GMC Yukon 1999 Denali 4WD 6.5L DSL Turbo Workshop Manual

gmc :: GMC Truck K Yukon/Denali 4WD V8-6.5L
DSL Turbo VIN S (1999)

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Accessory Delay Module: Diagram Information and Instructions

Electrical Schematics

IMPORTANT: 4-foot

The schematic does not represent the components and wiring as they physically appear on the vehicle. For example, a length ofwire is treated no differently in a schematic from one which is only a few inches long.

When diagnosing a horn problem use the service information located in the Horns service category. The following schematic is a typical example of aschematic with its supporting text.

Component Location Views

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The wiring schematic is the cornerstone of electrical diagnosis. Schematics break the entire electrical system into individual circuits, showing theelectrical current paths when a circuit is operating properly. Wiring which is not part of the circuit of interest is referenced to another page where thecircuit is shown complete. Schematics use a top (power) to bottom (ground) sequence to present electrical information.

RH Front Corner Of Vehicle

Component location views are line illustrations that indicate all of the vehicle's electrical components within each electrical system.

Connector End Views

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RH Horn A Note

Connector end views show the cavity or terminal locations for all the related 2-pin or larger connectors shown in the system schematic(s). The drawingsshow the connector's face as seen after the harness connector has been disconnected from a component or mating connector. Unused cavities are leftblank in the table.

In addition, the color and part number of the connector body is provided along with the family/series name. Below is an example of a typical connectorend view.

Diagnostic System Checks

Misdiagnosis could occur if the diagnostic system check is not performed before using the diagnostic tables.IMPORTANT:

Diagnostic Tables

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The diagnostic system check determines the diagnostic trouble codes (DTCs) present, verifies proper communication, and navigates to the appropriatediagnostic table.

Horns Inoperative (Part 1 Of 2)

Horns Inoperative (Part 2 Of 2)

Diagnostic tables provide a procedure that will help you locate the condition in a circuit that is causing a malfunction. All diagnostic procedures aresymptom based, to assist you in locating the condition as fast as possible. Diagnostic tables should exist for all possible (realistic) symptoms anddiagnostic trouble codes .(DTCs)

Circuit Descriptions

The circuit description describes how the system works electrically. It details how power, ground, inputs, and outputs are supplied to the system's relatedcomponents. The circuit description also explains the communication and interaction of all components that affect the operation of the system.

Battery positive voltage is applied at all times to the horn relay terminals 85 and 30. Pressing the horn switch grounds the horn relay coil on CKT 28(BLK). The relay coil can also be grounded on CKT 28 (BLK) by the Dash Integration Module (DIM). The horn relay applies battery positive voltage tothe horns on CKT 29 (DK GRN) when energized. The horns sound until the horn switch is released or the DIM signal is gone.

Truck Zoning

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Truck Zoning

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All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle.The following table explains the numbering system.

Electrical Symbols

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Electrical Symbols (Part 1 Of 4)

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Electrical Symbols (Part 2 Of 4)

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Electrical Symbols (Part 3 Of 4)

Electrical Symbols (Part 4 Of 4)

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Accessory Delay Module: Diagnostic Aids

Basic Knowledge Required

Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity andknow the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shortedwire. You should be able to read and understand a wiring diagram.

Refer to in General Information in order to properly diagnose and repair the customer concern.Strategy Based Diagnosis

Checking Aftermarket Accessories

Do not connect aftermarket accessories into the following circuits:

CAUTION: Refer to SIR Service Precautions Caution in Cautions and Notices.

- SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.

Refer to in Cautions and Notices.NOTE: OBDII Symbol Description Notice

- OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol.

Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect thesystem to verify that these add-on accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:

- Power feeds connected to points other than the battery.

- Antenna location.

- Transceiver wiring located too close to vehicle electronic modules or wiring.

- Poor shielding or poor connectors on antenna feed line.

- Check for recent service bulletins detailing installation guidelines for aftermarket accessories.

Intermittents and Poor Connections Diagnosis

Most intermittents are caused by faulty electrical connections or wiring. Inspect for the following items:

- Wiring broken inside the insulation.

­Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specificprocedure.

­Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire theinsulation rather than the wire itself and corrosion in the wire to terminal contact area, etc.

- Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle.

-

Symptom Diagnostic Example

The following is an example of a symptom and the correct course of action taken by the technician.

IMPORTANT:

Research for possible bulletins, DTCs and the vehicle's service history. Also, thoroughly screen the customer regarding the problem inorder to complete the repair of the vehicle and completely satisfy the customer when a DTC or a symptom diagnosis is not available.

Verify the Customer Concern, Check the Problem

Customer complaint is the headlamps are inoperative. Verify the normal operating procedure of the circuit and the components that share thatcircuit. Refer to Strategy Based Diagnosis.

Review the Headlamps Electrical Schematic (Preliminary Checks)

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Electrical Intermittents

Refer to Testing for See: Diagrams/Diagnostic Aids for test procedures to detect intermittent open, high resistance, shortto ground, and short to voltage conditions.

Review the schematic, it is essential to understand how a circuit should work before trying to figure out why it doesn't. After understanding how acircuit should operate, read the schematic again, this time keeping in mind what has been learned by operating the circuit. Since both the low beamheadlamps are inoperative, ensure that the following components are operating properly.-

The headlamp Switch.

- The YEL wire.

- Low contacts of the Headlamp Dimmer Switch.

- C100 terminal 1E.

- The TAN wires.

- Grounds G105 and G109.

Refer to .Strategy Based Diagnosis

Perform the System Check

The system check indicates that the low beam headlamps operate when the high beam switch is in high. Also, the high beam indicator illuminatesbut neither high beam headlamp operates. Refer to .Strategy Based Diagnosis

Utilizing a combination of Techline tools and the information accumulated from the Preliminary Checks, check for bulletins.Check for Bulletins

Isolate the Root Cause

At this point analyze and (diagnose the problem), and develop text. Since the high beam indicator illuminated when the headlamp dimmer switchwas in the high position, the high contacts of the headlamp dimmer switch and the LT GRN wire between the headlamp dimmer switch and C100are good. At this point, it is extremely unlikely that the high beam filaments in the RH and LH headlamps are both open or that both headlampconnections are bad. The cause must be a bad connection at C100 or an open in the LT GRN wire between C100 and the RH headlamp.

Repair and Verify Fix

From isolating the root cause, basically the problem has been diagnosed. Using the Component Location Table and the corresponding figure,quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair.

Check the thoroughness of the repair by performing a final system check on the headlamp circuit. This of course means making sure that both highbeams, both low beams, and the high beam indicator are working.

Testing For Electrical Intermittents

6 inches

Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about apart) while watchingthe test equipment.

- Testing for Short to Ground

- Testing for Continuity

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If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate thecircuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected.

IMPORTANT:

The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltagewhile recording the minimum (MIN), and maximum (MAX) values measured.

1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to

Troubleshooting with a Digital Multimeter

See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Digital Multimeterforinformation on connecting the J 39200 to the circuit.

2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position.3. Press the range button of the J 39200 in order to select the desired voltage range.4. Press the MIN MAX button of the J 39200. The J 39200 displays RECORD and emits an audible tone (beep).100 ms
The RECORD mode is the length of time an input must stay at a new value in order to record the full change.IMPORTANT: 100 ms

5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or
performing other operations.

6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded.7. Press the MIN MAX button once in order to display the MAX value and note the value.8. Press the MIN MAX button again in order to display the MIN value and note the value.9. Determine the difference between the MIN and MAX values.

-

1 volt

If the variation between the recorded MIN and MAX voltage values is or greater an intermittent open or high resistance condition exists.Repair the condition as necessary.

-

1 volt

If the variation between the recorded MIN and MAX voltage values is less than an intermittent open or high resistance condition doesnot exist.

Testing For Proper Terminal Contact

It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must beinspected to ensure good terminal contact. A poor connection between the make and female terminal at a connector may be the result of contamination ordeformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connectoritself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit orintermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, orrepeatedly separating and joining the connector halves.
Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Round Wire Connectors

Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to J 38125-B Terminal Repair Kit or the J 38125-4Instruction Manual for terminal identification.

Follow the procedure below in order to test terminal contact.1. Separate the connector halves.2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or

between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector thatshows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a

suspect terminal. Replace the female terminal in question.

There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side.Flat Wire (Dock and Lock) Connectors

Follow the procedure below in order to test terminal contact.1. Remove the component in question.2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may

be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal

contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter kit on the flat wire harness connector in order to test the circuit in

question.

Measuring Voltage

Refer to in Cautions and Notices.NOTE: Test Probe Notice

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The following procedure measures the voltage at a selected point in a circuit.

1. Apply power to the circuit.2. Set the rotary dial of the DMM into the V (AC) or V (DC) position.3. Connect the positive lead of the DMM to the point of the circuit to be tested.4. Connect the negative lead of the DMM to a good ground.5. Operate the circuit.6. The DMM displays the voltage measured at that point.

Measuring Voltage Drop

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedure determines the difference in voltage potential between two points.

1. Set the rotary dial of the DMM to the V (DC) position.2. Connect the positive lead of the DMM to one point of the circuit to be tested.3. Connect the negative lead of the DMM to the other point of the circuit.4. Operate the circuit.5. The DMM displays the difference in voltage between the two points.

Testing For Continuity

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedures verify good continuity in a circuit.

With a DMM

1. Set the rotary dial of the DMM to the Ohm position.2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit.3. Disconnect the load.4. Press the MIN MAX button on the DMM.5. Connect one lead of the DMM to one end of the circuit to be tested.6. Connect the other lead of the DMM to the other end of the circuit.7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity.

With a Test Lamp

Only use the test lamp procedure on low impedance power and ground circuits.IMPORTANT:

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Connect one lead of the test lamp to one end of the circuit to be tested.4. Connect the other lead of the test lamp to battery positive voltage.5. Connect the other end of the circuit to ground.6. If the test lamp illuminates (full intensity), then the circuit has good continuity.

Testing For Short to Ground

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedures test for a short to ground in a circuit.

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With a DMM

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Set the rotary dial of the DMM to the Ohm position.4. Connect one lead of the DMM to one end of the circuit to be tested.5. Connect the other lead of the DMM to a good ground.6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.

With a Test Lamp

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Connect one lead of the test lamp to battery positive voltage.

4. Connect the other lead of the test lamp to one end of the circuit to be tested.5. If the test lamp illuminates, there is a short to ground in the circuit.

Fuse Powering Several Loads

1. Review the system schematic and locate the fuse that is open.2. Open the first connector or switch leading from the fuse to each load.3. Connect a DMM across the fuse terminals (be sure that the fuse is powered).

- When the DMM displays voltage the short is in the wiring leading to the first connector or switch.

- If the DMM does not display voltage refer to the next step.

4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted.

Digital Multimeter

Refer to in Cautions and Notices.NOTE: Test Probe Notice

IMPORTANT: 10 megohm

Circuits which include any solid state control modules, such as the PCM, should only be tested with a or higher impedancedigital multimeter such as the J 39200.

The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand forfuture reference.

A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present,a DMM indicates how much voltage is present.

The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means goodcontinuity.

IMPORTANT:

Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMsapply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading.

Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take areading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Followingare examples of the various methods of connecting the DMM to the circuit to be tested:

-

- Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses.

­If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuitor for testing multiple circuits quickly.

Short Finder

The J 8681-A can locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows the location of theshort through the body trim or sheet metal.

Test Lamp

Refer to in Cautions and Notices.NOTE: Test Probe Notice

A test lamp can simply and quickly test a low impedance circuit for voltage.

The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a light bulb with an attached pair of leads.12 volt

To properly operate this tool use the following procedure.

1. Attach one lead to ground.2. Touch the other lead to various points along the circuit where voltage should be present.3. When the bulb illuminates, there is voltage at the point being tested.

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Probing Electrical Connectors.

Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness forcontinuous monitoring while you perform other operations or test driving. Refer to See: General ElectricalDiagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors

Probing Electrical Connectors

IMPORTANT: (CPA) (TPA)

Always be sure to reinstall the Connector Position Assurance and Terminal Position Assurance when reconnectingconnectors or replacing terminals.

Disconnect the connector and probe the terminals from the mating side (front) of the connector.Frontprobe

NOTE:

Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform mostterminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector TestAdapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they candamage terminals and cause incorrect measurements.

Do not disconnect the connector and probe the terminals from the harness side (back) of the connector.Backprobe

-IMPORTANT:

Backprobe connector terminals only when specifically required in diagnostic procedures.

-

Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire(dock and lock) connector.

-

Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the testprobe too far into the cavity or by using too large of a test probe.

- After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact.

Fused Jumper Wires

A fused jumper may not protect solid state components from being damaged.IMPORTANT:

The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire issupplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit beingtested.

Using Connector Test Adapters

NOTE:

Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. Adeformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and causeincorrect measurements.

Fuses

Circuit Protection - Fuses

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Fuse Types

The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a

circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time thecircuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken,also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equalcurrent rating.

Circuit Breakers

A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a shortor other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuitbreakers are used.

Circuit Breaker:

This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause ofthe high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high currentis removed.

Positive Temperature Coefficient (PTC) Circuit Breaker:

This type greatly increases its resistance when excessive current passes through it. Theexcessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectivelyopen. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once thevoltage is removed the circuit breaker will re-close within a second or two.

Fusible Links

Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter orelectrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. Ifbroken, it must be replaced with fusible link of the same gage size.

Repairing a Fusible Link

Fusible links cut longer than will not provide sufficient overload protection.IMPORTANT: 225 mm (approx. 9 inches)

Refer to . See: Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice ClipsSplicing Copper Wire Using Splice Clips

Repairing Damaged Wire Insulation

Wire Size Conversion Table

Splicing Copper Wire Using Splice Clips

If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace thefaulty segment of the wire. Refer to See: Wiring Repairs/Typical Electrical Repairs/Splicing Copper WireUsing Splice Clips and follow the instruction to repair the wire.

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Splicing Copper Wire Using Splice Clips
TOOLS REQUIRED

J 38125-B Terminal Repair kit

1. Open the harness.

- If the harness is taped, remove the tape.

- To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

- If the harness has a black plastic conduit, pull out the desired wire.

2. Cut the wire.

- Cut as little wire off the harness as possible.

-

Ensure that each splice is at least away from other splices, harness branches and connectors. This helps prevent moisture from40 mm (1.5 in)

bridging adjacent splices and causing damage.

3. Select the proper size and type of wire.

- The wire must be of equal or greater size than the original (except fusible link).

- The wire's insulation must have the same or higher temperature rating.

- Use general purpose insulation for areas that are not subject to high temperatures.

- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.

Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.IMPORTANT:

Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.

4. Strip the insulation.

- Select the correct size opening in the wire stripper or work down from the largest size.

-

Strip approximately of insulation from each wire to be spliced.7.5 mm (5/16 inches)

5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B Terminal Repair Kit in order to determine the proper clip size
crimp tool and anvil.

6. Overlap the two stripped wire ends and hold them between thumb and forefinger.7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.

- Ensure that the wires extend beyond the clip in each direction.

- Ensure that no insulation is caught under the clip.

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8. Center the crimp tool over the splice clip and wires.9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut.

10. Crimp the splice on each end (2).

11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment.

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12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires.

13. Additional tape can be applied to the wire it the wire does not belong in a conduit or another harness covering. Use a winding motion in order to
cover the first piece of tape.

Splicing Copper Wire Using Splice Sleeves

Crimp And Seal Splice Table

Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzeland coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp andseal splice sleeves.

TOOLS REQUIRED

J 38125-B Terminal Repair Kit

1. Open the harness.

- If the harness is taped, remove the tape.

- To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

- If the harness has a black plastic conduit, pull out the desired wire.

2. Cut the wire.

- Cut as little wire off the harness as possible.

-

40 mm (1.5 in)

Ensure that each splice is at least away from other splices, harness branches and connectors. This helps prevent moisture frombridging adjacent splices and causing damage.

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3. Select the proper size and type of wire.

- The wire must be of equal or greater size than the original.

-

The wire's insulation must have the same or higher temperature rating (4).-

Use general purpose insulation for areas that are not subject to high temperatures.

- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.

Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.IMPORTANT:

Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.

4. Strip the insulation.

- Select the correct size opening in the wire stripper or work down from the largest size.

-

Strip approximately of insulation from each wire to be spliced (1).7.5 mm (5/16 inches)

5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table.6. Place the nest tool in the J 38125 crimp tool.7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice.8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest.9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent
the wire from passing through the splice (3).

10. Close the handles of the J 38125 until the crimper handles open when released. The crimper handles will not open until the proper amount of
pressure is applied to the splice sleeve.

11. Shrink the insulation around the splice.

- Using the heat torch apply heat to the crimped area of the barrel.

-

Gradually move the heat barrel to the open end of the tubing.-

The tubing will shrink completely as the heat is moved along the insulation.

- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Splicing Twisted or Shielded Cable

Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio andthe Delco-Bose speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in orderto repair the twisted/shielded cable.

1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape.2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made.

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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by is recommended.65 mm

4. Re-assemble the cable.

- Rewrap the conductors with the MYLAR tape.

- Use caution not to wrap the drain wire in the tape (1).

- Follow the splicing instructions for copper wire and splice the drain wire.

- Wrap the drain wire around the conductors and tape with MYLAR tape.

Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire.IMPORTANT:

5. Tape over the entire cable. Use a winding motion when you apply the tape.

Splicing Inline Harness Diodes

Many vehicle electrical Systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use thefollowing procedure.

1. Open the harness.

- If the harness is taped, remove the tape.

- To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

- If the harness has a black plastic conduit, pull out the diode.

2. If the diode is taped to the harness, remove all of the tape.3. Check and record the current flow direction and orientation of diode.4. Remove the inoperative diode from the harness with a suitable soldering tool.

IMPORTANT:

If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the solderingtool.

5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the
new diode.

6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.

7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment.

8. Reinstall terminal(s) into the connector body if previously removed .9. Tape the diode to the harness or connector using electrical tape.

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To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape.IMPORTANT:

H02S Wiring Repairs

Do not solder repairs under any circumstances as this could result in the air reference being obstructed.NOTE:

If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt torepair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference isobtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction ofthe air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:

­Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poorperformance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a

path for foreign materials to enter the sensor and cause performance problems.

­Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through thelead wire.

­Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground asthe only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance.

- To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector.

The engine harness may be repaired using the J 38125-B.

General Information

(SIR)

The Supplemental Inflatable Restraint system requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow thespecific procedures and instructions when working with the SIR system wiring, and the wiring components (such as connectors and terminals).

IMPORTANT:

Do not use the terminals in the kit in order to replace damaged SIR system terminals unless specifically indicated by the terminalpackage.

TOOLS REQUIRED

J 38125-B Terminal Repair Kit
The tool kit J 38125-B contains the following items:

- Special sealed splices - in order to repair the SIR system wiring

- A wire stripping tool

- A special crimping tool

- A heat torch

- An instruction manual

The sealed splices have the following 2 critical features:

- A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.

- A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits.

The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items:

- A large sampling of common GM electrical terminals

- The correct tools in order to attach the terminals to the wires

- The correct tools in order to remove the terminals from the connectors

Sir Connector (Plastic Body and Terminal Metal Pin) Repair

Use the connector repair assembly packs in order to repair the damaged SIR wire harness connectors and the terminals. Do not use the connector repairassembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice thenew wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You mustuse the splice crimping tool in order to apply these splices.

The terminals in the SIR system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits.These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs.

If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order toreplace the SDM harness connector:

- The SDM harness connector pigtail assembly

- The SDM harness connector replacement kit

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If the individual terminals are damaged on any other SIR connection, use the appropriate connector repair assembly pack in order to replace the entireconnection. Replace the entire SIR wiring harness, if needed, in order to maintain SIR circuit integrity.

Sir Wire Pigtail Repair

IMPORTANT:

Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly tothe device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steeringwheel module coil is an example of a pigtail component.

Sir Wire Repair
TOOLS REQUIRED

J 38125-B Terminal Repair Kit

IMPORTANT

: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information inorder to ensure circuit integrity.

(0.5 mm, 0.8 mm, 1.0 mm etc.)

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size .Use the sealed splices and splice crimping tool from the J 38125-B. Use the following wiring repair procedures in order 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 obtaina clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

- Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage.

- Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.

- Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least away from the other splices, harness branches, or connectors.40 mm (1.5 in)

3. Strip the insulation:

- When adding a length of wire to the existing harness, use the same size wire as the original wire.

-

Perform one of the following items in order to find the correct wire size:-

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 stripper and work down until achieving a clean strip of theinsulation.

-

Strip approximately of insulation from each wire to be spliced.7.5 mm (0.313 in)

- Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.

- If the wire is damaged, repeat this procedure after removing the damaged section.

4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of
the splice sleeves and the crimp tool nests.

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5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool.

6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the
middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold thesplice sleeve in the proper nest.

7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.8. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end ofthe splice.

9. Using the heat torch, apply heat to the crimped area of the barrel.

10. Gradually move the heat barrel to the open end of the tubing:

- The tubing will shrink completely as the heat is moved along the insulation.

- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Sir System Wire Splice Repair

Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR wiringharness. Carefully follow the instructions included in the kit for proper splice clip application.

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Connector Position Assurance (CPA)

(CPA)

The Connector Position Assurance is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPAensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR matingterminals.

Terminal Position Assurance (TPA)

(TPA)

The Terminal Position Assurance insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securelyseated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement.

Flat Wire Repairs

NOTE:

The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harnessmust be replaced.

Connector Position Assurance Locks

(CPA)

The Connector Position Assurance is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPAensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR matingterminals.

Terminal Position Assurance Locks

(TPA)

The Terminal Position Assurance insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securelyseated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement.

Push to Seat Connectors
TERMINAL REMOVAL

Follow the steps below in order to repair push to seat connectors.

(TPA) (CPA)

1. Remove the Terminal Position Assurance device, the Connector Position Assurance device, and/or the secondary lock.2. Separate the connector halves (1).

3. Use the proper pick or removal tool (1) in order to release the terminal.4. Gently pull the cable and the terminal (2) out of the back of the connector.

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5. Re-form the locking device it you are going to reuse the terminal (1).6. To repair the terminal, refer to .Terminal Repair

TERMINAL REPAIR

5 mm (3/16 in)

1. Slip the cable seal away from the terminal.2. Cut the wire as close to the terminal as possible.3. Slip a new cable seal onto the wire.4. Strip of insulation from the wire.5. Crimp a new terminal to the wire.6. Solder the crimp with rosin core solder.7. Slide the cable seal toward the terminal.8. Crimp the cable seal and the insulation.9. If the connector is outside of the passenger compartment, apply grease to the connector.

REINSTALLING TERMINAL

Wiring Repairs.

1. In order to reuse a terminal or lead assembly. Refer to See: Diagrams/Diagnostic Aids2. Ensure that the cable seal is kept on the terminal side of the splice.3. Insert the lead from the back until it catches.4. Install the TPA, CPA and/or the secondary locks.

Pull to Seat Connectors
TERMINAL REMOVAL

Follow the steps below in order to repair pull-to-seat connectors.

TERMINAL REPAIR

5 mm (3/16 in)

1. Slip the cable seal away from the terminal.2. Cut the wire as close to the terminal as possible.3. Slip a new cable seal onto the wire.4. Strip of insulation from the wire.5. Crimp a new terminal to the wire.6. Solder the crimp with rosin core solder.7. Slide the cable seal toward the terminal.8. Crimp the cable seal and the insulation.9. If the connector is outside of the passenger compartment, apply grease to the connector.

TERMINAL INSTALLATION

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(TPA) (CPA)

1. Remove the Terminal Position Assurance device, the Connector Position Assurance device, and/or the secondary lock.2. Separate the connector halves.3. Using the proper pick or removal tool (4) insert into the front of the connector body.4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3).5. Inspect the terminal for damage, if damaged refer to 6. Reform the locking tang (2) if the terminal is being reused.Terminal Repair.

Terminal Repair.

1. Inspect the terminal for damage. If damaged refer to 2. Reform the locking tang (2) if the terminal is being reused.3. Ensure that the cable seal is kept on the terminal side of the splice.4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body.5. Install the TPA, CPA and/or the secondary locks.

Weather Pack Connectors

The following is the proper procedure for the repair of Weather Pack(R) Connectors.

- Separate the connector halves (1).

- Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1).

- Grasp the wire and push the terminal to the forward most position. Hold the wire in this position.

- Insert the Weather Pack terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1).

- Gently pull on the wire to remove the terminal through the back of the connector (2).

Never use force to remove a terminal from a connector.IMPORTANT:

-

Repairing Connector Terminals.

Inspect the terminal and connector for damage. Repair as necessary. Refer to See: ConnectorRepairs/Repairing Connector Terminals

- Reform the lock tang (2) and reset terminal in connector body.

- Close secondary locks and join connector halves.

- Verify that circuit is complete and working satisfactorily.

- Perform system check.

Repairing Connector Terminals

Use the following repair procedures in order to repair the following:

- Push to Seat terminals

- Pull to Seat terminals

- Weather Pack(R) terminals

Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B TerminalRepair kit contains further information.

1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal.2. Apply the correct seal per gauge size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation
removal.

3. Remove the insulation.4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation.5. Position the strip in the terminal.
For Weather Pack(R) terminals, position the strip and seal in the terminal.

6. Hand crimp the core wings.7. Hand crimp the insulation wings.
For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable.

8. Solder all of the hand crimp terminals.

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Retained Accessory Power (RAP) Schematics (BCM And Fuses)

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Accessory Delay Module: Description and Operation

(RAP) (BCM)

The Retained Accessory Power system is a subsystem of the Body Control Module . It is designed to provide power to the followingaccessories when the ignition is in the Run or Accessory position and up to of power when the ignition is cycled to the Off position.10 minutes

^ Power Windows Circuit
^ Rear Window Wiper Circuit
^ Front Windshield Wipers Circuit
^ Radio Circuit
^ Courtesy Lamp Circuit

10 minutes

All components in the circuits powered by the RAP system will be enabled when the Ignition Switch is in the Accessory or Run position. Once theIgnition Switch is turned to the Off position, and all doors remain closed, the components in these circuits will remain enabled for . Once anyof the doors open, the timer is cancelled and power to these components is disabled.10 minute

In addition, anytime the the doors are opened, and remain opened while the Ignition Switch is in the Run position, the courtesy lights will come on for then turn off. The same holds true for the Glove Compartment Light when the Ignition Switch is in the Off position.10minutes

Power is supplied to the RAP System through CKT 342 (RED), from the IGN B fuse #5. Power is then sent out of the Body Control Module throughCKT 75 (DK BLU) to the I/P fuse block to power the PWR WDO CIRCUIT BREAKER; RR WIPER fuse #23; WIPER fuse #11; and RADIO fuse #17.Control for the courtesy lamp feed runs through CKT 40 (ORN) from the Body Control Module and returns to the Body Control Module through CKT157 (GRA), courtesy lamp return. Driver Door Jamb teed for the RAP System runs through CKT 159 (TAN) to the Body Control Module as does thePassenger Door Jamb feed runs through CKT 328 (PPL) to the Body Control Module. The ignition switch feed for the RAP system comes fromGAUGES fuse #4 and runs through CKT 39 (PNK). Ground for the RAP system runs through CKT 150 (BLK) to ground G202.

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RAP Inoperative

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RAP System Check

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Theft Deterrent Module Replacement

Alarm Module: LocationsTheft Deterrent Module Replacement
EVO/PASSLOCK MODULE

Locations View

The EVO/Passlock Module is located behind the RH side of Instrument Panel , under IP auxiliary storage compartment.(IP)

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Alarm Module: Diagram Information and Instructions

Electrical Schematics

IMPORTANT: 4-foot

The schematic does not represent the components and wiring as they physically appear on the vehicle. For example, a length ofwire is treated no differently in a schematic from one which is only a few inches long.

When diagnosing a horn problem use the service information located in the Horns service category. The following schematic is a typical example of aschematic with its supporting text.

The wiring schematic is the cornerstone of electrical diagnosis. Schematics break the entire electrical system into individual circuits, showing theelectrical current paths when a circuit is operating properly. Wiring which is not part of the circuit of interest is referenced to another page where thecircuit is shown complete. Schematics use a top (power) to bottom (ground) sequence to present electrical information.

Component Location Views

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RH Front Corner Of Vehicle

Component location views are line illustrations that indicate all of the vehicle's electrical components within each electrical system.

Connector End Views

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RH Horn A Note

Connector end views show the cavity or terminal locations for all the related 2-pin or larger connectors shown in the system schematic(s). The drawingsshow the connector's face as seen after the harness connector has been disconnected from a component or mating connector. Unused cavities are leftblank in the table.

In addition, the color and part number of the connector body is provided along with the family/series name. Below is an example of a typical connectorend view.

Diagnostic System Checks

Misdiagnosis could occur if the diagnostic system check is not performed before using the diagnostic tables.IMPORTANT:

Diagnostic Tables

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The diagnostic system check determines the diagnostic trouble codes (DTCs) present, verifies proper communication, and navigates to the appropriatediagnostic table.

Horns Inoperative (Part 1 Of 2)

Horns Inoperative (Part 2 Of 2)

Diagnostic tables provide a procedure that will help you locate the condition in a circuit that is causing a malfunction. All diagnostic procedures aresymptom based, to assist you in locating the condition as fast as possible. Diagnostic tables should exist for all possible (realistic) symptoms anddiagnostic trouble codes .(DTCs)

Circuit Descriptions

The circuit description describes how the system works electrically. It details how power, ground, inputs, and outputs are supplied to the system's relatedcomponents. The circuit description also explains the communication and interaction of all components that affect the operation of the system.

Battery positive voltage is applied at all times to the horn relay terminals 85 and 30. Pressing the horn switch grounds the horn relay coil on CKT 28(BLK). The relay coil can also be grounded on CKT 28 (BLK) by the Dash Integration Module (DIM). The horn relay applies battery positive voltage tothe horns on CKT 29 (DK GRN) when energized. The horns sound until the horn switch is released or the DIM signal is gone.

Truck Zoning

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Truck Zoning

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All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle.The following table explains the numbering system.

Electrical Symbols

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Electrical Symbols (Part 1 Of 4)

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Electrical Symbols (Part 2 Of 4)

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Electrical Symbols (Part 3 Of 4)

Electrical Symbols (Part 4 Of 4)

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Alarm Module: Diagnostic Aids

Basic Knowledge Required

Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity andknow the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shortedwire. You should be able to read and understand a wiring diagram.

Refer to in General Information in order to properly diagnose and repair the customer concern.Strategy Based Diagnosis

Checking Aftermarket Accessories

Do not connect aftermarket accessories into the following circuits:

CAUTION: Refer to SIR Service Precautions Caution in Cautions and Notices.

- SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.

Refer to in Cautions and Notices.NOTE: OBDII Symbol Description Notice

- OBDII circuits, all such circuits are indicated on circuit diagrams with the OBDII symbol.

Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect thesystem to verify that these add-on accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:

- Power feeds connected to points other than the battery.

- Antenna location.

- Transceiver wiring located too close to vehicle electronic modules or wiring.

- Poor shielding or poor connectors on antenna feed line.

- Check for recent service bulletins detailing installation guidelines for aftermarket accessories.

Intermittents and Poor Connections Diagnosis

Most intermittents are caused by faulty electrical connections or wiring. Inspect for the following items:

- Wiring broken inside the insulation.

­Poor connection between the male and female terminal at a connector. Refer to Testing for Proper Terminal Contact below for the specificprocedure.

­Poor terminal to wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire theinsulation rather than the wire itself and corrosion in the wire to terminal contact area, etc.

- Wire insulation which is rubbed through. This causes an intermittent short as the bare area touches other wiring or parts of the vehicle.

-

Symptom Diagnostic Example

The following is an example of a symptom and the correct course of action taken by the technician.

IMPORTANT:

Research for possible bulletins, DTCs and the vehicle's service history. Also, thoroughly screen the customer regarding the problem inorder to complete the repair of the vehicle and completely satisfy the customer when a DTC or a symptom diagnosis is not available.

Verify the Customer Concern, Check the Problem

Customer complaint is the headlamps are inoperative. Verify the normal operating procedure of the circuit and the components that share thatcircuit. Refer to Strategy Based Diagnosis.

Review the Headlamps Electrical Schematic (Preliminary Checks)

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Electrical Intermittents

Refer to Testing for See: Diagrams/Diagnostic Aids for test procedures to detect intermittent open, high resistance, shortto ground, and short to voltage conditions.

Review the schematic, it is essential to understand how a circuit should work before trying to figure out why it doesn't. After understanding how acircuit should operate, read the schematic again, this time keeping in mind what has been learned by operating the circuit. Since both the low beamheadlamps are inoperative, ensure that the following components are operating properly.-

The headlamp Switch.

- The YEL wire.

- Low contacts of the Headlamp Dimmer Switch.

- C100 terminal 1E.

- The TAN wires.

- Grounds G105 and G109.

Refer to .Strategy Based Diagnosis

Perform the System Check

The system check indicates that the low beam headlamps operate when the high beam switch is in high. Also, the high beam indicator illuminatesbut neither high beam headlamp operates. Refer to .Strategy Based Diagnosis

Utilizing a combination of Techline tools and the information accumulated from the Preliminary Checks, check for bulletins.Check for Bulletins

Isolate the Root Cause

At this point analyze and (diagnose the problem), and develop text. Since the high beam indicator illuminated when the headlamp dimmer switchwas in the high position, the high contacts of the headlamp dimmer switch and the LT GRN wire between the headlamp dimmer switch and C100are good. At this point, it is extremely unlikely that the high beam filaments in the RH and LH headlamps are both open or that both headlampconnections are bad. The cause must be a bad connection at C100 or an open in the LT GRN wire between C100 and the RH headlamp.

Repair and Verify Fix

From isolating the root cause, basically the problem has been diagnosed. Using the Component Location Table and the corresponding figure,quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair.

Check the thoroughness of the repair by performing a final system check on the headlamp circuit. This of course means making sure that both highbeams, both low beams, and the high beam indicator are working.

Testing For Electrical Intermittents

6 inches

Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about apart) while watchingthe test equipment.

- Testing for Short to Ground

- Testing for Continuity

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If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate thecircuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected.

IMPORTANT:

The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltagewhile recording the minimum (MIN), and maximum (MAX) values measured.

1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to

Troubleshooting with a Digital Multimeter

See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Digital Multimeterforinformation on connecting the J 39200 to the circuit.

2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position.3. Press the range button of the J 39200 in order to select the desired voltage range.4. Press the MIN MAX button of the J 39200. The J 39200 displays RECORD and emits an audible tone (beep).100 ms
The RECORD mode is the length of time an input must stay at a new value in order to record the full change.IMPORTANT: 100 ms

5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or
performing other operations.

6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded.7. Press the MIN MAX button once in order to display the MAX value and note the value.8. Press the MIN MAX button again in order to display the MIN value and note the value.9. Determine the difference between the MIN and MAX values.

-

1 volt

If the variation between the recorded MIN and MAX voltage values is or greater an intermittent open or high resistance condition exists.Repair the condition as necessary.

-

1 volt

If the variation between the recorded MIN and MAX voltage values is less than an intermittent open or high resistance condition doesnot exist.

Testing For Proper Terminal Contact

It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must beinspected to ensure good terminal contact. A poor connection between the make and female terminal at a connector may be the result of contamination ordeformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connectoritself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit orintermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, orrepeatedly separating and joining the connector halves.
Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Round Wire Connectors

Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to J 38125-B Terminal Repair Kit or the J 38125-4Instruction Manual for terminal identification.

Follow the procedure below in order to test terminal contact.1. Separate the connector halves.2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or

between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector thatshows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a

suspect terminal. Replace the female terminal in question.

There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side.Flat Wire (Dock and Lock) Connectors

Follow the procedure below in order to test terminal contact.1. Remove the component in question.2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may

be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal

contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter from the J 42675 Flat Wire Probe Adapter kit on the flat wire harness connector in order to test the circuit in

question.

Measuring Voltage

Refer to in Cautions and Notices.NOTE: Test Probe Notice

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The following procedure measures the voltage at a selected point in a circuit.

1. Apply power to the circuit.2. Set the rotary dial of the DMM into the V (AC) or V (DC) position.3. Connect the positive lead of the DMM to the point of the circuit to be tested.4. Connect the negative lead of the DMM to a good ground.5. Operate the circuit.6. The DMM displays the voltage measured at that point.

Measuring Voltage Drop

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedure determines the difference in voltage potential between two points.

1. Set the rotary dial of the DMM to the V (DC) position.2. Connect the positive lead of the DMM to one point of the circuit to be tested.3. Connect the negative lead of the DMM to the other point of the circuit.4. Operate the circuit.5. The DMM displays the difference in voltage between the two points.

Testing For Continuity

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedures verify good continuity in a circuit.

With a DMM

1. Set the rotary dial of the DMM to the Ohm position.2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit.3. Disconnect the load.4. Press the MIN MAX button on the DMM.5. Connect one lead of the DMM to one end of the circuit to be tested.6. Connect the other lead of the DMM to the other end of the circuit.7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity.

With a Test Lamp

Only use the test lamp procedure on low impedance power and ground circuits.IMPORTANT:

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Connect one lead of the test lamp to one end of the circuit to be tested.4. Connect the other lead of the test lamp to battery positive voltage.5. Connect the other end of the circuit to ground.6. If the test lamp illuminates (full intensity), then the circuit has good continuity.

Testing For Short to Ground

Refer to in Cautions and Notices.NOTE: Test Probe Notice

The following procedures test for a short to ground in a circuit.

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With a DMM

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Set the rotary dial of the DMM to the Ohm position.4. Connect one lead of the DMM to one end of the circuit to be tested.5. Connect the other lead of the DMM to a good ground.6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.

With a Test Lamp

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.2. Disconnect the load.3. Connect one lead of the test lamp to battery positive voltage.

4. Connect the other lead of the test lamp to one end of the circuit to be tested.5. If the test lamp illuminates, there is a short to ground in the circuit.

Fuse Powering Several Loads

1. Review the system schematic and locate the fuse that is open.2. Open the first connector or switch leading from the fuse to each load.3. Connect a DMM across the fuse terminals (be sure that the fuse is powered).

- When the DMM displays voltage the short is in the wiring leading to the first connector or switch.

- If the DMM does not display voltage refer to the next step.

4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted.

Digital Multimeter

Refer to in Cautions and Notices.NOTE: Test Probe Notice

IMPORTANT: 10 megohm

Circuits which include any solid state control modules, such as the PCM, should only be tested with a or higher impedancedigital multimeter such as the J 39200.

The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand forfuture reference.

A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present,a DMM indicates how much voltage is present.

The ohmmeter function on a DMM shows how much resistance exists between two points along a circuit. Low resistance in a circuit means goodcontinuity.

IMPORTANT:

Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMsapply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading.

Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take areading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Followingare examples of the various methods of connecting the DMM to the circuit to be tested:

-

- Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses.

­If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuitor for testing multiple circuits quickly.

Short Finder

The J 8681-A can locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows the location of theshort through the body trim or sheet metal.

Test Lamp

Refer to in Cautions and Notices.NOTE: Test Probe Notice

A test lamp can simply and quickly test a low impedance circuit for voltage.

The J 34142-B Test Lamp is Micro-Pack compatible and comprised of a light bulb with an attached pair of leads.12 volt

To properly operate this tool use the following procedure.

1. Attach one lead to ground.2. Touch the other lead to various points along the circuit where voltage should be present.3. When the bulb illuminates, there is voltage at the point being tested.

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Probing Electrical Connectors.

Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness forcontinuous monitoring while you perform other operations or test driving. Refer to See: General ElectricalDiagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors

Probing Electrical Connectors

IMPORTANT: (CPA) (TPA)

Always be sure to reinstall the Connector Position Assurance and Terminal Position Assurance when reconnectingconnectors or replacing terminals.

Disconnect the connector and probe the terminals from the mating side (front) of the connector.Frontprobe

NOTE:

Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform mostterminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector TestAdapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they candamage terminals and cause incorrect measurements.

Do not disconnect the connector and probe the terminals from the harness side (back) of the connector.Backprobe

-IMPORTANT:

Backprobe connector terminals only when specifically required in diagnostic procedures.

-

Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire(dock and lock) connector.

-

Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the testprobe too far into the cavity or by using too large of a test probe.

- After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact.

Fused Jumper Wires

A fused jumper may not protect solid state components from being damaged.IMPORTANT:

The J 36169-A fused jumper includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire issupplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit beingtested.

Using Connector Test Adapters

NOTE:

Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. Adeformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and causeincorrect measurements.

Fuses

Circuit Protection - Fuses

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Fuse Types

The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a

circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time thecircuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken,also check for continuity using a J 39200 DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equalcurrent rating.

Circuit Breakers

A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a shortor other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuitbreakers are used.

Circuit Breaker:

This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause ofthe high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high currentis removed.

Positive Temperature Coefficient (PTC) Circuit Breaker:

This type greatly increases its resistance when excessive current passes through it. Theexcessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectivelyopen. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once thevoltage is removed the circuit breaker will re-close within a second or two.

Fusible Links

Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter orelectrical center. Use a continuity tester or a J 39200 DMM at each end of the wire containing the fusible link in order to determine if it is broken. Ifbroken, it must be replaced with fusible link of the same gage size.

Repairing a Fusible Link

Fusible links cut longer than will not provide sufficient overload protection.IMPORTANT: 225 mm (approx. 9 inches)

Refer to . See: Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice ClipsSplicing Copper Wire Using Splice Clips

Repairing Damaged Wire Insulation

Wire Size Conversion Table

Splicing Copper Wire Using Splice Clips

If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace thefaulty segment of the wire. Refer to See: Wiring Repairs/Typical Electrical Repairs/Splicing Copper WireUsing Splice Clips and follow the instruction to repair the wire.

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Splicing Copper Wire Using Splice Clips
TOOLS REQUIRED

J 38125-B Terminal Repair kit

1. Open the harness.

- If the harness is taped, remove the tape.

- To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

- If the harness has a black plastic conduit, pull out the desired wire.

2. Cut the wire.

- Cut as little wire off the harness as possible.

-

Ensure that each splice is at least away from other splices, harness branches and connectors. This helps prevent moisture from40 mm (1.5 in)

bridging adjacent splices and causing damage.

3. Select the proper size and type of wire.

- The wire must be of equal or greater size than the original (except fusible link).

- The wire's insulation must have the same or higher temperature rating.

- Use general purpose insulation for areas that are not subject to high temperatures.

- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.

Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.IMPORTANT:

Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.

4. Strip the insulation.

- Select the correct size opening in the wire stripper or work down from the largest size.

-

Strip approximately of insulation from each wire to be spliced.7.5 mm (5/16 inches)

5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B Terminal Repair Kit in order to determine the proper clip size
crimp tool and anvil.

6. Overlap the two stripped wire ends and hold them between thumb and forefinger.7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.

- Ensure that the wires extend beyond the clip in each direction.

- Ensure that no insulation is caught under the clip.

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8. Center the crimp tool over the splice clip and wires.9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut.

10. Crimp the splice on each end (2).

11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment.