Mechanical - 5.0L, 5.7L).............. 6-416
Rocker Arm Cover Replacement Clean and Inspect
(Engine Mechanical - 4.3L).................. 6-64, 6-66 (Engine Mechanical - 7 .4L).......................... 6-891
Rocker Arm Cover Replacement Description...........................................................6-989
(Engine Mechanical - 6.5L)......................... 6-502 Installation (Engine Mechanical - 4.3L)........... 6-221
INDEX 21
Water Pump (cont.) Wheel Cylinder
Installation Replacement
(Engine Mechanical - 5.0L, 5.7L)................6-440 (Drum Brakes)...................... 5-137, 5-138, 5-141
Installation (Engine Mechanical - 6.5L)........... 6-666 Wheel Drive Shafts
Installation (Engine Mechanical - 7.4L)........... 6-914 Boot Cover Replacement.................................... 4-42
Removal (Engine Mechanical - 4.3L).............. 6-126 Special Tools.........................................................4-47
Removal (Engine Mechanical - 5.0L, 5.7L).....6-353 Specifications
Removal (Engine Mechanical - 6.5L).............. 6-601 Fastener Tightening.........................................4-29
Removal (Engine Mechanical - 7.4L).............. 6-825 Wheel Hub
Replacement (Engine Cooling)..............6-968, 6-971 Bolt Replacement
Wheel Front Suspension....................... 3-43, 3-44, 3-45
Installation Wheel Hub, Bearing, Knuckle,
Tires and W heels...........................................3-120 and Seal Replacement
Removal Front Suspension............................3-72, 3-74, 3-76
Tires and W heels................................3-118, 3-119 Wheels
Wheel Alignment Aluminum Wheels Description..........................3-131
Description Description...........................................................3-131
General Description................................ 3-30, 3-31 Repair Description.............................................. 3-131
Diagnosis Wheel Speed Sensor
Preliminary Alignment Inspection.......... 3-21, 3-22 Replacement (ABS).................. 5-254, 5-255, 5-256
Frame Bracket Knock Out Removal........3-25, 3-27 Wheel Stud
Special Tools......................................................... 3-33 Replacement
Specifications............................................... 3-17, 3-18 Rear Suspension...............................3-109, 3-110
Fastener Tightening..........................................3-19 Window Removal............................................................ 5
GM SPO GroupNumbers................................ 3-20 Window Retention........................................................... 6
Wheel Bearing Adjustment Wiring Harness
Front Suspension........................................ 3-81, 3-82 Assembly Removal
Rear Drive A xle .......................................4-158, 4-159 (Engine Mechanical - 6 .5 L )..........................6-596
Wheel Bolt Work Sheets, Diagnostic............................................0-6
Replacement Work Stall Test................................................................ 6
Rear Suspension............................................3-101
22 INDEX
BLANK

1998 Gmt-98 Ck-1 Service Manual-Volume 1 of 4

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BM

S ervice in fo rm a tio n p rovided by General M otors C orporation is intended fo r use by

• S u b -S e ctio n 9J - S u p p le m e n ta l In fla ta b le R e s tra in ts , re fe r to CAUTIONS u nd e r

Volum e 1 Volum e 2 Volum e 3

NORTH AMERICAN OPERATIONS

©1997 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

When calling, be prepared with the following information:

United States and Canada General Motors Dealer Employees

Canada, French Speaking General Motors Dealer Employees

International English Speaking General Motors Dealer Employees

United States and Canadian Vehicle Owner/Operator

Cautions and Notices ............................................3 SIR Inflator Module Disposal Caution.................5

Cautions and Notices

Window Retention Caution locking compound or sealant are identified in the

Nylon Fuel Lines Notice Single Cylinder Flooding Notice

General Inform ation ............................................0-3 M aintenance........................................................ 0-45

in 25.4 mm mph 1.6093 km/h

mi 1.609 km *F = 9/5( * C+32)

AREA FUEL PERFORMANCE

645.2 sq mm 235.215/mpg = L/100 km

qt 0.9464 L 3/64 0.046875 1.19062

kg 9.807 11/64 0.171875 4.36562

hp 0.745 kW 21/64 0.328125 8.33437

PRESSURE (STRESS) 11/32 0.34375 8.73125

inches of H 20 0.2491 23/64 0.359375 9.12812

ENERGY (WORK) 25/64 0.390625 9.92187

Btu 1055.0 13/32 0.40625 10.31875

lb ft 1.3558 J (J= one Ws) 27/64 0.421875 10.71562

Special Tools Ordering Information

C/K Model Identification

C105 (16) 5.7L V8 (L31) — 4 Spd. Auto. (M30) —

Model Codes: C-Rear Wheel Drive

Position Definition Character Description

A VIN derivative can be used to determine if a

VIN Derivative Position Equivalent VIN Position

The vehicle certification label displays the following

Tire Placard Engine ID and VIN Derivative Location

(1) Specified Occupant Seating Positions

The Tire Placard is permanently located on the edge

The engine unit number or date code is either laser

The transmission model identification is located on a

RPO Code List

How to Obtain Replacement Labels Fasteners

Prevailing Torque Fasteners A prevailing torque nut is designed to develop an

4. Thread the thread insert onto the mandrel of

Tapered Beam Model Torque Wrench Click-type Torque Wrench

Abbreviation M eaning BP Back Pressure

A BPM Brake Pressure Modulator

A Ampere(s) BPP Brake Pedal Position

ABS Antilock Brake System BRN Brown

A/C Air Conditioning BTDC Before Top Dead Center

AC Alternating Current BTSI Brake Transmission Shift Interlock

ACC Accessory, Automatic Climate Control Btu British thermal units

ACL Air Cleaner C

ACR4 Air Conditioning Refrigerant, Recovery, •c Degrees Celsius

A bbreviations Table (cont’d) A bbreviations Table (cont’d)

CRTC Cathode Ray Tube Controller EEVIR Evaporator Equalized Values

E FEDS Fuel Enable Data Stream

EBCM Electronic Brake Control Module FF Flexible Fuel

mi 1.609 km F = 9/5( C+32)

The temperature of the air coming from the air distri