1994 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

CHEVROLET CAMARO AND PONTIAC FIREBIRD
CONTENTS - BOOK 1
TABLE OF CONTENTS
GENERAL INFORMATION
General Information
Maintenance and Lubrication
HEATING AND AIR CONDITIONING
Heater and Ventilation
Heater, Ventilation and Air
Conditioning
Manual Control Air Conditioning
HD6/HR6-HE Air Conditioning
Compressor Service or Unit Repair
STEERING, SUSPENSION, TIRES
AND WHEELS
Steering, Suspension, Tires and
Wheels Diagnosis
Wheel Alignment
Power Steerin~ Gear and Pump
On-Vehicle ervice
Power Steering Gear Unit Repair
Power SteerinQ Pump Unit Repair
Front Suspension
Rear Suspension
Tires and Wheels
Steering Wheel and Column
On-Vehicle Service
Supplemental Inflatable Restraint
(SIR) Tilt Steering Column Unit
Repair
FINAL DRIVE
Propeller Shaft
Rear Axle
BRAKES
Brakes
Master Cylinder
Front Disc Brakes
Rear Disc Brakes
Duo-Servo Drum Brakes
Vacuum Booster System
Antilock Brake System
Antilock Brake System with Traction
Control System (Refer to
Supplement)
Parking Brake
ENGINE
Engine General Description
3.4 Liter V6 Engine On-Vehicle
Service RPO L32 - VIN S
3.4 Liter V6 E"ine Unit Repair
RPO L32- INS
5.7 Liter V8 Engine On-Vehicle
Service RPO LT1 - VIN P
5.7 Liter V8 Engine Unit Repair
RPO LT1 -VIN P
Cooling and Radiator
Engine Fuel
Engine Electrical
SECTION
OA
OB
1/1A
18
191
102
3
3A
38
381A
3B1B
3C
30
3E
3F
3F5B
4A
48
5
SA
581
582
5C2
501
5E1
5E2
SF
6
6A2A
6A2B
6A3A
6A3B
68
6C
60
TABLE OF CONTENTS
Battery
Cranking System
Charging System
Ignition Wlstem
Engine iring
Exhaust System
TRANSMISSION
Automatic and Manual Transmission
Automatic Transmission On-Vehicle
Service
HYDRA-MATIC 4L60-E Automatic
Transmission Diagnosis
.
RPO M30
Transmission Unit Repair
RPO M:30
Manual Transmission On-Vehicle
Service RPO MM6 and M49
Borg-Warner (T5) 5-Speed Manual
RPO M49
Borg-Warner (T56) 6-Speed Manual
RPO MM6
Clutch
ELECTRICAL - BODY AND CHASSIS
Lighting Systems and Horns
Instrument Panel, Gages and
Console
Windshield Wiper/Washer System
SECTION
601
602
603
604
605
6F
7
7A
7A14A
7A-148
78
78-68
78-108
7C
8
88
SC
SE
ACCESSORIES
Audio Systems
Cruise Control
Theft Deterrent Systems
Engine Coolant Heater
Supplemental Inflatable Restraint
(SIR) ~stem
Remote eyless Entry
9
9A
98
90
9E
BODY SERVICE
General Body Service
Stationary Windows
Body Dimensions, and Underbody
Bumpers
Body Front End
Doors
Rear Quarters
Body Rear End
Roof and Folding Top
Seats and Carpet
Seat Belts
10
101
102
103
104
105
106
10-7
108
109
10-10
10-11
BODY STRUCTURE
Structural Body Repair and
Dimensions
9J
9K
11
INDEX1
INDEX
CONTENTS - BOOK 2
TABLE OF CONTENTS
ENGINE
Driveability and Emissions General Information
Driveability and Emissions Fuel Injection (Port) (3.4L)
Driveability and Emissions Se~uential Multiport Fuel Injection
(SF) (5.7L)
TABLE OF CONTENTS
SECTION
ELECTRICAL - BODY AND CHASSIS

Electrical Diagnosis
6E
6E3 (3.4L)
6E3 (5.7L)
INDEX
SECTION
SA
INDEX-1
DRIVEABILITY AND EMISSIONS- FUEL INJECTION 6E-1
SECTION 6E
DRl'JEABILITY AND EMISSIONS

GENERAL INFORMATION
CAUTION: On vehicles equipped with Supplemental Inflatable Restraint (SIR), refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR
components or wiring. Failure to follow CAUTIONS could result in possible air bag
deployment, personal injury, or otherwise unneeded SIR system repairs.
CONTENTS
Section Content
Strategy Based Diagnostics
Emissions Control Information Label
Maintenance Schedule
Visual/Physical Underhood
Inspection
Basic Knowledge and Tools
Required
Electrostatic Discharge Damage
Diagnostic Information
Malfunction Indicator Lamp (MIL)
Intermittent Malfunction Indicator
Lamp
Data Link Connector (DLC)
6E-1
6E-2
6E-4
6E-4
Reading Diagnostic Trouble Codes Using

a Tech 1 or o~her Sc.m Tool
Flashing Diagnostic Trouble Codes with

12 Pin Connector(Pin "B" included)
Clearing Diagnostic Trouble
Codes ,
Diagnostic Mode
Field Service Mode
Learning Ability
On-Board Diagnostic System c;:heck
DLC Scan Tools
Tech 1 Tool Use With lntermittents
Wiring Harness Service
Tools Needed to Service the System
Special Tools (1 of 6)
6E-4
. . . . . . .. . . . . . .
.. ..... ... . . .
6E-4
6E-4
6E-4
6E-4
6E-6
6E-6
SECTION CONTENT
The driveability and emissions section describes

the function and operation of the engine control
module system that controls the driveability and
emissions of the vehicle. Emphasis is placed on the
diagnosis and repair of problems related to the system.
It is divided into three major sub-sections dealing
with diagnosis and repair. They can be summarized as
follows:
Component Locations.
Wiring Diagrams.
ECM/PCM/VCM Terminal End View and
Terminal Definitions.
GE-6
GE-6
GE-7
GE-7
GE-7
GE-7
GE-7
GE-7
GE-8
GE-8
GE-9
On-Board Diagnostic System Check. This must be

the first step of any diagnostic procedure.
Diagnostic Trouble Code Charts with facing pages
containing circuit diagrams, circuit operation
information, and helpful diagnostic information.
SECTION B: SYMPTOMS
SECTION A: ENGINE COMPONENTS/WIRING

DIAGRAMS/DIAGNOSTIC CHARTS
GE-6
This sub-section assists in dia.gnosis of

intermittent problems or problems which don't
result in the storing of diagnostic trouble.codes. It
is arranged by symptoms of poor driveability and
emissions and lists possible causes of the problems.
SECTION C: COMPONENT SYSTEMS
Component and Circuit Descriptions.

On-Vehicle Service for each Sub-System.
Functional Checks/Diagnostic Charts.
6E-2 DRIVEABILITY AND EMISSIONS - FUEL INJECTION

HOW TO USE ELECTRICAL SYSTEMS
DIAGNOSTIC INFORMATION
Sc. No Matching Symptom - Analyze the complaint
and develop a plan for diagnostics utilizing the

wiring diagrams, theory of operation, call
technical assistance for like instances where
repair history may be available, and technician
knowledge combined with efficient use of the
service available information.
STRATEGY BASED DIAGNOSTICS
The strategy based diagnostic is a uniform

approach to repair all electrical/electronics systems.
The diagnostic flow can always be used to resolve an
E/E system problem and is the place to start when
repairs are necessary. The steps found in Figure 1,
that the technician should follow, are outlined below:
1.
Sd. lntermittents - Conditions that are not always
present are intermittent. These may be resolved

by observing history DTC's, evaluating the
symptoms and conditions described by the
customer and using a check sheet or other method
to pinpoint the circuit or electrical system
component. Most important is to follow the
suggestions for intermittent diagnosis found in the
service documentation. The Tech 1 and Fluke 87
both have excellent data capture capabilities that
can assist in detection of intermittents.
Verify the Customer Complaint
To verify the customer complaint the technician

will need to know the correct t or normal operation
of the system and verify the customer complaint is
a deviation from normal operation.
2.
PreliminaryChecks
This step is a visual confirmation of systems or

components that are malfunctioning. With the
additional information gained the technician may
now conduct a thorough visual inspection, consult
the service history, listen for unusual sounds or
odors, and gather diagnostic code information to
further effect a good repair.
3.
6.
Service Diagnostics (Paper/Electronic)
Sa. OTC Stored - Follow the designated OTC chart
exactly to make an effective repair.

Sb. No OTC - Select the symptom from the symptom
tables and follow the diagnostic paths or

suggestions to complete the repair.
Re-Examine the Complaint
When the complaint cannot be successfully found

or isolated a re-evaluation is necessary. The
complaint should be re-verified and could be found
to be intermittent or normal as per 5c or 5e above.
Service information (Manual) System Check(s)
Most service manual sections contain "System

Checks" that verify proper operation of the system
and lead the technician on a very organized
approach to diagnostics that closely follows the
original development process and failure mode
testing.
5.
This condition exists when the vehicle is found to

operate normally. It is most important to verify
that the condition described by the owner is
normal compared to other vehicles. The condition
may be intermittent so verify the complaint under
the conditions described by the customer before the
vehicle is released.
Check Bulletins and Other Service Information
From the steps above the technician should have

enough information updates. This includes videos,
newsletters, or Pulsat programs.
4.
Se. Vehicle operates as designed/No trouble Found -
7.
Repair and Verification Tests
After a cause has been isolated the repairs should

be made and validated for proper operation and
verification that the symptom has been corrected.
This may involve road testing or other methods to
verify the complaint has been resolved under the
conditions noted by the customer.
DRIVEABILITY AND EMISSIONS - FUEL INJECTION 6E-3
STRATEGY BASED DIAGNOSTICS

DIAGNOSTIC FLOW
01.____v_E_R_1FY~c.--o_M_P_LA_1_NT_
__.j +- -
PRELIMINARY CHECKS
(VISUAUOPERATIONAUDTC)
HARD CODE
PERFORM
SERVICE
MANUAL
DIAGNOSTIC
PROCEDURES
~--,
CHECK BULLETINS AND

TROUBLESHOOTING HINTS
PERFORM SERVICE
MANUAL SYSTEM CHECK(s)
~-,
SELECT
SYMPTOM
FROM SERVICE
MANUAL
SYMPTOM
CHART&
PERFORM
PROCEDURE
I
I
'.------.....
~-,
NO CODE
-,
I
I
NO MATCHING
SYMPTOM IN
SERVICE
MANUAL
ANALYZE &
DEVELOP
DIAGNOSTICS
FROM WIRING
CHART
&THEORY
I
I
I
INTERMITIENT
REFER TO
INTERMITTENT
DIAGNOSTIC
DETAILS
OPERATING AS DESIGNED
CALL TECHNICAL ASSISTANCE FOR LA TEST
INFORMATION OR EXPLAIN OPERATION TO
CUSTOMER
FIND/I SOLA TE
THE PROBLEM
RE-EXAMINE
THE COMPLAINT
REPAIR/RESOLVE
&VERIFY FIX
5-21-93
PS 18291
Figure 1 Strategy Based Diagnostics
6E-4 DRIVEABlUTY AND EMISSIONS - FUEL INJECTION

EMISSIONS CONTROLINFORMATION LABEL
Electrostatic Discharge Damage
The underhood "Vehicle Emissions Control

Information" label (Figure 2) contains important
emission specifications and setting procedures. In the
upper left corner is exhaust emission information
which identifies the year, the manufacturing di vision
of the engine, the displacement of the engine in liters,
the class of vehicle, and type of fuel metering. There is
also an illustrated emission components and vacuum
hose schematic.
This label is located in the engine compartment of
every General Motors vehicle. If the label has been
removed, it can . be ordered from GM Service Parts
Operations (GMSPO).
Refer to SECTION OA for handling electronic

discharge service parts.
MAINTENANCE SCHEDULE
Refer to the General Motors Maintenance
Schedule in SECTION OB for the maintenance service
that should be performed to retain emission control
performance.
VISUAL/PHYSICAL UNDERHOOD INSPECTION

A careful visual and physical underhood
inspection must be performed as part of any
diagnostic procedure or in finding the cause of an
emissions test failure. This can often lead to fixing a
problem without further steps. Inspect all vacuum

hoses for correct routing, pinches, cuts, or disconnects.
Be sure to inspect hoses tp.at are difficult to see
beneath the air cleaner, compressor, generator, etc.
Inspect all the wires in the engine compartlhent for
proper connections, burned or chafed spots, pinched
wires, or contact with sharp edges or hot exhaust
manifolds. This visual/physical inspection is very
important. It must be done carefully and thoroughly.
BASIC KNOWLEDGE AND TOOLS REQUIRED

To use the driveability and emissions section most
effectively, a general understanding of basic electrical
circuits and circuit testing tools is required. You
should be familiar with wiring diagrams, the meaning
Qfvoltage, ohms, amps, the basic theories of electricity,
and understand what happens in an open or shorted
wire.
To perform system diagnosis, the use of a Tech 1
Diagnostic Computer or equivalent scan tool is
required. A test light, ohmmeter, digital voltmeter
with 10 megohms impedance, vacuum gauge, and
jumper wires are also required. Become acquainted
with the special tools and their use before attempting
to diagnose a vehicle. Special tools which are required
for system service are illustrated at the end of this
section.
The diagnostic charts in SECTION A ancf
functional checks in SECTION C are designed t6
locate a faulty circuit or component through logic
based on the process of elimination. The charts are
prepared with the requirement that the vehicle
functioned correctly at the time of assembly and that
there are no multiple failures.
There is a continual self-diagnosis on certain
control functions. This diagnostic capability is
complemented by the diagnostic procedures contained
in this manual. The language for communicating the
source of a malfunction is a system of diagnostic
trouble codes. When a malfunction is detected by the
ECM/PCM/VCM, a diagnostic trouble code is set and
the Malfunction Indicator Lamp (MIL) "Service
Engine Soon" is illuminated on some applications.
Refer to SECTION A within .each engine section for
more information.
Malfunction Indicator Lamp {MIL)

The MIL (Service Engine Soon) lamp is on the
instrument panel and has the following functions:
It informs the driver that a problem has
occurred and that the vehicle should be taken
for service as soon as reasonably possible.
Some applications will flash diagnostic trouble
codes stored by the ECM/PCM/VCM which
help the technician diagnose system problems.
Some applications will flash "Open Loop" or
"Closed Loop" operation.
As a bulb and system check, the MIL (Service
Engine Soon) will come "ON" with the key "ON" and
the engine not running. When the engine is started,
the lamp will turn "OFF." If the lamp remains "ON,"
the self-diagnostic system has detected a problem. If
the problem goes away, the lamp will go out in most
cases but a diagnostic trouble code will remain stored.
When the light remains '"ON" while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, an On-Board
Diagnostic System Check must be performed. The
procedures for these checks are given in SECTION A.
These checks will expose malfunctions which may not
be detected if other diagnostics are performed
prematurely.
ENGINE ADJUSTMENT
--- ----- --'"'
ADJUSTMENT
PROCEDURE
LABEL CODE
ENGINE SIZE
\
\
\
\
\
\
\
--
-- -----'
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC
"ALWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL

FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS" .
..__ _ EVAPORATIVE EMISSION SYSTEM
,___--------EXHAUST EMISSION SYSTEM

R 1G 3.8 V 8 JAW 7
CERT YEAR
R = 1994
CHECKSUM
DIGIT
Engine Family Suffix Code
(Describes Emission System)
1G = GMPTCAR
2G = (RESERVED)
3G = GMPT TRUCK
4G = SATURN
VEHICLE CLASS AND STANDARDS

v Gasoline Vehicle
Calif. Std Gasoline Vehicle
W
T = Gasoline Truck
X = Calif Std. Gasoline Truck
Diesel Truck
K
M
Methanol/Gas Vehicle
Cal Meth'I/Gas Vehicle
N
CATALYST DESIGNATOR
=
=
=
FUEL METERING
B
= CMFI
5 = TBI
6
= SFI-SC
= IFI (DIESEL)
8 = MFI or SFI or
MFI/SFI
4-8-92
MS 11461-6E
Figure 2 - Vehicle Emission Control Information Label
6E-6 DRIVEABILITY AND EMISSIONS - FUEL INJECTION.

Intermittent Malfunction Indicator Lamp
In the case of an "Intermittent" problem, the MIL
(Service Engine Soon) may light and then go out.
However, the corresponding diagnostic trouble code
will be stored in the memory. When unexpected
diagnostic trouble codes appear during the diagnostic
trouble code reading process, one can assume that
these diagnostic trouble codes were set by an
intermittent malfunction and could be helpful in
diagnosing the system.
An intermittent diagnostic trouble code may or
may not reset. If it is an intermittent failure, a
Diagnostic Trouble Code (DTC) Chart should not be
used. Consult the "Diagnostic Aids" on the page facing
the diagnostic trouble code chart corresponding to the
intermittent diagnostic trouble code. SECTION B also
covers the "Intermittents." A physical inspection of
the applicable sub-system most often will resolve the
problem.
Once terminals "A" and "B" have been connected,

the ignition switch must be moved to the "ON"
position, with the engine not running. At this point,
the MIL (Service Engine Soon) should flash Diagnostic
Trouble Code (OTC) 12 three times consecutively.
This would be the following flash sequence: "flash,
pause, flash-flash, long pause, flash, pause, flash-flash,
long pause, flash, pause, flash-flash." OTC 12
indicates that the diagnostic system is operating. If
OTC 12 is not indicated, a problem is present within
the diagnostic system itself, and should be referred to
the appropriate diagnostic chart in SECTION A.
Following the output of OTC 12, the MIL (Servicfl
Engine Soon) will indicate a diagnostic trouble code
three times if a diagnostic trouble code is present, or it
will continue to output D'.l'C 12. If more than one
diagnostic trouble code has been stored in memory, the
diagnostic trouble codes will be output from the lowest
to the highest, with each diagnostic trouble code being
displayed three times.

12 PIN DLC
The provision for communicating is the Data Link

Connector (DLC) (refer to Figure 3). It is usually
located under the instrument panel and is sometimes
covered by a plastic cover labeled "DIAGNOSTIC
CONNECTOR." It is used in the assembly plant to
receive information in checking that the engine is
operating properly before it leaves the plant. The
connector can also be used by the service technician to
identify stored trouble codes using the procedures
outlined below and to read ECM/PCM/VCM data using
a hand held scan tool.
TERMINAL IDENTIFICATION
GROUND
TCC (IF USED)
[!]
DIAGNOSTIC TERMINAL
SERIAL DATA
CD
SERIAL DATA (IF USED)
Reading Diagnostic Trouble Codes Using a

Tech 1 or Other Scan Tool
The recommended method for reading diagnostic
trouble code<s> ~tored in memory is by using diagnostic
scan tool plugged int; the DLC connector. Follow
instructions supplied by. tool manufacturer.
Flashing 't>iagnostic Trouble Codes With 12

Pin 01.;C Connect<>r (Pin "B" Included)
Although it is recommended that a diagnostic scan
tool be used to read diagnostic trouble codecs>, it may be
possible to flash trouble codes on certain vehicles
equipped with a 12 pin DLC connector. The DLC
connector terminal "B" (diagnostic terminal, if
equipped) is the second terminal from the right of the
DLC connector's top row. The terminal is grounded by
connecting it to terminal "A" (internal
ECM/PCM/VCM ground), the terminal to the right of
terminal "B" on the top row of the DLC connector.
TERMINAL IDENTIFICATION
SERIAL DATA (CLASS 2)
CD
OUTPUT/FIELD
SERVICE ENABLE
GROUND
IT]
SERIAL DATA
GROUND
@]
B+
PS 17928
Figure 3 - DLC Connectors
Clearing Diagnostic Trouble Codes

To clear any Diagnostic Trouble Code (DTC) from
the memory, either to determine if the malfunction
will occur again or because repair has been completed,
power feed must be disconnected for at least thirty (30)
seconds.

Depending on application, the following methods
may be used to clear DTC's:
Disconnect power source to ECM/PCM/VCM

ie., fuse, pigtail at battery etc.
Disconnect negative battery cable. (The
negative battery cable may be disconnected,
but other on-board memory data, such as
preset radio tuning, will also be lost.)
NOTICE: To prevent system damage, the key

must be "OFF" when disconnecting or
reconnecting power.
It is also possible to clear a Diagnostic Trouble
Code (DTC) using a diagnostic scan tool. Follow
instructions supplied by tool manufacturer.
Learning Ability
The system has a "learning" ability which allows it
to make corrections for minor variations in the fuel
system to improve driveability. If the battery is
disconnected, to clear diagnostic trouble codes or for
other repair, the ~learning" process resets and begins
again. A change may be noted in the vehicle's
performance. To "teach" the vehicle, ensure that the
engine is at operating temperature. The vehicle
should be driven at part throttle, with moderate
acceleration and idle conditions until normal
performance returns.
ON-BOARD DIAGNOSTIC SYSTEM CHECK

Refer to "On-Board Diagnostic System Check" in
SECTION A.
Diagnostic Mode
DLC SCAN TOOLS
When the diagnostic terminal is grounded with the
ignition "ON" and the engine "OFF," the system will
enter what is called the Diagnostic Mode. In this mode
the ECM/PCMNCM will:
1. On certain vehicles with a 12 pin DLC
connector (pin "B" included), display a DTC 12
by flashing the MIL (Service Engine Soon)
(indicating the system is operating correctly).
If any additional DTC's are set, it will flash
those DTC's. Each DTC will be flashed three
times, then DTC 12 will be flashed again.
2. Energize most system controlled relays and
solenoids except fuel pump relay. This allows
checking circuits which may be difficult to
energize without driving the vehicle and being
under particular operating conditions.
3. The IAC valve moves to its fully extended
position on most models, blocking the idle air
passage. This is useful in checking the
minimum idle speed.
Field Service Mode

If the diagnostic terminal is grounded with the
engine running, the system will enter the Field
Service mode.
In "Open Loop" the MIL (Service Engine Soon)
flashes two and one-half times per second.
In "Closed Loop," the light flashes once per second.
Also, in "Closed Loop," the light will stay "OFF" most
of the time if the system is running lean. It will stay
"ON" most of the time if the system is running rich.
While the system is in Field Service Mode, new
codes cannot be stored and the "Closed Loop" timer is
bypassed.
The system can communicate a variety of

information through DLC connector terminals "E" or
"M" (depending on the engine). This data is
transmitted at a high frequency which requires a Tech
1 Diagnostic Computer (scan) tool for interpretation.
There are several scan tools available for reading this
information.
With an understanding of the data which the tool
displays, and knowledge of the circuits involved, the
tool can be very useful in obtaining information which
would be more difficult or impossible to obtain with
other equipment.
Tech 1 and scan tools do not make the use of
diagnostic trouble code charts unnecessary, nor can
they indicate exactly where a problem is in a
particular circuit. Tree charts incorporate diagnosis
procedures using a Tech 1 tool where possible and most
charts require the use of a Tech 1 when it is applicable.
A TECH 1 TOOL THAT DISPLAYS FAULTY DATA
SHOULD NOT BE USED AND THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER.
THE USE OF A FAUL TV SCAN TOOL CAN RESULT IN
MISDIAGNOSIS AND UNNECESSARY PARTS
REPLACEMENT.
TECH 1 TOOL USE WITH INTERMITTENTS

In some scan tool applications, the data update
rate makes the tool less effective than a voltmeter
such as when trying to detect an intermittent prob le~
which lasts for a very short time. However, the Tech 1
allows manipulation of wiring harnesses or
components under the hood with the engine not
running, while observing the Tech 1 readout.
6E-8 DRIVEABILITY AND EMISSIONS - FUEL INJECTION

The Tech 1 tool can be plugged in and observed
while driving the vehicle under the condition when the
MIL (Service Engine Soon) turns "ON" momentarily
or when the engine driveability is momentarily poor.
If the problem seems to be related to certain
parameters that can be checked on the Tech 1, they
should be checked while driving the vehicle. If there
does not seem to be any correlation between the
problem and any specific circuit, the Tech 1 can be
checked on each position, watching for a period of time
to see if there is any change in the readings that
indicates intermittent operation.
The Tech 1 is also an easy way to compare the
operating parameters of a poorly operating engine
with those ofa known good one. For example, a sensor
may shift in value but not set a diagnostic trouble
code. Comparing the sensor's readings with those of a
known good vehicle may uncover the problem.
The Tech 1 has the ability to save time in diagnosis
and prevent the replacement of good parts. The key to
usi~g the Tech 1 successfully for diagnosis lies in the
technician's ability to understand the system he is
trying to diagnose as well as an understanding of the
Tech 1 operation and limitations. The technician
should read the tool manufacturers operating manual
to become familiar with the tool's operation.
WIRING HARNESS SERVICE

Refer to SECTION SA for wiring harness service.
Special tools needed to service:
J 38125-A
Terminal Repair Kit.
J 34636
Circuit Tester.
J 35689-A
Metri-Pack Terminal Remover.
J 28742-A
Weather-Pack Terminal Remover.
J 33095
Micro-Pack Terminal Remover.
TOOLS NEEDED TO SERVICE THE SYSTEM

Refer to "Special Tools" at the end of this section
for driveability and emissions tools needed to service
system.
TECH 1 DIAGNOSTIC SCAN TOOL

A hand-held scan toot used.to analyze and
with interchangeable program cartridge kits, or
mass storage cartridge.
MASS STORAGE CARTRIDGE KIT

Use with GM Powertrain, Chassis Body System
Service Programming Software.
12 to 16 PIN DLC HARNESS ADAPTER - 3000055
Necessary for some applications.
TK-OffK-0-A & 7000001
REFER TO USERS MANUAL FOR COMPLETE

INSTRUCTIONS.
VOLTMETER -Voltage position measures magnitude
of voltage when connected in parallel to an existing
circuit. A digital voltmeter with a 10 megohm input
impedance is used because this type of meter will
not load down the circuit and result in faulty
readings. Some circuits require accurate low voltage
readings because they have a very high resistance.
AMMETER - When used as an ammeter, this meter
accurately measures extremely low current flow.
Refer to meter instructions for more information.
Selector must be set properly for both function
and range. DC is used for most automotive
measurements.
OHMMETER - Measures resistance of circuit directly
in ohms.
OL display in all ranges indicates open circuit.
Zero display in all ranges indicates a short circuit.
An intermittent connection in a circuit may be
indicated by a digital reading that will not
stabilize on the circuit.
FLUKE 87 WITH Hz METER
Range Switch -Automatic and Manual.
HIGH IMPEDANCE MULTIMETER
400Q - Reads ohms directly
(DIGITAL VOLTMETER-DVM)
4K,40K,400Kn - Reads ohms in thousands
4M,40Mn,400Mn - Reads ohms in millions
J 39200
UNIVERSAL BREAKOUT BOX
Used to test individual circuits in the system by
monitoring voltage or resistance using a high
impedance multimeter. Can also be used for
pinout circuit checks by disconnecting the option
adapters at the vehicle system control module.
Refer to ECM/PCM/VCM Connector End View
tables in appropriate engine section for specific
engine adapter harness J 39700-XXX.
J 39700
611-93
7533826E
6E-10 DRIVEABILITY AND EMISSIONS- FUEL INJECTION
SIGNAL GENERATOR & INSTRUMENT

PANEL TESTER
Used to generate VSS signal.
J 33431-B
TRANSAXLE TEST BOX
Refer to appropriate engine section for specific

adapter harness J 38791-XX.
J 38791
4L60E JUMPER HARNESS
Used to measure electronic component and

circuit resistance in the transmission. Also used
to test the transmission wiring harness and
Powertrain Control Module during diagnosis.
J 39775
UNPOWERED TEST LIGHT
Used for checking wiring for complete circuit,

short to ground, or voltage.
J 34142-8
CONNECTOR TEST ADAPTER KIT
Used for making electrical test connections in

current Weather Pack, Metri-Pack and MicroPack style terminals.
J 35616-A/BT-8637
SPARK TESTER
Used for checking available secondary ignition

voltage. Also called an ST 125.
J 26792/BT-7220-1
6-11-93
MS 11188-6E

PORT FUEL li\lJECTION DIAGNOSTIC KIT
Used to diagnose port fuel injection systems.
I des:
Fuel Pressure Gage - (J 34730-1A)
Injector Test Light- (J 34730-2C)
Test Harness Adapter - (J 34730-225) - used to
connect J 39021 to CPI engine harness
Injector Poppet Tester - (J 34730-230) - used to
check CPI fuel flow.
Fuel Injector Tester- (J 39021)- used to check
injector coils and to perform injector balance (fuel
flow) check
J 34730-E
TEST HARNESS ADAPTER
Used to connectJ 39021 to 2.2L Pc1ssenger.
J 39021-70
TEST HARNESS ADAPTER
Used to connect J 39021 to 2.2L Truck.
J 39021-60
INJECTOR HARNESS TESTER
Used for checking the electrical circuit to a TBI fuel
injector.
J 34730-350/BT-8320
INJECTOR HARNESS TESTER

Used for checking the electrical circuit to a TBI fuel
injector.
J 34730-2A/BT-8329A
IAC MOTOR ANALYZER
Used to test IAC motors for correct functioning and
proper response to commands.
J 37027-3 IAC System Check Lights
ALSO
222-L IAC Driver and Node Light Kit
6-8-93
J 37027-A
MS 11457-6E
6E-12 DRIVEABILITY AND EMISSIONS .. FUEL INJECTION

INLET & RETURN FUEL LINE SHUT-OFF ADAPTERS
Used with J 34730-1 for checking and monitoring
fuel line pressure.
J37287-1 Inlet Adapter
J37287-2 Return Adapter
J 37287
FUEL PRESSURE GAGE KIT
Used for checking and monitoring fuel line
pressure of TBI fuel system.
15 PSI and 60 PSI gages
J 29658-150 Relief Valve
J 29658-82 Fuel Line Adapter
J 29658-85 Fuel Line Adapter
J 29658-89 Quick-Connect Fuel Line Adapter
J 29658-D
,.
FUEL LINE QUICK-CONNECT SEPARATOR

Used to release fuel line quick-connect fittings.
J 37088-A/BT-9171
FUEL/INJECTION LINE WRENCH
Used to service fuel or injection line.
I)
J 29698-A/BT-8251
FUEL LINE DISCONNECT TOOL SET (W CAR)

Used to disconnect fuel line disconnect locking
tabs under ABS modulator.
J 39504
VACUUM PUMP WITH GAGE (20 IN. HG. MINIMUM)
Use the gage to monitor manifold engine vacuum
and use the hand pump to check vacuum sensors,
solenoids and valves.
6-11-93
MS 11459-6E
J 23738-A
DRIVEABILITY AND EMISSIONS- FUEL INJECTION 6E-13

EXHAUST BACK PRESSURE TESTER
Used to diagnose a restricted exhaust at 02S.

AIR PUMP ADAPTER
J 35314-A/BT-8515/BT-851 SA
IDLE AIR CONTROL REMOVER
Used to remove idle air control assembly on port fuel

injection engine.
J 35632/BT-8514A
OXYGEN SENSOR WRENCH
Used for removing or installing the oxygen sensor.
J 29533-A/BT-8127
HEATED OXYGEN SENSOR WRENCH
Used to remove or install the heated oxygen sensor.
J39194-B
__~
OIL PRESSURE SENDING UNIT SOCKET
Used to remove and install oil pressure sending unit.
J 35748
IDLE AIR CONTROL WRENCH
Used for removing or installing IAC valve on throttle

body.
J 33031/BT-8130
6-11-93
MS 11460-6E
6E-14 DRIVEABILITY AND EMISSIONS- FUEL INJECTION
BALANCER REMOVER
(3800 Engine)
Used to remove crankshaft pulley.
J 38197/BT-9189
COOLANT SENSOR SOCKETS

(3800 Engine)
J 38724
SPARK PLUG BOOT REMOVAL TOOL
(3800 Engine)
Used to prevent damage to wire by
breaking plug/boot bond.
J 38491
OIL PRESSURE SENSOR WRENCH

(3800 Engine)
Used to remove or install oil pressure sensor.
J 39228
SPARK PLUG BOOT PULLER
{U-Van w/3800 Engine)
Used to remove spark plug wire on rear
bank of engine.
-~ --
J 39294
6-8-93
MS 11466-6E
ORIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (SFI) 6e3-1
SECTION 6E3
DRIVEABILITY AND EMISSIONS

SEQUENTIAL MULTIPORT
FUEL INJECTION
THIS SECTION APPLIES TO:
11
3.4L (L32) (VIN S) F" CARLINE (SFI)

5.7L (LT1) (VIN P) "F" CARLINE (SFI)
CAUTION: The procedures in this section must be followed in the order listed to
temporarily disable the Supplemental Inflatable Restraint (SIR) System and prevent false
Diagnostic Trouble Codes from setting. Failure to follow procedures could result in
possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used .
. Fasteners that are not reused, and those requiring thread-locking compound will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed,
parts or system damage could result.
CONTENTS
3.4L {L32) (VIN S) "F" CARLINE
General Description
3.4L (VIN S)
6E3-3
Diagnosis Procedure
3.4L (VIN S)
6E3-3
Section A
Engine Components/Wiring Diagrams/Diagnostic Charts
3.4L (VIN S)
6E3-A-1
Section B
Symptoms
3.4L (VIN S)
6E3-B-1
Section C
Component Systems
3.4L (VIN S)
6E3-C-1
C1
Powertrain Control Module (PCM) and Sensors
3.4L (VIN S)
6E3-C1-1
C2
Fuel Metering System
3.4L (VIN S)
6E3-C2-1
C3
Evaporative Emission (EVAP) Control System
3.4L (VIN S)
6E3-C3-1
C4
Electronic Ignition (El) System
3.4L (VIN S)
6E3-C4-1
cs
Knock Sensor (KS) System
3.4L (VIN S)
6E3-CS-1
CG
Secondary Air Injection (AIR) System
3.4L (VIN S)
6E3-C6-1
C7
Exhaust Gas Recirculation (EG R) System
3.4L (VIN S)
6E3-C7-1
CB
Automatic Transmission Control System
3.4L (VIN S)
6E3-C8-1
3.4L (VIN S)
6E3-C10-1
..........................
C10 A/C Compressor Clutch Control

Index
. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .
End of Section
6E3-2 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (SFI) DRIVEABILITY AND EMISSIONS
. . . . . . . . . . . . . . . . .. . . . .. . . . .
Crankcase Ventilation System
. . . . . . . . . . . . .. . . . . . ..
Air Intake System .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
C12 Cooling Fan Control
3.4L (VIN S)
6E3-C12-1
Cl 3
3.4L (VIN S)
6E3-C13-1
3.4L (VIN S)
6E3-C14-1
C14
5. 7L (VIN P) "F" CARLINE'
........ ....... .
General Description
.............................
Diagnosis Procedure
Section A
Engine Components/Wiring Diagrams/DjagnostiC'Charts
Section B
Symptoms
Section C
Component Systems
5.7L (VIN P) 6E3-3
5.7L (VIN P) 6E3-A-1
5.7L (VIN P) 6E3-B-1
Powertrain Control Mod_ule (PCM) and Sensors
C2
C3
Evaporative Err11ssion (EVAP) Control System
C4
Distributor Ignition (DI) System
CS
C6
Se.condary Air Injection (AIR) System
C7
Exhaust Gas Recircu:l,ation (EGR) System
5.7L (VIN P). 6E3-C7-1
CB
5.7L (VIN P) 6E3-C8-1
Cl 2 E,lectric Cooling Fan(s)
..............................
5.7L (VIN P) 6E3-C1-1

5.7L (VIN P) 6E3-C2-1
5.7L (VINP) 6E3-C3-1
5.7L (VIN P) 6E3-C4-1
5.7L (VIN P) 6E3-C5-1
5.7L (VIN.P) 6E3-C6-1
5.7L (VIN P) 6E3-C10-1
5.7L (VIN P) 6E3-C12-1
C13 Crankcase Ventilation System

C14 Air Intake System
5.7L (VIN P) 6E3-C-1
Cl
Cl O A/C Clutch Circuit Diagnosis
Index
5.7L (VIN P) 6E3-3
5.7L (VIN P) 6E3-C13-1
5.7L (VIN P) 6E3-C14-1
............................................
End of Section
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (SFt) 6E3-3
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING IO THE REQUIREMENTS OF THE
REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS
CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY
STANDARDS. IN MOST CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE, TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT,
MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO THE
ORIGINAL INTENT OF THE DESIGN.
INTRODUCTION
GENERAL DESCRIPTION
DIAGNOSIS PROCEDURE
This section applies to the 3.4L (VIN S) and 5.7L

The following sections are written for specific
(VIN P) engines. These engines have a fuel injector in
engine applications and are clearly identified. Be sure
to use only the section which applies to the engine
the intake manifold near the intake valve for each
. family being diagnosed.
cylinder.
These engines have controls that reduce exhaust
Before using this section of the manual, you should
emissions, and maintain good driveability and fuel
be familiar with the information and the proper
diagnostic procedures as described in SECTION 6E. If
economy.
the proper diagnosis procedures are not followed, as
A Powertrain Control Module (PCM) is the heart
described in SECTION 6E, it may result in
of this control system and has sensors used to provide
unnecessary replacement of good parts.
information about engine operation and the various
Diagnostic charts incorporate diagnostic
systems it controls. Details of basic operation,
procedures using a Data Link Connector (DLC) scan
diagnosis, functional checks, and on-vehicle service
(Tech 1 Diagnostic Computer) tool, where possible.
are covered in "Component Systems," Section "6E3-C".
The PCM has the ability to do some diagnosis of
The scan tool has the ability to save tim~ in
diagnosis and prevent the replacement of good parts.
itself, and of other parts of the system. When it finds a
The key to using a scan tool successfully for
problem, it will light the Malfunction Indicator Lamp
diagnosis lies in the technician's ability to understand
(MIL) "Service Engine Soon" on the instrument panel
the system being diagnosed, as well as an
and a Diagnostic Trouble Code (DTC) will be stored in
understanding of the scan tool's limitations. Refer to
the PCM memory. This does not mean the engine
SECTION 6E for more information.
should be stopped right a way, but that the cause of the
light coming "ON" should be checked as soon as
reasonably possible.
6E3-4 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (SFI) DRIVEABILITY AND EMISSIONS
BLANK
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-1
SECTION A
ENGINE COMPONENTS/WIRING DIAGRAMS

DIAGNOSTIC CHARTS
B:ASIC PROCEDURE
\ If you have not reviewed the basic information on
how to use the diagnostic procedures, go the
Introduction of this section. The facing page of each
chart in this section will provide a general circuit
description and in some instances, alternate diagnostic
steps or other diagnostic aids specific to that chart or
circuit.
ON-BOARD DIAGNOSTIC (OBD)

SYSTEM CHECK
The OBD system check verifies the system is
functioning correctly and is the starting point for
diagnosing. Some special considerations to keep in
mind when diagnosing are:
Blocking Drive Wheels

The vehicle drive wheels should always be blocked
and the emergency brake set while checking the
system.
CONTENTS
Engine Component Locations
Underhood Electrical Center
PCMWiringDiagram(1 of6)
PCM Terminal Connector End View
PCM Connector Terminal End View (1 of 3)
On-Board Diagnostic (OBD) System Check

Typical Tech 1 Data Values
Transmission Tech 1 Data
Engine and Transmission Tech 1 Data Definitions
Typical Tech 1 Engine Data Definitions

Transmission Data
PCM Diagnostic Trouble Codes
No Malfunction Indicator Lamp (MIL) "Service Engine Soon" - ChartA-1
Engine Cranks But Will Not Run - Chart A-3

Fuel System Diagnosis - Chart A-7 ( 1 of 3)
DTC 13 - Left (Bank 2) Oxygen Sensor (025) Circuit (Open Circuit)
DTC 14- Engine Coolant Temperature (ECT) Sensor Circuit (High Temperature Indicated)
DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit (Low Temperature Indicated)
DTC 16 - System Low Voltage
DTC 17 - Camshaft Position Sensor Circuit Error
DTC 21 - Throttle Position (TP) Sensor Circuit (Signal Voltage High)
DTC 22 - Throttle Position (TP) Sensor Circuit (Signal Voltage Low)

DTC 23 - Intake Air Temperature (IA T) Sensor Circuit (Low Temperature Indicated)
DTC 24 - Vehicle Speed Sensor (VSS) Circuit
DTC 25- Intake Air Temperature (IAT) Sensor Circuit (High Temperature Indicated)
DTC 28 - Transmission (TR) Pressure Switch Assembly Fault
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High-Low Vacuum)
DTC 34- Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low-High Vacuum)
DTC 35 - Idle Speed Error
DTC 36 - 24X Signal Circuit Error
DTC 37 - TCC Brake Switch Error
DTC 39 - Clutch Switch Error
DTC 41 - Ignition Control (IC) Timing Circuit Error
DTC 42 - Ignition Control (IC) Error
.. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PageA-3
PageA-4
PageA-5
Page A-11
PageA-12
PageA-16
Page A-18
PageA-20
Page A-21
PageA-22
Page A-24
PageA-26
Page A-28
PageA-30
PageA-32
PageA-38
PageA-40
PageA-42
PageA-44
Page A-46
PageA-48
Page A-SO
PageA-52
PageA-54
PageA-56
PageA-58
PageA-60
PageA-62
Page A-64
PageA-66
PageA-68
PageA-70
PageA-72
Page A-74
6E3-A-2 3.4L. (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

DTC 43 - Knock Sensor (KS) Circuit .
DTC 44 - Left (Bank 2) Oxygen Serisor (025) Circuit (Lean Exhaust Indicated)
DTC 45 - Left (Bank 2) Oxygen Sensor (025) Circuit (Rich Exhaust Indicated)
DTC 46 - Personal Automotive Security System (PASS -KeyII) Circuit
DTC 53 - System Voltage Overcharge (High Battery Voltage)
DTC 54- Fuel Pump Circuit (Low Voltage)
DTC 58 - Transmission Fluid Temperature' (TFT) Sensor Circuit Low (High Temperature Indicated)
DTC 59 - Transmission Fluid Temperature (TFT) Sensor Circuit High
Low Temperature Indicated
DTC 61 - A/C System Performance
DTC 63 - Right (Bank 1) Oxygen Sensor (025) Circuit (Open Circuit)
DTC 64 - Right (Bank 1) Oxygen Sensor (025) Circuit (Lean Exhaust Indicated)
DTC 65 - Right (Bank 1) Oxygen Sensor (025) (Rich Exhaust Indicated)
DTC 66-A/C Refrigerant Pressure Sensor Circuit (Low Pressure)
DTC 67 -A/C Refrigerant Pressure Sensor (Circuit Error)

DTC 68-A/C Compressor Relay (Shorted Circuit)
DTC 69-A/C Compressor Relay (Open Circuit)

DTC 70-A/C Refrigerant Pressure Sensor Circuit (High Pressure)
DTC 71 -A/C Evaporator Temperature Sensor Circuit (Low Temperature Indicated)
DTC 72 - Vehicle Speed Sensor (VSS) Circuit Signal Error

DTC 73.-A/C Evaporator Temperature Sensor Circuit (High Temperature Indicated)
DTC 75 - Digital EGR #1 Solenoid Error- Exhaust Gas Recirculation (EGR) Circuit
(Electrical Diagnosis)
PageA-76
Page A-78
PageA-80
PageA-82
PageA-84
PageA-86
PageA-88
PageA-90
PageA-92
PageA-94
PageA-96
PageA-98
PageA-100
PageA-102
PageA-104
PageA-106
PageA-108
PageA-110
PageA-112.
PageA-114
. PageA-116
DTC 76- Digital EGR #2 Solenoid Error - Exhaust Gas Recirculation (EGR) Circuit
PageA-118
DTC 77 - Digital EGR # 3 Solenoid Error Exhaust Gas Recirculation (EGR) Circuit
DTC 79- Transmission Fluid Overtemp
OTC 80- Transmission Component Slipping
OTC 82 - Ignition Control 3X Signal Error

OTC 51 - PROM Error
DTC 85 - PROM Error
DTC 87 - EE PROM ERROR
. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .
DTC 86 - AID Error

DTC 90 - TCC Error
. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . .
OTC 93 - PCS ci'rcuit (Current Error)

DTC 96 - Transmission System Voltage Low
DTC 98 - lnval id PCM program
DTC 99 - Invalid PCM Program
PageA-120
PageA-122
PageA-124
PageA-126
PageA-129
PageA-129
PageA-129
PageA-130
PageA-132
PageA-134
PageA-136
PageA-138
PageA-138
DRIVEABILITY Al\!D EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-3
II
F"
3.4L
RPO: L32
CARLINE
VG
SFI
O
C1
C2
C3
C4
CS
C6
CS
C9
COMPUTER HARNESS
Powertrain Control Module (PCM)
"Service Engine Soon"
Battery junction block
PCM harness grounds
1/P fuse panel
Underhood electrical center*
Fuel pump "test" connector
::::: NOT PCM CONNECTED

N1 Crankcase ventilation valve
N7 Oil pressure sensor
N17 Evaporative emission canister (not
shown), located in left rear fender,
near filler tube
D
1
2
5
8
9
10
15
18
CONTROLLED DEVICES
Fuel injector
Idle Air Control (IAC) valve
Torque Convj!rter Clutch (TCC)
connector
Fuel pump relay
Air Injection pump
Ignition coil assembly
Evaporative emission canister purge
solenoid valve
Eng;;;.? cooling fan
Digital Exhaust Gas Recirculation
(EGR)valve
SIR system components. Refer to
SECTION 9J of the service manual,
for "Cautions" and information on
SIR system components.
INFORMATION SENSORS
A
B
C
D
Manifold Absolute Pressure (MAP)

Oxygen Sensor (025)
Throttle Position (TP) sensor
Engine Coolant Temperature (ECT)
sensor (beneath .intake plenum)
Vehicle Speed Sensor (VSS)
(transmission mounted, not shown)
Intake Air Temperature (IAT) sensor
Knock Sensor (KS)
A/C refrigerant pressure sensor
A/C evaporator temperature sensor
Camshaft position sensor
Low resolution 3x crankshaft position
sensor
High resolution 24x crankshaft
position sensor
F
G
K
L
N
P
R
* See Figure A-2 for full illustration of

fuses and relays.
6-29-93
NS 15594
Figure A1 Engine Component Locations 3.4L (VIN S) "F" Carline
6E3-A,.4 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
UNDERHOOD ELECTRICAL CENTER
ABS IGN
A/C COMPRESSOR
RELAY
INJECTOR
FOG LTS
INJECTOR
D~D
IGNITION
AIR PUMP
~#8E6 ~(I~[>,
NOT USED
L HDLP DR
w
w
w
w
ABS BAT
~~
~ 0.0
FANS/ACTR
ABS
RELAY
COOLANT FAN
RELAY, #1
AIR PUMP
RELAY
A/C-CRUISE
ASR/TCS
COOLANT FAN
RELAY, #2
FOG LIGHTS
RELAY
COOLANT FAN
RELAY,#3
TOP VIEW
#78
H [i}
J 84
[j}
E}
58 rfuB sE] C8J 00 sG C8J El srJ C8J B
#38
~1
81
01
01
rn ~...
a
0
8
sE] t8J BsE] ~ EJ s(J C8J E] sEJ ~ i
#18
E ;
;1
EL c ,EL
F
~#8~
#48
502
ff2
#5;}
641
502
, : 3
139
#128
#118
] #108
#98
BACK VIEW
6-26-93W
NS 15595
Figure A-2 Underhood Electrical Center 3.4L (VIN S) "F" Carline
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-A-5
PCM
10-WA Y INJ/ECM CONN. {BLACK)
ECT SENSOR SIGNAL
THROTTLE
POSITION
{TP)
SENSOR
470BLK - - - - - - - - - - - - - - 4 7 0 B L K
SENSOR GROUND
417DKBLU
417DKBLU
TP SENSOR SIGNAL
416 GRY
5 VOLT REFERENCE
416 GRY
MANIFOLD
ABSOLUTE
PRESSURE
{MAP)
SENSOR
416GRY---....,,
432LTGRN------+-----~432LTGRN
452 BLK
MANIFOLD
VACUUM
IAT SENSOR SIGNAL
INTAKE AIR
TEMPERATURE
{IAT) SENSOR
SENSOR GROUND
A/C
REFRIGERANT
PRESSURE
SENSOR
452 BLK - - - - - - ~ - - -
A/C
EVAPORATOR
TEMPERATURE
SENSOR
452 BLK _ _ _ _ _ __..._ _ __.
380 RED/BLK
------1-------1-------1
416GRY - - - - - -
732DKBLU-------+------------11
416GRY
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
A/C
SELECT SWITCH
1/P FUSE #3
TO - - . r v - - - - - 2 4 1 BRN - - - - - - ~ - - - - - - IGNITION
15 AMP
FUSE # 12 *
SWITCH~~-- __ -----"' _ ....
_ _ _ _ . . . . . ~139PNK--~
20AMP
A/CREQUEST
10-WAY FWD LAMP HARNESS

CONNECTOR {BLACK)
A/C
COMPRESSOR
RELAY*
,----,
459 DK GRN/WHT
---..;..i
459 DK GRN/WHT
59DKGRN------H
A/C COMPRESSOR
CLUTCH RELAY CONTROL
A/CSTATUS
A/C COMPRESSOR
CLUTCH
* LOCATED IN UNDERHOOD ELECTRICAL CENTER
Figure A-3 - PCM Wiring Diagram 3.4L (VIN S) "F" Carline (1 of 6)
7-1-93
NS 15519
6E3-A;.6 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
PCM
t-.---1744BLK
INJ DRIVER CYL #1
1746 PNK/BLK
INJ DRIVER CYL #3
845BLK/WHT
INJ DRIVER CYL #5

INJ DRIVER CYL #2
INJ DRIVER CYL #4
846 YEL/BLK
INJ DRIVER C.YL #6
. - - - - - - - - - - - - - - - - - - - - 496 DK BLU
---------t
KNOCK SENSOR
SIGNAL
...__ _ 633 BRN/WHT
---------t
CAMSHAFT POSITION
SENSOR SIGNAL
CAMSHAFT
POSITION
SENSOR
- - - - 632 PNK/BLK
ENGINE~
CASE
GROUND
._______...___.
HIGH
RES.
1800 LT BLU/WHT
--------1
CAMSHAFT & 24X

CRANKSHAFT POSITION
SENSORS REF LOW
24X REFERENCE
SIGNAL
24X CRANKSHAFT
POSITION SENSOR
10-WAY FWD LAMP

FUSE #11 *
HARNESS CONNECTOR
10 AMP
(BLACK)
I G N I T I O N ~ 239 PNK - - - - 1 G ...__ __.
B+
450 BLK
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
GND
;;~~.:. . . I_. . . .
SIGNAL
TWISTED 9 TIMES/FOOT
MINIMUM
1--------- 424 TAN/BLK

1----------- 423 WHT
IGNITION
CONTROL
MODULE
(ICM)
-----1
IGNITION CONTROL
BYPASS
IGNITION CONTROL
-----t
3X REF HIGH
----1
3XREFLOW
-----1
121 WHT ---..TACH SIGNAL
-------tF
11-------- 647 LT BLU/BLK

1--------- 453 RED/BLK
PRIMARY
WINDING
Figure A-4 PCM Wiring Diagram 3.4L (VIN S) "F" Carline (2 of 6)
7-1-93
NS 15520
TO PASS-Key <11
DECODER MODULE
PCM
10-WAY INLINE 1/P

CONNECTOR #2
1/PFUSE #5
'TOIGN-----11
SWITCH
15AMP
1------ 439 PNK
IGNITION FEED
FUEL PUMP REQUEST
-i
451 BLKJWHT
1050
BLK
1---------~120GRY
FUEL TANK/ABS
PASSTHRU
CONNECTOR
INLINE 1/P
CONNECTOR #1
FUEL PUMP PRIME

CONNECTOR
4-WAY INLINE 1/P

REFER TO SECTION SA
1/P FUSE
CONNECTOR #3 (BLACK)
r -+- FOR BRANCH CIRCUITS
#4
I
B+ .... - - - - - - ~ - - - - - - 1 ( I ] 1 - - - - - - t 1 + - - - - - - 3 4 0 ORN
10AMP
3400RN
O g_____
II~~-- ...
VEHICLE
SPEED SENSOR
(TRAJ~:tslON
MOUNTED)
~-
BATTERY INPUT
BATTERY INPUT
400 YEL
VSS INPUT HIGH
_ AB 1
_ - - - - - - - - 4 0 1 PPL
VSS INPUT LOW
-ri__._.11-----101--INSTRUMENT
CLUSTER
FUEL PUMP SIGIIIAL
817 DK GRN/WHT
BUFFERED SPEED OUTPUT

(4000 PULSES PER MILE)
10-WAY INLINE
1/P CONNECTOR #1
(NATURAL)
10 WAY INLINE 1/P

MALFUNCTION INDICATOR CONNECTOR #2 (BLUE)
/
LAMP(MIL)
r--,i
,-,/
TO IGN
1/P FUSE #9
; In)
SWITCH..,.----~--1- 39 PNK ~ 4 1 9 BRN/WHT
10AMP
L - - J
"SERVICE ENGINE SOON"
MIL CONTROL
TO INTERIOR
8 GRY __. LIGHTS
(DIMMING)
TUR~, r---4S1BLK/WHT
#2-8-~
T0~141BRN
IGNITION
SWITCH
553 LT BLU----1
2ND GEAR START

SWITCH SIGNAL
1493DKBLU
2ND GEAR START SWITCH

LAMP CONTROL
10 WAY INLINE 1/P

CONNECTOR #2 (BLUE)
/
CLUTCH
ANTICIPATE/CRUISE
RELEASE SWITCH
48GRY
CLUTCH ANTICIPATE
INPUT (MIT ONLY)
7-6-93
NS 15521
Figure A-5. PCM Wiring Diagram 3.4L (VIN S) "F" Carline (3 of6)
6E3-A-8 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
PCM
B+
FUSE LINK
~402RED
10-WAY INLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
335DKGRN
COOLING
FAN
CONTROL
RELAY ..
C1rmmrn...-
COOLING FAN CONTROL
541 BRN
409 LT BLU
~150BLK-i
ENGINE
COOLING FAN
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
II
FUSE #6 ..
TO
IGNITION
SWITCH
10AMP
428DK
GRN/WHT
EVAP CANISTER PURGE

SOLENOID CONTROL
541 BRN
DIGITAL
EXHAUST GAS
RECIRCULATION
(EGR)VALVE
EGR #3 CONTROL
EGR #2 CONTROL
1 1 - - - , - - - - - - - - - - 5 9 1 LT BLU
EGR #1 CONTROL
TO
FUSE #7 ..
I G N I T I O N ~ 4 4 1 BRN-----,
SWITCH
20 AMP
FUSE LINK K
~502RED
SECONDARY
AIR INJECTION
PUMP
RELAY ..
SECONDARY A o-----78 R E D - - AIR

INJECTION
B ____
RED---78
PUMP
ASSEMBLY
436BRN
SECONDARY AIR INJECTION

PUMP RELAY CONTROL
10-WAY FORWARD
LAMP HARNESS
CONNECTOR (BLACK)
150
BLK
_j__
.. LOCATED IN UNDERHOOD ELECTRICAL CENTER
Figure A-6 - PCM Wiring Diagram 3.4L (VIN S) "F" Carline (4 of 6)
6-20-93
NS 15522
PCM
IDL~:~~~~::oi-11.
""-II
d.
q_
1747LTBLU/WHT
C:. ~ - - - - - - -
IAC COIL HB" HIGH
- - - - - - - - 444 LT GRN/BLK
IA( COIL HB" LOW
. 583LTBLU/BLK
:~~-I ~ I
PARK/NEUTRAL
POSITION (PNP)
SWITCH
~-
PASS-KeyII SIGNAL
(FUEL ENABLE INPUT)
TO BRAKE
SWITCH
816TAN/WHT
IA( COIL "A" LOW
1748LTBLU/BLK
1749LTGRN/WHT
TO PASS-KeyII T H E F T - - - - - - - - - - 2 2 9 DK BLU
DETERRENT MODULE
IA( COIL HA .. HIGH
583 LT BLU/BLK
451 BLK/WHT - - - - - ,
(PARTOFTHE
TRANSMISSION
POSITION SWITCH)
LEFT 025 GROUND
1 351 BLK/WHT
-*-
ENGINE
GROUND-:=-
816
TAN/WHT
RIGHT 025 GROUND
.-------------551TAN/WHT
i I~
ENGINE
--:::!::-_ \_Y
-t
GROUND
LEFT (BANK 2) OXYGEN SENSOR (025)
ECMGROUND
't...1.1.1
551 TAN/WHT
Vvv..::(\-1----<1.(~1666PPL
_
_
RIGHT (BANK 1) OXYGEN SENSOR (025)
~--------------<rE-1665PPL/WHT
TO
Tcc--.....~ - - - - - - - - - - - - - - - - - - - - - ~ 4 2 2 T A N / B L K
SOLENOID
422TAN/BLK
ECMGROUND
RIGHT(BANK 1)
02SSIGNAL
LEFT(BANK2)
02SSIGNAL
TCCCONTROL
10-WAY 1/P CONN.

(BLUE)
448WHT/BLK-0--448WHT/BLK
IN-LINE 1/P CONN #3 (BLACK)
DIAGNOSTIC
ENABLE
TO OIL LEVEL SENSOR

ECMGROUND
ECMGROUND
DATA LINK
CONNECTOR (DLC)
..__ _ _ _ 800 TAN
TO DIAGNOSTIC ,..__
ENERGY RESERVE
MODULE (DERM)
__.
SOOTAN
10-WAY FWD
LAMP HARNESS
CONNECTOR
(BLACK)
TO ELECTRONIC BRAKE
CONTROL MODULE (EBCM)
Figure A-7. PCM Wiring Diagram 3.4L (VIN S) "F'' Carline (5 of 6)
7-12-93
NS 15571
6E3-A-10 3.4L (L32) (VIN S) (SFI) DRIVEABILIJY AND EMISSIONS
BRAKE SWITCH
(NORMALLY CLOSED)
#9GAUGES
T O ~ 39PNK
IGNITION 10 AMP
SWITCH
.
~ (20-40Q)
TORQUE
CONVERTER
CLUTCH
(TCC)
SOLENOID
fnl
~
--~~ ~
3-2
CONTROL
SOLENOID
PCM
BRAKE TRANSMISSION
SHIFT INTERLOCK
.t
S83LTBLU/BLK
- - - - - - - - 422 TAN/BLK
TCC SOLENOID
CONTROL
- - - - - - - - - 687WHT
3-2CONTROL
SOLENOID
CONTROL
#11 IGNITION
239PNK ~ I G N I T I O N
10 AMP
SWITCH
1-2 SHIFT
SOLENOID
11+-------~1222LTGRN
1-2 SHIFT
SOLENOID
CONTROL
_ _ _TRANSMISSION
CONNECTOR
2-3 SHIFT
SOLENOID
PRESSURE
CONTROL
SOLENOID
(PCS)
H--------1223YEL/BL~
2-3 SHIFT
SOLENOID
CONTROL
- - - - - - 1229 LT BLU/WHT
PCS"LOW"
1-r-------- 1228 RED/BLK
PCS "HIGH"
1224PNK
RANGE
SIGNAL "A"
1225 DK BLU
RANGE
SIGNAL "8
1226RED
RANGE
SIGNAL "C"
- - - - - - - - 1227 YEL/BLK
TFTSIGNAL
t + - - -........- - - - - - ~
H--------
TRANSMISSION
FLUID
TEMPERATURE
(TFT) SENSOR
(INTERNAL)
-------1--t
SENSOR
GROUND
TP SENSOR AND TP
SENSOR INTERFACE
MODULE
* AT 2oc (68F)
- - - - - - - - 6-16-93
PS 18509
Figure A-8 PCM Wiring Diagram 3.4L (VIN S) "F" Carline (6 of 6)
DRIVEABIUTY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-11
PCM TERMINAL CONNECTOR END VIEWS
32 O O 16
32 0 0 16
00
00
00
00
00
00
00
00
00
00
00
00
00
00
170 0 1
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FRONT VIEW
32 PIN
PCM CONNECTOR '' A"
(CLEAR)
17 0 0 1
FRONT VIEW
32 PIN
PCM CONNECTOR "B"
(BLACK)
1 O O 17
00
00
00
00
00
00
00
00
00
00
00
00
00
00
16 0 0 32
FRONT VIEW
32 PIN
PCM CONNECTOR "C"
(BLUE)
NOTICE: DO NOT BACKPROBE PCM CONNECTORS!

Install the BOB between the PCM harness connectors and the PCM, then probe the pin listed
under "BOB PIN #." Voltage may vary due to low battery charge or other reasons, but should
be close. All voltages shown in the ENG "RUN" column are typical with engine at idle, closed
throttle, normal operating temperature, park or neutral, system in "Closed Loop," all
accessories "OFF," and scan tool not installed.
DVM NEGATIVE LEAD MUST BE CONNECTED

TO A KNOWN GOOD GROUND.
(1)
(2)
(3)
(4)
(5)
INCREASES WITH VEHICLE .SPEED (MEASURE ON AC SCALE).

NORMAL OPERATING TEMPERATURE.
VARIES
12 VOLTS FIRST TWO SECONDS.
VARIES WITH TEMPERATURE.
LESS THAN 1 VOLT.
5-25-93
PS 17933
6E3-A-12 3.4L (L32) (VIN S) (SFI) DRIVEABILffY AND EMISSIONS

USE KENT MOORE BREAKOUT BOX (BOB) J 39700 WITH J39700-110
ADAPTER AND J39700-112 OVERLAY RPO: L32 3.4L (YINS)
PCM CONNECTOR ''A" (CLEAR)

PCM PIN/FUNCTION
VOLTAGE
CKT#
WIRE
COLOR
BOB
PIN
#
KEY
ON
KEY
OFF
6E3
REFERENCE
A1
SENSOR GROUND FOR MAP, IAT, A/C REFRIGERANT

PRESSURE AND A/C EVAPORATOR TEMPERATURE SENSORS
452
BLK
201
O*
0*
A2
A/CREQUEST
762
DKGRN/WHT
202
A/C
OFFO*
A/C
OFFO*
SECC-10
A3
A/C EVAPORATOR TEMPERATURE SENSOR SIGNAL
732
DKBLU
203
1.5 (5)
1.5 (5)
DTC(s) 71,73
A/C
OFF
.5-1.5
A/C
OFF
.5-1.5
DTC(s) 66,70
A4
204
AS
A/C REFRIGERANT PRESSURE SENSOR SIGNAL
380
RED/BLK
205
A6
FUEL PUMP SIGNAL
120
GRY
206
A7
AS
DTC(s)
22,23,33,71
B+
DTC54
O* (4)
B+
DTC54
207
465
FUEL PUMP REQUEST
DKGRN/WHT
208
A9
209
A10
210
A 11 SHIFT SOLENOID OUTPUT 1-2
1222
LTGRN
211
B+
O*
SEC CS
A 12 SHIFT SOLENOID OUTPUT 2-3
1223
YEUBLK
212
B+
0*
SECC8
215
B+
B+
DTC90
SECC8
A13
213
A14
214
A 15 TCC CONTROL CIRCUIT
--
422
---
-.-
----
TAN/BLK
-----
A 16 3-2 CONTROL SOLENOID
687
WHT
216
B+
B+
A 17 SENSOR GROUND FOR TP SENSOR AND ECT SENSOR
470
BLK
217
A18 TCC/BRAKE SWITCH INPUT
583
LT BLU/BLK
218
B+
B+
DTC37
B+
B+
DTC28
A19
219
A20
220
A21 TRANS RANGE PRESSURE SWITCH SIGNAL" A"
1224
PNK
221
DTC(s) 15,21,22
~-------------------- --- ----- ~-- --- --- ----A22 TRANS RANGE PRESSURE SWITCH SIGNAL "B" {A/T)
CLUTCH ANTICIPATE SWITCH {MIT)
A23 TRANS RANGE PRESSURE SWITCH SIGNAL"("
1225
DKBLU
222
O*
O*
DTC(s) 28, 80
48
GRY
222
O*
O*
SECC8
1226
RED
223
B+
B+
DTC28
A24
224
A25
225
A26
226
A27
227
A28
228
A29 MAP SENSOR SIGNAL
432
LTGRN
229
4.8(3)
1.2(3)
OTC 33,34,44
A30 TP SENSOR SIGNAL
417
DKBLU
230
0*(3)
(3)
DTC{s)21,22
A31 ECT SENSOR SIGNAL
410
YEL
231
(5)
(5)
DTC(s) 14,15
A32 TRANS TEMPERATURE SENSOR SIGNAL
1227
YEUBLK
232
(5)
(5)
DTC 58,59,79
7-3-93 NS 15590
Figure A-9 PCM Connector Terminal End View (1 of 3)
PCM CONNECTOR ''B" (BLACK)

'
PCM PIN/FUNCTION
USE KENT MOORE BREAKOUT BOX {BOB)J 39700 WITH J39700-110

ADAPTER AND J 39700-112 OVERLAY RPO: L32 3.4L {VINS)
CKT#
WIRE COLOR
COOLANT FAN RELAY CONTROL
83, SECONDARY AIR INJECTION PUMP RELAY CONTROL

84
VOLTAGE
KEY
KEY
ON
OFF
,--
---
REFERNECE
101
B~
Bi
BOB
PIN
#
EVAP CANISTER PURGE CONTRQL
335
DKGRN
102
B+
B+
SECC12
436
BRN
103
B+
B+
SECC6
428
DKGRN,WHT
104
B+
B+
SECC3
105
85
86
A/C COMPRESSOR CLUTCH RELAY CONTROL
459
DKGRNiWHT
106
B+
B+
DTC68
87
MALFUNCTION INDICATOR LAMP {MIL)

419
BRN,WHT
107
O*
B+
CHART A-1
88
108
89
109
810
110
811 EGR #1 CONTROL
697
LTBLU
111
B+
B+
DTC75
812 EGR #2 CONTROL
698
BRN
112
B+
B+
DTC76
813 EGR #3 CONTROL
699
RED
113
B+
B+
DTC77
814 BATTERY+ {KEEP ALIVE MEMORY)
340
ORN
114
B+
B+
CHART A-3
815 BATTERY+ {KEEP ALIVE MEMORY)
340
ORN
115
B+
B+
CHART A-3
816 PCM GROUND
451
BLK,WHT
116
CHART A-1
117
817
818 2No GEAR START INDICATOR LAMP CIRCUIT OUTPUT
1493
BKBLU
118
O*
O*
SECC8
819 SERIALDATA
800
TAN
118
4.1
CHART A-1
820 LEFT {BANK 2) 02S GROUND
351
BLK,WHT
120
O*
O*
DTC{s) 13,44,45
821 LEFT {BANK 2) 02S SIGNAL
1665
PPLiWHT
121
O*
(3)
DTC{s) 13,44,45
822 RIGHT (BANK 1) 02S SIGNAL
1666
PPL
122
0*
(3)
DTC{s) 63,64,65
823 RIGHT (BANK 1) 02S GROUND
351
BLK,WHT
123
O*
O*
DTC{s) 63,64,65
824 IAC COIL "B" HIGH
1749
LTGRN,WHT
124
(3)
(3)
DTC35
825 IAC COIL "B" LOW
444
LT GRN/BLK
125
(3)
(3)
DTC35
1748
LT BLU/BLK
126
(3)
(3)
DTC35
1747
LTBLU,WHT
127
(3)
(3)
DTC35
828 BUFFERED SPEED OUTPUT (4000 PULSESiMILE)
817
DKGRNiWHT
128
10
DTC24
829 VSS INPUT LOW
401
PPL
129
0* (3)
DTC{s) 24, 72
830 VSS INPUT HIGH
400
YEL
130
0* (3)
DTC{s) 24, 72
831 5 VOLT REFERENCE - MAP, TP AND A/C REFRIGERANT

PRESSURE SENSORS
416
GRY
131
832 PCM GROUND
451
BLK,WHT
132
O*
O*
826 IAC COIL "A" LOW

827 IACCOIL "A" HIGH
'
DTC{s)22,34,66,
67,70,71,73
FIG A-1
7-3-93 NS 15591
Figure A-10 - PCM Connector Terminal End View (2 of 3)
USE KENT MOORE BREAKOUT BOX (BOB)

J 39700 WITH J 39700-110 ADAPTER AND
J 39700-112 OVERLAY
PC.M CONNECTOR
3.4L (VIN S}
RPO: L32
c" (BLUE)
VOLTAGE
PCM PIN/FUNCTION.
C1
PCM GROUND
C2
A/C STATUS
C3
IGNITION FEED
CKT#
551
59
439
WIRE COLOR
BOB
PIN#
KEY
"ON"
ENG
"RUN"
6E3
REFERENCE
TAN/WHT
301
FIG A~1
DKGRN
302
A/C
OFFO*
A/C OFF
O*
OTC (S) 68; 69)
PNK
303
B+
B+
DTCB2
304
C4
.,.
cs
PRESSURE CONTROL SOLENOID HIGH
1228
RED/BLK
305
O*
7(3)
DTC93
C6
PRESS URE CONTROL SOLENOID 1:.0W
1229
LTBLU/WHT
306
O*
1.2 (3)
DTC93
C7
307
'
cs
308
448
WHT/BLK
309
OBD SYSTEM CHECK
C10 2ND GEAR START SWITCH SIGNAL
SS3
LTBLU
310
B+
B+
SEC.CB
C11 PARK/NEUTRAL POSITION SWITCH INPUT
434
ORN/BLK
311
C12 INJECTOR DRIVER CYL #3
1746
PNK/BLK
312
B+
B+
SEC,C2
1745
LTGRN/BLK
31.3
B+
B+
SEC.C2
C14 INJECTOR DRIV~R CYL t1
1744
BLK
314
B+
B+
SEC:C2
846
YEL/BLK
315
B+
B+
FIGA1
C16 INJECTOR DRIVER CYL #S
845
BLK/WHT
316
B+
B+
SEC.C2
C17 PCMGROUND
SS1
TAN/WHT
317
FIGA1
C18 REFERENCE LOW CAMSHAFT & CRANKSHAFT

SENSORS
632
PNK/BLK
318
SEC. C4
C9
DIAGNOSTIC ENABLE
319
(19
C20 KNOCK SENSOR SIGNAL
496
DKBLU
320
2.3
2.3
DTC43
C21 24X REFERENCE SIGNAL
1800
LTBLU/WHT
321
B+
5131
DTC36
2.S
2.S
DTC46
B+
B+
DTC17
322
C22
C23 PASS-KeyII SIGNAL (FUEL ENABLE)
229
DKBLU
323
324
C24
C2S CAMSHAFT POSITION SENSOR SIGNAL
633
BRN/WHT
325
326
C26
C27 IGNITION CONTROL
423
WHT
327
0*
1.3 (3)
DTC41
C28 IGNITION CO.NTROL BYPASS
424
TAN/BLK
328
O*
4.7
DTC42
C29 IA T SENSOR SIGNAL
472
TAN
329
(5)
(S)
OTC (S) 23.25

DTC82
C30 3X REFERENCE HIGH
647
LTBLU/BLK
330
O*
2.3.( 3)
C31 3X REFERENCE LOW
453
RED/BLK
331
O*
O*
SEC.C4
844
LTBLU/BLK
332
B+
B+
SEC.C2
7.3.93
NS 1SS92
Figure A-11 - PCM Connector Terminal End View (3 of 3)
BLANK
6E3-A-16 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
PCM
rec-----------------------422 TAN/BLK
10-WAY INLINE 1/P
TO
SOLENOID
TCCCONTROL
CONNECTOR #2
(BLUE)
INLINE 1/P
CONNECTOR #2
----1IT]11------ 448 WHT/BLK
DIAGNOSTIC ENABLE
TO OIL LEVEL
SENSOR
PCM GROUND
I
L- -
DATA LINK
CONNECTOR
(DLC)
-REFER TO SECTION SA
FOR BRANCH CIRCUITS
TO ELECTRON!
,-------;~ BRAKE CONTROL
MODULE (EBCM)
..___ _ SOOTAN
TO DIAGNOSTIC ENERG-----'
RESERVE MODULE (DERM)
SOOTAN
10-WAYFWD
LAMP
HARNESS
CONNECTOR
(BLACK)
...
TO BRAKE
SWITCH
...
"SERVICE
ENGINE
To
IGN ~
1/PFUSE#S I
SOON"
(MIL)
SERIAL DATA
KEEP ALIVE
MEMORYB+
-::,.--r-:------1-11r-,
C!l-!
r- 1/PFUSE#9
TO IGN ~ 9 PNK - -.....
:-""
SWITCH
10AMP
... -
PCM GROUND
419 BRN/WHT
G
15 AMP
MIL CONTROL
L - .J
39
PNK
IGNITION FEED
10-WAY INLINE 1/P

CONNECTOR #2(BLUE)
7-1-93
NS 15596
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

3.4L (VIN S) .. F.. CARLINE (SFI)
Circuit Description:
The on-board diagnostic system check is an organized approach to identifying a problem created by an
electronic engine control system malfunction. It must be the starting point for any driveability complaint
diagnosis, because it directs the service technician to the next logical step in diagnosing the complaint.
Understanding the chart and using it correctly will reduce diagnostic time and prevent the unnecessary
replacement of good parts.
Chart Test Description: Number(s) below refer to

circled number(s) on the diagnostic chart.
1. This step is to determine if the Tech 1 can establish
communication with the PCM. If it cannot, "No
DLC Data" will be displayed on the Tech 1.
2. This test is to determine if the PCM can control the
MIL using the MIL system check.
rn
Important
This vehicle is equipped with a Powertrain

Control Module (PCM) utilizing an
Electrically Erasable Programmable Read
Only Memory (EEPROM).
When diagnostics call for replacement of the
PCM, the new PCM must be programmed.
Refer to "PCM Replacement and Programming
Procedures" in Section "6E3-Cl".

,
G)
.
3.4L (VIN S) "F" CARLINE (SFI)
IGNITION "OFF," ENGINE "OFF."

INSTALL TECH 1 SCAN TOOL
IGNITION "ON" ENGINE "OFF."
SELECT APPLICABLE CARLINE DATA LIST.
IS DLC COMMUNICATION PRESENT?
(TECH 1 WILL DISPLAY "NO DATA.")
USING A TECH 1 ENTER MISC

TESTS. SELECT OUTPUT TESTS.
SELECT MIL.
DOES MIL FUNCTION PROPERLY?
IS B+ PRESENT AT PCM TERMINALS "814",

s15" AND "C3"? ARE PCM POWER
GROUNDS "OK"?
CHECK SERIAL DATACKTSOO FOR OPEN,

SHORT TO GROUND
OR
SHORT TO VOLTAGE SEE ELECTRICAL
DIAGNOSIS SECTION "SA". IF "OK" THEN
FAULTY CALIBRATION OR FAULTY PCM.
REFER TO PCM AND SENSORS SECTION
"C1 "FOR REPROGRAMMING AND/OR
REPLACEMENT OF PCM.
r
I
CHECK 10 AMP FUSE #4.

CHECK 15 AMP FUSE #5,
CHECK FUSIBLE LINKS. IF
BLOWN, REPAIR AS
NECESSARY. REFER TO
SECTION "SA". IF "OK," CHECK
FOR OPEN IN CKT 340, 439, 441
AND551
OR
FAUL TY PCM CONNECTIONS.
----------,
USE CHART A-1.
L----------...1
---------,
I USE CHART A-3. 1

L----------.J
REFER TO PCM DIAGNOSTIC TROUBLE CODES

TABLE IN THIS SECTION FOR VALID DTCs.
ARE ALL DTCs DISPLAYED VALID?
INCORRECT
OR
FAUL TY CALIBRATION
OR
FAULTY PCM. REFER TO
"PCM AND SENSORS"
SECTION "C1" FOR
REPROGRAMMING AND/OR
REPLACEMENT OF PCM.
COMPARE TECH 1 SCAN DATA WITH TYPICAL VALUES

SHOWN IN THIS SECTION. ARE VALUES NORMAL OR
WITHIN TYPICAL RANGES?
REFER TO ENGINE
DRIVE ABILITY
"SYMPTOMS," SECTION "B".
FOR TRANSMISSION
DRIVEABILITY SYMPTOM,S.
REFER TO SECTION "C-8" FOR
ELECTRICAL FUNCTIONAL
CHECK.
REFER TO "INDICATED
COMPONENT(S) SYSTEM
CHECKS" IN SECTION "C".
7-1-93
PS 17871
6E3-A-18 3.4L (L32) (VIN S) (SFI) DRIVl:ABILITY AND EMISSIONS

If after completing the "On-Board Diagnostic (OBD) System Check" and finding the Tech 1 diagnostics
functioning properly and no diagnostic trouble codes displayed, the "Typical Tech 1 Data Values" may be used for
comparison with values obtained on the vehicle being diagnosed. The "Typical Tech 1 Data Values," are an
average of display va'lues recorded from normally operating vehicles and are intended to represent what a
normally functioning system would display.
A SCAN TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AND THE PROBLEM SHOULD BE
REPORTED TO THE MANUFACTURER. THE USE OF A FAULTY SCAN TOOL CAN RESULT IN MISDIAGNOSIS
AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed are used in this manual for diagnosis. If a scan tool reads other parameters, the
values are not recommended by General Motors for use in diagnosis. For more description on the values and use
of the Tech 1 to diagnosis PCM inputs, refer to the applicable diagnosis section in "Component Systems," Section
"6E3-C". If all values are within the range illustrated, refer to "Symptoms," Section "6E3-B".
TYPICAL TECH 1 DATA VALUES

3.4L (VIN S) "F" CARLINE
Idle I Upper Radiator Hose Hot I Closed Throttle I Park or Neutral I "Closed Loop" I Acc. "OFF"
Scan Position
Units Displayed
Typical Data Value
6E3 Reference Sec.
Engine Speed
RPM
100 RPMfrom desired RPM

( 50 RPM in drive).
Desired Idle
RPM
Engine Coolant Temp

Intake Air Temp
Co/Fo
Co/Fo
MAP
kPa/Volts
BARO
kPa/Volts
Throt Position
Throttle Angle
025 Right(Bank 1)
025 Left (Bank 2)
S. T. Fuel Trim
(Bank 1)
L. T. Fuel Trim
(Bank 1)
S. T. Fuel Trim
(Bank 2)
L. T. Fuel Trim
(Bank 2)
Loop Status
Fuel Trim Cell
Volts
0-100%
Millivolts
Millivolts
Counts
ECM idle command

(varies with temperature)
85C- l 09C ( 185F-223F)
10C-80C (50.F-176F) depends
on underhood temperature.
29 - 48 kPa ( 1 - 2 volts) depends
on Vac. & Baro pressure.
58- 114 kPa (2.5 - 5.5) depends
on altitude & Baro pressure.
.29 - .98
0%
100-1000 and varying
100-1000 and varying
Varies
Counts
110 - 156
Counts
Varies
Counts
110 - 156
Open Lp/Closed Lp
Cell Numbers
Closed Loop
0 - 16 (Depends on air flow and RPM)
Fuel Trim Enable
No/Yes
No
Spark Advance
# of Degrees
Varies
Spark Retard
# of Degrees
O*
* NOTICE:
If maximum retard is indicated, go to CHART C-5.
C2, CHART C-2B

C2, CHART C-2B
Cl
Cl
Cl, CHARTC-lD
Cl, CHART C-1 D
Cl, C2
Cl, C2
Cl, C2
Cl, C2
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C 1, C2, Typical Tech 1
C2, Typical Tech 1 Data
Definitions
C2, Typical Tech
Data
Definitions
CS, Typical Tech 1
Data Definitions
CS, Typical Tech 1
Data Definitions
DRIVEABILITY AND EMISSIONS 3.4l (L32) '(VIN S) (SFI) 6E3-A-19

Knock Signal
,EGR 1/EGR ~
EGR3
Idle Air Control
Park/Neutral Pos
MPH Km/h
Torque Converter
Clutch
System Voltage
No/Yes
Off/On
Off/On
Counts (steps)
P-N
vehicle speed
Off/On
Volts
No (Ye~, indicates knock is being

detected)
Off(On when commanded by PCM)
Off (011 when commanded by PCM)
5-50
Park/Neutral (P-N)
0
. 'off!(On with TCC commanded)
13.5 - 14.5 Volts
Fuel Pump Volts

lgn Cntrl 3X SIG
Volts
RPM
13.5 - 14.5 Volts

Varies
lgn Cntrl 24X SIG
RPM
Varies
lgn Cntrl CAM SIG
0/1
Varies
A/C Request
A/CClutch
A/C Status
A/C Refrigerant
Pressure
A/C EVAP Temp
Engine Cool Fan
No/Yes
On/Off
On/Off
No (Yes with A/C requested)

Off (On with A/C commanded On)
Off (On with A/C clutch engaged)
psi/Volt
OC/OF
Off/On
lnj. Pulse Width

Fuel EVAP Purge
TCC
4th gear switch
TCC Brake Switch
Clutch Pedal Switch
Air Pump Relay
PASS-Key/Vats
DTC lgn Counter
Milliseconds
0-100%
Off/On
Off/On
Closed/Open
Off/On
Off/On
Fault/OK
# of Key Cycles
Varies (Depends on temperature)

Varies (Depends on temperature)
"Off'' (On@109C, then
"Off" @ 9S~C)
1-4 and varying
0%
Off (On with TCC commanded)
Off (On when 4th gear switch closes)
Closed (Open with brake depressed)
Off (On with clutch pedal depressed)
Off (On when commanded by PCM)
OK (Fault if DTC 46 is set)
0 (Counts Key Cycles)
DTCStored
# of DTCs stored
0 (Counts# of DTCs Stored)
Time From Start
Hrs/Min
Varies
Injector Fault
TCC Solenoid
No/Yes
Off/On
No
Off
CS, Typical Tech 1

Data Definitions
C7
C7
C2, CHART C-28

C1, CHART C-lA
C1, CS, SA
cs
Typical Tech 1 Data
Definitions
C2
C1, C4 Typical' Tech
Data Definitions
C1, C4 Typical Tech
Oata Definitions
C1, C4 Typical Tech! Data
Definitions
C10
C10
C10
C10,C12
C10,C12
C10,C12
C2, CHART C-2A
C3
C1,CS,SA
C8,SA
C1, C8,SA
C1, CS; SA
CG
DTC46, SA
'rypical Tech
Data
Definitions
Typical Tech
Data
Definitions
Typical Tech 1 Data
Definitions
Tech 1 Data Definitions
C-S
TRANSMISSION TECH 1 DATA

Idle I Lower Radiator Hose Hot I Closed Throttle I Park or Neutral I Closed Loop I Accessories off
SCAN Po.sition
Units Displayed
Typical Data Value
Refer To Sec:
Engine Speed
Trans Output Spd
Eng Cool Temp
Trans Fluid Temp
Throt Position
Throttle Angle
A/B/C RNG
Trans Range Sw
Commanded Gear
Adaptable Shift
1-2 Sol 2-3 Sol
3-2 Control Sol
Hot Mode
TCC Solenoid
TCC Slip Speed
Desired PCS
Actual PCS
PCS Duty Cycle
MPH Km/h
TCC Brake Switch
1-2ShiftTime
2-3 Shift Time
1-2 Shift Time Error
Curr Adapt Cell
Curr Adapt PSI
2nd GR Start SW
DTC lgn Counter
DTCStored
Time From Start
System Voltage
RPM
RPM
co/Fo
co/Fo
Volts
Percentage
Off/On
Invalid, Rev,
Drive 4, Drive 3,
Drive 2, Low,
Park/Neut
1-4
No,Yes
Off/On
Percentage
No, Yes
Off/On
RPM
Amps
Amps
Percentage
0-255
Closed, Open
Seconds
Seconds
Seconds
%TP
PSI
On/Off
0-255
0-255
Hrs/Min/Sec
Volts
100 RPM From desired

ORPM
85.C - 105C ( 185F - 221 F)
82C - 94C ( 180F - 200F)
0.3 - 0.9V
0%
Off/On/Off
C1
C1
C1
C1
Park/Neut
1
No
On/On
0%
No
Off
50 RPM From Engine Speed
1.01 Amps 0.1 Amps
1.01 Amps 0.1 Amps
40% -60%
0
Closed
Cl
0
0
N/A
<
25%
Off
0
0
Varies
12.0-14.5V
60
6-22-93 NS 15597
ENGINE ANDTRANSMISSION TECH 1 DATA DEFINITIONS

PCM DATA DESCRIPTION
A list of explanations for each data message displayed
on the Tech 1 scan tool begins below.
This information will assist in tracking down emission
or driveability problems, since the displays can be
viewed while the vehicle is being driven. Refer to the
"On-Board Diagnostic System Check" for additional
information.
THROT POSITION - Used by the PCM to determine the

amount of throttle demanded by the driver. Should
read .29 - 98 volt at idle to above 4 volts at Wide Open
Throttle (WOT).
THROTTLE ANGLE - Computed by the PCM from TP
sensor voltage (Throt position); should read 0% at idle

100% at Wide Open Throttle (WOT).
'
02S RIGHT (BANK 1) - Represents the right exhaust
ENGINE SPEED - Engine speed is computed by the PCM
from the fuel control reference input (low resolution

crankshaft position sensor). It should remain close to
desired idle under various engine loads with engine
idling.
DESIRED IDLE - The calculated idle speed that is
commanded by the PCM. The PCM will compensate

for various engine loads to keep the engine at the
desired idle speed.
ENGINE COOLANT TEMP - The Engine Coolant
Temperature (ECT) sensor is mounted in the intake
manifold and sends engine temperature information to
the PCM. The PCM supplies 5 volts to the ECT sensor
circuit. The sensor is a thermistor which changes
internal resistance as temperature changes. When the
sensor is cold (internal resistance high), the PCM
monitors a high signal voltage which it interprets as a
cold engine. As the sensor warms (internal resistance
decreases), the voltage signal will decrease and the
PCM will interpret the lower voltage as a warm
engine.
INT AIR TEMP SENSOR - The Intake Air Temperature
(IAT) sensor is used by the PCM to adjust fuel delivery

and spark timing according to incoming air density.
The PCM supplies 5 volts to the IAT thermistor. As
intake air temperature varies, the resistance changes
causing a change in voltage drop across the sensor.
The PCM measures the voltage drop and calculates the
air temperature at the air intake.
MAP - The Manifold Absolute Pressure (MAP) sensor
measures the changes in the intake manifold pressure
which results from engine load and RPM changes and
converts these into a voltage output.
BARO - MAP sensor is also used to measure barometric
pressure during ignition key "ON" cycle and during

Wide Open Throttle (WOT), allowing the PCM to
make adjustments for altitudes. The PCM uses the
MAP sensor to control fuel delivery and ignition
timing.
Oxygen Sensor (028) output voltage. Should fluctuate

constantly within a range between 100 mV (lean
exhaust) and 1000 m V (rich exhaust) when operating
in "Closed Loop."
02S LEFT (BANK 2) - Represents the left exhaust
Oxygen Sensor (02S) output voltage. Should fluctuate
constantly within a range between 100 m V (lean
exhaust) and 1000 m V (rich exhaust) when operating
in "Closed Loop."
SHORT TERM FUEL TRIM (Bank 1 or Bank 2) - This
represents a short-term correction to fuel delivery by

the PCM in response to the amount of time the oxygen
sensor voltage spends above or below the 450 m V
threshold. If the oxygen sensor voltage has mainly
been below 450 mV, indicating a lean air/fuel mixture,
short term fuel trim will increase to tell the PCM to
add fuel. If the oxygen sensor voltage stays mainly
above the threshold, the PCM will reduce fuel delivery
to compensate for the indicated rich condition. Under
certain conditions such as extended idle and high
ambient temperatures, EVAP canister purge may
cause short term fuel trim to read less than 100
counts.
LONG TERM FUEL TRIM (Bank 1 or Bank 2) - Long
term fuel trim is derived from the short term fuel trim
value and is used for long-term correction of fuel
delivery. A value of 128 counts indicates that fuel
delivery requires no compensation to maintain a
14.7:1 air/fuel ratio. A value below 128 counts means
that the fuel system is too rich and fuel delivery is
being reduced (decreased injector pulse width). A
value above 128 counts indicates that a lean 028
signal condition exists and the PCM is compensating
by adding fuel (increased injector pulse width). Long
term fuel trim tends to follow short term fuel trim;
normal values of 110-150 counts at idle should not be
considered unusual.
TYPICAL TECH 1 ENGINE DATA DEFINITIONS

FUEL TRIM CELL - The 60 V6 engine uses sixteen fuel
trim cells. Cell sixteen is the idle mode cell. Throttle
position and MAP determine which cell the engine will
be in.
MPH KM/H - The Vehicle Speed Sensor (VSS) signal is

converted into km/h and mph for display.
TORQUE CONVERTER CLUTCH (TCC) Tech 1 displays
TCC "OFF" or "ON" as commanded by the PCM.
LOOP STATUS - "Closed Loop" displayed indicates that
the PCM is controlling fuel delivery according to

oxygen sensor voltage. In "Open Loop," the PCM
ignores the oxygen sensor voltage and bases the
amount of fuel to be delivered on TP sensor, engine
coolant, and MAP sensor inputs ortly. "Closed Loop"
operation should hegin when both oxygen sensors
become active and engine coolant temperature exceeds
65C (149F) for more than 30 seconds.
FUEL TRIM ENABLE (Tech 1 Will Display "YES") - If
the. fuel trim enable system is learning, the L. T. fuel
trim is responding to the S. T. fuel trim. If fuel trim
enable reads "NO" then L. T. fuel trim will not respond
to changes in S. T. fuel trim.
SPARK ADVANCE - This is a display of the spark
advance calculation determined by the Ignition
Control (IC) logic which the PCM is delivering to the
electronic ignition control module. It computes the
desired spark advance using data such as engine
coolant temperature, RPM, load, vehicle speed, and
operating mode.
SPARK RETARD - Indicates the amount of spark
advance the PCM is removing from the Ignition
Control (IC) timing in response to the Knock Sensor
(KS) signal. Tech 1 should display 0 at idle.
SYSTEM VOLTAGE - System voltage with ignition

"ON" and engine "OFF" will reflect battery voltage.
Ignition "ON" engine "ON" will indicate charging
system voltage applied to the PCM ignition input.
FUEL PUMP VOLTS - When the ignition switch is
turned to the "ON" position, the PCM turns the fuel
pump relay "ON" for two seconds. If the PCM does not
receive ignition reference pulses within two seconds,
the PCM will shut "OFF" the fuel pump.
IGNITION CONTROL 3X SIGNAL - Indicates the PCM is
receiving 3X reference signal from the ignition control

module.
IGNITION CONTROL 24X SIGNAL - Indicates the PCM
is receiving 24X reference signals from the 24X, high

resolution crankshaft position sensor.
IGNITION CONTROL CAM SIGNAL - The ignition
control CAM signal provides the PCM with the

information to determine when the intake valve on
number one cylinder will open. "O" CLOSED, "1"
OPENED - The PCM sequences the injectors in
cylinder firing order based on the input from the
camshaft position sensor.
A/C REQUEST - Represents the state of the A/C request
KNOCK SIGNAL - Indicates whether or not a knock
input from the control head.
signal is being detected by the PCM. Tech 1 should

display "NO" at idle.
A/C CLUTCH - Represents the commanded state of the
EGR 1/EGR 2/EGR 3 - Any combination of the EGR
A/C clutch control relay. Clutch should be engaged

when "ON" is displayed.
solenoids may be opened during engine operation. The

Tech 1 can indicate which solenoids are open or when
all three are closed, such as at idle. The Tech 1 can
cycle each solenoid to evaluate its operation.
A/C STATUS - The Tech 1 will display "ON" if voltage

has been applied to the A/C compressor clutch.
A/C REFRIGERANT PRESSURE - Tech 1 displays
IDLE AIR CONTROL - Displays the commanded position
of the Idle Air Control (IAC) pintle in counts. The

higher the number of counts, the greater the
commanded idle speed. Idle Air Control (IAC) should
respond fairly quickly to changes in engine load to
maintain desired idle RPM.
PARK/NEUTRAL POSITION - P-N displayed indicates
the gear select lever is in "Park" or "Neutral."
refrigerant pressure represented by psi and voltage.

A/C EVAP TEMPERATURE - The Tech 1 will display the
AIC system temperature used by the PCM for cooling

fan operation, A/C compressor clutch control and A/C
diagnostic trouble codes.
ENGINE COOL FAN - When the PCM is commanding
the engine cooling fan "ON," the Tech 1 display will
switch from "OFF" to "ON." The coolant fan can also
be selected as an output test by the Tech 1.
TYPICAL TECH 1 ENGINE DATA DEFINITIONS

c Indicates the on time of the
injectors in milliseconds. When engine load is
increased, injector pulse width will increase.
CLUTCH 'PEDAL SWITCH - Tech 1 displays "ON" with
FUEL EVAP PURGE - A signal used to control canister

purge function. 0% indicates the evaporative emission
canister purge solenoid valve is commanded fully
closed while 100% indicates .that the valve is
commanded fully open.
AIR PUMP RELAY - The Tech 1 displays "ON" when
[NJECTOR PULSE WIDTH
(TCC) A/T - The Tech 1 only indicates when the PCM
has enabled the Torque Converter Clutch (TCC)

driver, but this does not confirm that the TCC has
engaged. To determine ifTCC is operating properly,
engine RPM should decrease when TCC is .enabled.
Refer to Chart C-8.
the clutch pedaldepressed and "OFF" with the clutch

pedal at rest.
sooondary air is commanded by the PCM and "OFF"
when conditions do not require secondary air injection.
PASS-KeyII -An input from the PASS-KeyII decoder
module that tells the PCM to enable the injectors if the

proper signal is received. The Tech 1 will normally
display "OK." If the P ASS-KeyII test has failed, the
display will switch .to "FAULT" and the fuel system
may be disabled.
TCC BRAKE SWITCH.- Tech 1 displays "CLOSED" when
OTC IGNITION COUNTER - Tech 1 displays the number

of key cycles after a OTC was stored in PCM memory.
The count increases by l with each key cycle.
the brake pedal is at rest and '.'OPEN" when the brake

pedal is applied. The switch sends a signal to the PCM
to disengage the TCC.
OTC STORED - Tech 1 displays the number of history

diagnostic trouble codes stored in PCM memory.
INJECTOR FAULT - The PCM can determine if any of
TIME FROM START Range 0:00:00 18:12:15

HR/MIN/SEC - A measure of how long the engine has
the six injectors are misfiring. "YES" will be displayed

if this is occurring.
been running. When the engine stops, it is reset to

zero.
TCC SOLENOID - This parameter is the commanded
state of the TCC solenoid. "ON" indicates a
commanded energized state (current flowing through
the solenoids). "OFF" indicates a commanded nonenergized state (current not flowing through the
solenoids).
TRANSMISSION DATA
ENGINE SPEED Scan tool displays O RPM to 8191 RPM
- This parameter indicates the rotatipnal speed of the

engine expressed as revolutions per minute.
TRANS OUTPUT SPEED Scan tool displays O RPM to
8191 RPM - This parameter indicates the rotational
speed of the transmission output shaft expressed as

revolutions per minute.
ENGINE (ENG) COOLANT (COOL) TEMPERATURE
(TEMP) - Scan tool displays a range of -40C to 151C,
40F to 304F - This parameter is the input signal of the
engine coolant temperature sensor. Engine coolant

temperature is high (151 C) when signal voltage is low
(0 volt), and engine coolant temperature is low (-40C)
when signal voltage is high (5 volts).
TRANS FLUID TEMP - Scan tool displays a range of 40C to 151C, 40F to 304F. - This parameter is the
signal input of the transmission fluid temperature

sensor. Transmission fluid temperature sensor is high
(151C) when signal voltage is low (0 volt), and
transmission fluid temperature is low (-40C) when
signal voltage is high (5 volts).
THROTILE (THROT) POSITION Scan tool displays a
range of 0.00 volt to 5.10 volts. - This parameter
indicates the signal input of the throttle position

sensor circuit. Low voltage (approximately .3V to
l.3V) indicates closed throttle, high voltage
(approximately greater than 4.5V) indicates wide open
throttle.
COMMANDED GEAR - Scan tool displays a range of 1,

2, 3, or 4 This parameter is the decoded commanded
state of the 1~2 and 2-3 Shift Solenoids. Gear 1 ON,
ON. Gear2 = OFF,ON. Gear3 = OFF,OFF. Gear4

ON,OFF.
ADAPTABLE SHIFT Scan tool displays NO/YES - This
parameter is the current adaptability of the last 1-2

shift. "YES" indicates the last shift time parametric
data may be sued to modify fluid line pressure for the
next 1-2 shift. "NO" indicates the last 1-2 shift time
parametric data may not be used to modify fluid line
pressure.
1 2 SOLENOID (SOL)/2-3 SOLENOID (SOL) - Scan tool
displays ON/OFF - These parameters are the
commanded status of the 1-2 and 2-3 shift solenoids.

"ON" represents a commanded energized state
(current flowing through solenoid). "OFF" represents
a commanded non-energized state (current not flowing
through solenoid).
3 2 CONTROL SOLENOID (SOL) Scan tool displays a
range of 0% to 100% - This parameter is the
commanded percentage of"ON" time of the 3-2 Control

Solenoid. "0%" represents a completely "OFF" (nonenergized) commanded state. "100%" represents an
"ON" (energized) commanded state.
TRANS HOT MODE - Scan tool displays ON/OFF - "ON"
indicates transmission fluid temperature has exceeded

146C (295F).
THROTILE ANGLE Range of 0-100% - Computed by
TCC SOLENOID Scan tool displays ON/OFF - This
the PCM from TP sensor voltage (throttle position) and

should display 0% at idle and 100% at wide open
throttle. Refer to DTC 21 if TP sensor angle is not 0%
at idle.
parameter is the commanded state of the TCC

solenoid. "ON" indicates a commanded energized state
(current flowing through the solenoid). "OFF"
indicates a commanded non-energized state (current
not flowing through the solenoid).
A/B/C RANGE (RNG) Scan tool displays ON/OFF,

ON/OFF, ON/OFF - These parameters are the three
inputs from the Transmission Range Pressure Switch

Assembly. "ON" represents a B + voltage signal,
"OFF" represents a O voltage signal.
TRANS RANGE SWITCH (SW) Scan tool displays a
range of Invalid, Park/Neutral, Reverse, Drive 4, Drive
3, Drive 2, and Low - This parameter is the decoded
status of the three A/B/C Range inputs from the

Transmission Range Pressure Switch Assembly and
represents the position of the transmission manual
valve.
TCC SLIP SPEED - Scan tool displays a range of -4096

RPM to + 4095 RPM - This parameter is the difference
between transmission input speed derived (from the

engine speed) and transmission output speed (from the
vehicle speed sensor). A negative value indicates
input speed is less than output speed (deceleration). A
positive value indicates input speed is greater than
output speed (acceleration). A value of zero indicates
input speed is equal to output speed (TCC applied).
TRANSMISSION DATA
DESIRED PRESSURE CONTROL SOLENOID (PCS) Scan
tool displays a range of 0.00 amp to 1.10 amps - This
parameter is the commanded current of the Pressure

Control Solenoid circuit. 0.00 amps (no current flow)
indicates commended higher line pressure. 1.10 amps
(high current flow) indicates commanded lower line
pressure.
ACTUAL PRESSURE CONTROL SOLENOID (PCS) Scan
parameter is the actual current of the Pressure

Control Solenoid circuit at the Control Module. 0.00
amps (no current flow) indicates actual higher line
pressure. 1.10 amps (high current flow) indicates
actual lower line pressure.
PRESSURE CONTROL SOLENOID (PCS} DUTY CYCLE
Scan tool displays a range of 0% to 100% - This
CURRENT (CURR) ADAPT CELL Scan tool displays a

range of NOT USED, 25% TP Cell, 40% TP Cell and
70% Ti> Cell - This parameter indicates the current
throttle position cell used for fluid line pressure

modification (adaptation). "NOT USED" represents
0% - 25% throttle angle. "25% TP Cell" represents
25% - 39% throttle cell. "40% TP Cell" represents 40%
- 70% throttle angle. "70% TP Cell" represents 70% 100% throttle angle.
CURRENT (CURR) ADAPT PSI Tech 1 Displays .5 to
+ 10 PSI - This parameter indicates the amount of line
pressure change due to shift time error at a particular
throttle opening. -5 psi represents the maximum
decrease in-line pressure for a particular shift. + 10 is
the maximum increase in-line pressure for a
. particular shift.
2ND
GEAR START SWITCH Tech 1 Displays ON/OFF -
parameter is the commanded state of the pressure

control solenoid expressed as a percent of energized of
on time. 0% indicates zero on time (non-energized) or
on current flow. 100% indicates maximum on time
(energized) or high current flow.
This parameter indicates if 2nd gear start has been

selected. The Tech 1 will display "OFF" when the
normal shift control program is effective and "ON"
when a second gear start is requested.
MPH/KM/h Range 0-255 km/h, mph - The vehicle
255 - This parameter is the number of ignition cycles

after the OTC was stored in memory.
OTC IGNITION COUNTER Tech 1 Displays a Range Oto
speed sensor signal is converted irito km/h and mph for

display.
TCC BRAKE SWITCH Scan tool displays CLOSED/OPEN
- This parameter indicates the state of the TCC Brake

Switch circuit input. "OPEN" indicates a O voltage
input (brake switch open, brake pedal applied).
"CLOSED" indicates a B + voltage input (brake switch
closed, brake pedal released).
1 2 SHIFT TIME Scan tool displays a range of 0.00
seconds to 6.38 seconds -This parameter is the actual
time of the last 1-2 shift.

2 3 SHIFT TIME Scan tool displays a range of 0.00
seconds to 6.38 seconds - This parameter is the actual

1 2 SHIFT ERROR Scan tool displays a range of 0.00
se.conds to 6.38 seconds - This parameter is the
difference between the desired 1-2 shift time and the
actual 1-2 shift time.
DTC STORED Tech 1 Displays a Range O to 255 - This

parameter is the number ofDTCs stored in memory.
TIME FROM START Range 0:00:00-18:12:15
HR/MIN/SEC - A measure of how lorig the engine has
been operating. When the ignition is cycled to "OFF"

the value is reset to zero.
SYSTEM VOLTAGE Scan tool displays 0.00 volt to
25.5 volts - This parameter is the battery ignition
voltage input to the control module.
6-28-93
NS 15604
6E3-A-26 3,4L (L32} (VIN S} (SFI} DRIVEABILITY AND EMISSIONS
PCM DIAGNOSTIC TROUBLE CODES

DESCRIPTION
DTC
ILLUMINATE
MIL
DTC 13
Left (Bank 2) Oxygen Sensor (025) - Circuit Error
YES
DTC 14
Engine Coolant Temperature (ECT) Sensor Circuit (high temperature indicated)
YES
DTC 15
Engine Coolant Temperature (ECT) Sensor Circuit (low temperature indicated)
YES
DTC16
System Voltage Discharge (low battery voltage)
YES
DTC17
Camshaft Position Sensor Circuit Error
NO
DTC21
Throttle Position (TP) Sensor Circuit (signal voltage high)
YES
DTC22
Throttle Position (TP) Sensor Circuit (signal voltage low)
YES
DTC23
Intake Air Temperature (IAT) Sensor Circuit (low temperature indicated)
YES
DTC24
Vehicle Speed Sensor (VSS) Circuit - (N<> Signal)
YES
DTC25
Intake Air Temperature (IAT) Sensor Circuit (high temperature indicated)
YES
DTC28
Trans Range Pressure. Switch Circuit Error
NO
DTC33
Manifold Absolute Pressu.re (MAP) Sensor Circuit (signal voltage high-low

vacuum)
YES
DTC34
Manifold Absolute Pressure (MAP) Sensor Circuit (signal voltage low-high

va~uum)
YES
DTC35
Idle Air Control (IAC) Circuit Error
YES
DTC36
24X Signal Circuit Error
NO
DTC37
TCC Brake Switch Error
NO
DTC39
Clutch Switch Error
YES
DTC41
Ignition Control (IC) Error
NO
c
DTC42
Ignition Control (IC) Bypass Error
DTC43
Knock Sensor (KS) Circuit Error
YES
DTC44
Left (Bank 2) Oxygen Sensor (025) Circuit Error- lean exhaust indicated
YES
DTC45
Left (Bank 2) Oxygen Sensor (02S) Circuit Error- rich exhaust indicated
YES
DTC46
PASS-KeyII Circuit (out of frequency range)
NO
DTC51
Prom Error (Faulty or Incorrect Calibration)
YES
DTC53
System Voltage Overcharge (high battery voltage)
YES
DTC54
Fuel Pump Circuit (low voltage)
YES
DTC58
Transmission Fluid Temperature Sensor Circuit (low voltage)
NO
DTC59
Transmission Fluid Temperature Sensor Circuit (high voltage)
NO
DTC61
A/C System Performance
NO
YES
'
PCM DIAGNOSTIC TROUBLE CODES (CONT.)
----- --"""" .
UIC..
UC:>\...n1r I IVl'II
ILLUMINATE
MIL
DTC63
Right (Bank 1) Oxygen Sensor (025) - Circuit Error
YES
DTC64
Right (Bank 1) Oxygen Sensor (025) - Lean Exhaust Indicated
YES
DTC65
Right (Bank 1) Oxygen Sensor (025) - Rich Exhaust Indicated
YES
DTC66
A/C Refrigerant Pressure Sensor Circuit (low pressure)
NO
DTC67
A/C Refrigerant Pressure Sensor- Circuit Error
NO
DTC68
A/C Relay Circuit (Shorted Circuit)
NO
DTC69
A/C Relay Circuit (Open Circuit)
NO
DTC70
A/C Refrigerant Pressure Sensor Circuit (high pressure)
NO
DTC71
A/C Evaporator Temperature Sensor Circuit (low temperature indicated)
NO
DTC72
VSS Signal Circuit Error
NO
DTC73
A/C Evaporator Temperature Sensor Circuit (high temperature indicated)
NO
DTC75
Digital EGR - Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#1 solenoid error)
YES
DTC76
Digital EGR- Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#2 solenoid error)
YES
DTC77
Digital EGR- Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#3 solenoid error)
YES
DTC79
Transmission Fluid Over Temperature
NO
DTC80
Transmission Component Slipping
NO
DTC82
Ignition Control 3X Signal Circuit Error
NO
DTC85
Prom Error (faulty or incorrect calibration)
YES
DTC86
AID Error
YES
DTC87
Electrically Erasable Programmable Read Only Memory (EE PROM) Error
NO
DTC90
TCC Error
NO
DTC93
PCS Circuit Error
NO
DTC96
Transmission System Voltage Low
NO
DTC98
Invalid PCM Program
NO
DTC99
Invalid PCM Program
NO
6-19-93
NS 15605
PCM
T O T c c - - - - - - - - - - - - - - - - - - - - - - - - 422 TAN/BLK
SOLENOID
TCCCONTROL
DIAGNOSTIC ENABLE
PCM GROUND
PCM GROUND
,_____ _ 800TAN
TO DIAGNOSTIC ENERGY----RESERVE MODULE (DERM)
SERIAL DATA
10-WAYFWD
LAMP
HARNESS
CONNECTOR
(B~ACK)
,... ....
1/P FUSE #9
I l'r\\. I
TOIGN ~ 9 P N K -___,,....._.,~ I
SWITCH
.._ - _.
10AMP
TO BRAKE
SWITCH
KEEP ALIVE
MEMORYB+
r-,
0-!
419 BRNIWHT
T O ~ S ~ ..
"SERVICE I
GN~~439PNK
ENGINE
15AMP L _ _J
SOON"
10-WAY INLINE 1/P
(MIL)
CONNECTOR #2(BLUE)
Mil CONTROL
IGNITION FEED
7-1-93
NS 15596
CHART A-1
NO MALFUNCTION INDICATOR LAMP (MIL) "SERVICE ENGINE SOON"
There should always be a steady Malfunction Indicator Lamp (MIL) "Service Engine Soon" when the ignition
switch is "ON" and engine stopped. Battery voltage is supplied directly to the light bulb. The Powertrain Control
Module (PCM) will control the light and turn it "ON" by providing a ground path through CKT 419 to the PCM.
Diagnostic Aids: If engine runs OK, check:

1. A fused jumper must be used. Do Not use a test
light.
2. Using a test light connected to B +, probe each of
the system ground circuits to be sure a good
ground is present. See "PCM Connector Terminal
End View" in front of this section for PCM pin
locations of ground circuits.
3. If the fusible link is open, determine short to
ground in CKT 1002.
4. Make sure to check CKT 439 if the I/P fuse #5 is
open and both 340 circuits if the 1/P fuse #4 was
open.
Refer to PCM wiring diagrams for information.
Faulty light bulb.

CKT 419 open.
Open 1/P fuse #9.
If engine cranks but will not run, check:
Continuous battery - fusible link open.
1/P fuse #4 PCM/BAT open.
1/P fuse #5 PCM/IGN open.
Battery CKT 340 to PCM open.
Ignition CKT 439 to PCM open.
Poor connection to PCM.
Faulty PCM ground circuit(s).
PASS-KeyII circuit problem.
CHART A-1
DOES THE ENGINE START?
IS FUSIBLE LINK FROM THE

BATTERY JUNCTION BLOCK AND
1/P FUSE #4 (10 AMP) OK?
IGNITION "OFF."
DISCONNECT PCM CONNECTORS.
IGNITION "ON."
PROBE CKT 419, WITH 10 AMP FUSED
JUMPER TO GROUND.
IS THE MIL "ON~?
FAULTY PCM
CONNECTION
OR PCM.
CHECK:
- 1/PFUSE #9
FAULTY CONNECTION AT 10 WAY
1/P CONNECTOR #2 (BLUE),
FAULTY BULB
OPEN CKT419
CKT 419 SHORTED TO VOLTAGE
OPEN IGNITION FEED TO BULB
IGNITION "OFF.''.
DISCONNECT PCM
CONNECTORS.
IGNITION "ON. u
PROBE CKT 340 & 439
WITH TEST LIGHT TO
GROUND.
IS THE LIGHT HON" FOR
BOTH CIRCUITS?
FAULTY PCM GROUNDS

OR PCM.
LOCATE AND CORRECT

SHORT TO GROUND IN
CIRCUIT THAT HAD A
BLOWN FUSE.
REPAIR OPEN IN CIRCUIT

THAT DID NOT LIGHT THE
TEST LIGHT.
"AFTER REPAIRS," CONFIRM uCLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
6-16-93
NS-15599-6E
PCM
INJ DRIVER CYL #1
INJ DRIVER CYL #3
INJ DRIVER CYL #5
INJ DRIVER CYL #2
INJ DRIVER CYL #4
INJ DRIVER CYL #6
KEEP ALIVE
MEMORVB+
340 ORN

CONNECTOR (BLACK)
-----1
G - - - - - - - - T O CAMSHAFT POSITION SENSOR

AND
HIGH RESOLUTION 24X CRANKSHAFT
POSITION SENSOR
B+
450BL~HT
GND
: ~ =fH.:. . . .I.__
SIGNAL
LOW RESOLUTION 3X
CRANKSHAFT POSITION SENSOR
1--------- 424 TAN/BLK

1----------- 423 WHT
IGNITION
CONTROL
MODULE
(ICM)
.....
_ _ _ _....,
IGNITION CONTROL
121 WHT ---TACH SIGNAL
1--~------ 647 LT BLU/BLK

----------11.....F t--------- 453 RED/BLK
________
.....;;;;...
IGNITION CONTROL
BYPASS
I!
LOCATED IN UNDERHOOD ELECTRICAL CENTER
3XREF HIGH
3XREFLOW
6-16-93
NS 15600
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank.
this test indicates the electronic ignition control'
module is not triggering the coils.
4. This test will determine if there is B + at the
1. A MIL (Service Engine Soon) "ON" is a basic test
injectors. The injectors are powered by 2 fuses
to determine if tliere is a 12 volt supply and
located in the underhood electrical center.
ignition 12 volts to the PCM. No data may be due
5. This test will determine if the ignition control
to a PCM problem. The engine will not start
module is not triggering the problem coil or if the
without reference _pulses and therefore the Tech 1
tested coil is at fault. This test could also be
scan tool should display RPM (reference) during
Qerformed bY. using another known good coil.
crank. If RPM is erratic it is possible that the
6. This test will determine if the ignition control
reluctor wheel on the crankshaft is damaged. See
module is not generating the reference pulse or if
SECTION 6A for base engine information.
the wiring or PCM are at fault. By touching and
2. For the first two seconds with ignition "ON," or
removing a test light to B + on CKT 647 a
whenever reference pulses are bemg received, the
reference pulse should be generated. If RPM is
scan tool should indicate fuel pump circuit voltage
indicated, the PCM and wirmg are OK.
(8 to 12 volts).
3. Because the electronic ignition control system uses
Diagnostic Aids:. A damaged reluctor wheel may
tw,o plugs and wir~s to complete the circuit of each
cause a crank but will not run. See SECTION 6A for
coil, the companion sparR plug lead should be
base engine diagnosis.
connected to a good ground. IfRPM was indicated
during crank, the electronic ignition control
modufe is receiving a crank signal~ but no spark at
CHART A-3
ENGINE CRANKS B TWILL N TR N
r-----------~--------------------------------------1
INSTALL TECH 1 SCAN TOOL.
IGN "ON" IF NO DATA, REFER TO "ON-BOARD DIAGNOSTIC SYSTEM CHECK."

CHECK THE FOLLOWING:
CHECK FOR DIAGNOSTIC TROUBLE CODES AND REFER TO THOSE CHARTS FIRST.
TP SENSOR-IF OVER 2.5 VOLTS AT CLOSED THROTTLE, SEE OTC 21.
MONITOR "IGNITION CONTROL 3X SIGNAL" WITH TECH 1.
IS RPM INDICATED DURING CRANKING?
(RPM SHOULD NOT BE ERRATIC).
L-
--------------------------------------------------
r.'\1
\....'...):
1
:
I
ISFUELPUMPVOLTAGE
INDICATED DURING CRANK?
IGNITION "OFF."
INSTALL FUEL PRESSURE GAUGE.
IGNITION "ON."
IS PRESSURE BETWEEN 41-47 PSI
(284-325 KPA)?
USING AN ST-125 (SPARK CHECKER)J 26792 OR

EQUIVALENT CHECK FOR SPARK ON EACH COIL (14, 2-5 AND 3-6).
CHECK ONE WIRE AT A TIME. GROUND THE
COMPANION CYLINDER PLUG LEAD. LEAVE THE
OTHER FOUR WIRES CONNECTED TO SPARK PLUGS
WHILE CRANKING.
IS THERE A CRISP, BLUE SPARK ON ALL WIRES?
r- ------,
NO SPARK. 1
: SEE OTC
:
I CHART 82.
1
I
L-------..1
'4'
\.::..,)
DISCONNECT #1 AND #2 INJECTOR

HARNESS CONNECTORS.
IGNITION "ON," ENGINE "OFF."
WITH TEST LIGHT CONNECTED TO
GROUND, PROBE CKTs 639 AND 839 ON
INJECTOR HARNESS CONNECTORS.
LIGHT SHOULD BE "ON." IS IT?
SEE FUEL
SYSTEM
DIAGNOSIS
CHARTA-7.
IGNITION "OFF."
DISCONNECT IGNITION
CONTROL MODULE
6-WA Y CONNECTOR.
IGNITION "ON."
MOMENTARILY TOUCH CKT
647 WITH A TEST LIGHT TO
B + WHILE OBSERVING
CRANK RPM.
IS RPM INDICATED?
SPARK ON ONE
fc\
\V
CONNECT INJECTOR TESTERJ 34730-3C. OPEN IN

TO #1 INJECTOR AND CRANK ENGINE.
CIRCUIT
REPEAT TEST ON REMAINING 5
THAT DID
INJECTORS. J 34730-3C TESTER
NOT LIGHT
SHOULD FLASH AT EACH INJECTOR
THE TEST
LIGHT.
WHILE ENGINE IS CRANKING.
DOES IT?
NO TROUBLE FOUND.
SEE DIAGNOSTIC AIDS ON FACING
PAGE.
CHECK PAIR OF WIRES

THAT DID NOT SPARK.
EACH WIRE SHOULD
MEASURE LESS THAN
30,000 OHMS. IF OK,
SWAP IGNITION COILS.
oots PROBLEM
FOLLOW SUSPECT COIL?
FAULTY 6-WAY
CONNECTION
OR
ELECTRONIC
IGNITION
CONTROL
MODULE.
CKT647
OPEN
OR
SHORTED TO
GROUND
OR
FAULTY
PCM.
OPEN IN
INJECTOR
CIRCUIT THAT
DID NOT
FLASH TESTER
OR
FAULTY PCM
CONNECTION
OR PCM.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
7-3-93
NS 16197

CAUTION:
ENGINE FUEL PIPES
TO REDUCE THE RISK OF FIRE AND PERSONAL INJURY,

WRAP A SHOP TOWEL AROUND THE FUEL PRESSURE
CONNECTION TO ABSORB ANY FUEL LEAKAGE THAT
MAY OCCUR WHEN INSTALLING THE PRESSURE GAGE.
PLACE TOWEL IN APPROVED CONTAINER.
DO NOT PINCH OR RESTRICT NYLON FUEL LINES TO

AVOID DAMAGE THAT COULD CAUSE A FUEL LEAK,
RESULTING IN POSSIBLE FIRE OR PERSONAL INJURY.
J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
RETURN LINE
J 34730-1
FUEL PRESSURE
GAGE ASSEMBLY
FUEL PUMP AND
RESERVOIR ASSEMBLY
CHART A-7
(Page 1 of 3)
FUEL SYSTEM DIAGNOSIS

When the ignition switch is turned "ON," the Powertrain Control Module (PCM) will turn "ON" the in-tank
fuel pump. It will remain "ON" as long as the engine is cranking or running, and the PCM is receiving reference
pulses. If there are no reference pulses, the PCM will shut "OFF" the fuel pump within 2 seconds after ignition
"ON" or engine stops.
Inside the fuel tank an electric fuel pump (within an integral reservoir) supplies fuel through an in-line filter
to the fuel rail assembly. The pump is designed to provide fuel at a pressure above the regulated pressure needed
by the injector. A pressure regulator attached to the fuel rail, keeps fuel available to the injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a separate line. The fuel pump "test" connector is located in
the engine compartment near the passenger side shock tower

1. Connect fuel pressure gage as shown in
illustration. Wrap a shop towel around the fuel
connection to absorb any small amount of fuel
leakage that may occur when installing the gage.
With ignition "ON," and fuel pump running,
pressure should be 284-325 kPa (41-47 psi). This
pressure is controlled by spring pressure within
the regulator assembly.
2. When the engine is idling, manifold pressure is
low (high vacuum) and is applied to the pressure
regulator diaphragm. Vacuum will offset spring
pressure and result in a lower fuel pressure. Fuel
pressure at idle will vary somewhat depending on

barometric pressure but, should be less than
pressure noted in Step (1).
3. A system that does not hold pressure is caused by
one of the following:
Leaking fuel pump check valve.
Leaking fuel pump flex pipe.
Leaking valve/seat within pressure regulator.
Leaking injector(s).
4. A leaking injector can best be determined by
checking for a fouled or saturated spark plug(s).
CHART A-7
Pa e 1 of 3
INSTALL FUEL PRESSURE GAGE AS SHOWN ON FACING PAGE.

IGNITION "OFF" FOR 10.SECONDS. A/C "OFF."
IGNITION "ON." FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
IT MAY BE NECESSARY TO CYCLE THE IGNITION "ON" MORE
THAN ONCE TO OBTAIN MAXIMUM PRESSURE.
NOTE FUEL PRESSURE WITH PUMP RUNNING, PRESSURE
SHOULD BE 284-325 kPa (41-47 psi). WHEN PUMP STOPS,
PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY.
IS PRESSURE CORRECT AND DOES IT HOLD?

r------------,
FROM CHART A-3
L----______
I
-------------------------~
FUEL PRESSURE
WITHIN SPEC., BUT
DOES NOT HOLD.
: IF FUEL PRESSURE IS WITHIN NORMAL

I RANGE BUT IS SUSPECTED OF DROPPING
: OFF DURING ACCELERATION, CRUISE OR
I HARD CORNERING, SEE CHART A-7 (2 OF 3).
L
-------------------------~
DISCONNECT VACUUM HOSE

FROM PRESSURE REGULATOR
ASSEMBLY.
WITH ENGINE IDLING, APPLY
12-14 INCHES OF VACUUM TO
PRESSUREREGULATOL FUEL
PRESSURE NOTED IN STEP (1)
SHOULD DROP
APPROXIMATELY 21-69 kPa
(3-10 psi).
DOESIT?
LOCATE AND
REPAIR LOSS
OF VACUUM
TO PRESSURE
REGULATOR.
FUEL
PRESSURE
OUT OF SPEC.
NO FUEL PRESSURE
r- - - - - - - - - - - - - - ,
I USE OTC 54 CHART TO
I
r- - - - - - - - , : DIAGNOSE FUEL PUMP :
I
: SEE CHART A-7 : I ELECTRICAL CIRCUIT.
~ (2 OF 3 ) ____ J L-
-------------J
STARTENGINE,ALLOWITTOIDLEAT
FUEL PRESSURE NOTED IN STEP (1) SHOULD
DROP APPROXIMATELY 21-69 kPa (3-10 psi).
DOES IT?
NO TROUBLE
FOUND,
REVIEW
"SYMPTOMS,"
SECTION "B".
PRESSURE
REGULATOR
IS FAULTY.
(v
INSTALL J 37287 FUEL LINE

SHUT-OFF ADAPTORS, REFER TO
PAGES30F3ANDFAONGPAGE
ILLUSTRATION.
MAKE SURE VALVES ARE OPEN.
IGNITION "OFF."
USING A 10 AMP FUSED JUMPER
WIRE, CONNECT FUEL PUMP
"TEST" CONNECTOR TO B +
AND WAIT FOR PRESSURE TO
BUILD.
DISCONNECT JUMPER AND
CLOSE VALVE IN FUEL PRESSURE
LINE. PRESSURE SHOULD HOLD.
DOES IT?
OPEN VALVE IN FUEL

PRESSURE LINE.
RECONNECT PUMP "TEST"
JUMPER AND WAIT FOR
PRESSURE TO BUILD.
CLOSE VALVE IN FUEL
RETURN LINE. PRESSURE
SHOULD HOLD.
DOES IT?
CHECK FOR:
PLUGGED IN-LINE
FILTER.
RESTRICTED FUEL
PRESSURE LINE.
PLUGGED FUEL
PUMP STRAINER.
LEAKING FUEL
PUMP FLEX PIPE.
FUEL PUMP IS
FAULTY. (LEAKING
CHECK BALL INSIDE
PUMP.)
LOCATE AND CORRECT LEAKING

INJECTOR(S).
6-17-93
NS 16048-6E

CAUTION:
ENGINE FUEL PIPES


J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
RETURN LINE
J 34730-1
FUEL PRESSURE
GAGE ASSEMBLY
FUEL PUMP AND
RESERVOIR ASSEMBLY
NS 16047
CHART A-7
(Page 2 of 3)

7.

5. Fuel pressure that drops off during acceleration,
cruise or hard cornering may cause a lean
condition and result in a loss of power, surgihg or
misfire. This condition can be diagnosed using a
Tech 1 scan tool. If the fuel system is very lean,
one or both oxygen sensors will stop toggling and
output voltage will drop below 500 m V. Also,
injector pulse width will increase.
rn
6.
NOTICE:
Do not allow pressure to exceed 414

kPa (60 psi) as damage to the regulator may result.
8.
Important
Make sure system is not operating at "FuelCut-Off" which may cause false readings on
the scan tool.
Fuel pressure below 284 kPa (41 psi) may cause a

lean condition and may set a DTC 44/64.
Driveability conditions can include hard starting
cold, hesitation, poor driveability, lack of power,
surging or misfire.
Restricting the fuel return line causes fuel

pressure to build above regulated pressure. With
battery voltage applied to the pump "test"
connector, pressure should rise above 325 kPa (47
psi) as the valve in the return line is partially
closed.
Fuel pressure above 325 kPa (47 psi) may cause a

rich condition and may set a DTC 45/65.
(followed by black smoke) and a strong sulphur
smell in the exhaust.
9. This test determines if the high fuel pressure is
due to a restricted fuel return line or a faulty fuel
pressure regulator.
DRIVEABILITYAND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-35
CHART A-7
r--------,
:
FROM
:
CHARTA-7 1
:L- (1______
OF 3) J:
I
FUEL PRESSURE DROPS OFF

DURING ACCELERATION, CRUISE
OR HARD CORNERING.
CHECK FOR RESTRICTED IN-LINE
FUEL FILTER OR FUEL PRESSURE
LINE. IS THERE A RESTRICTION?
SERVICE AS
REQUIRED
AND RECH'ECK
'
INSTALLJ 37287-2 FUEL

RETURN LINE SHUT-OFF
ADAPTER, REFER TO PAGES
3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVE IS OPEN.
IGNITION "OFF."
USING A 10 AMP FUSED
JUMPER WIRE, CONNECT FUEL
PUMP "TEST" CONNECTOR
TOB+.
SLOWLY CLOSE SHUT -OFF
VALVE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi).
DO NOT EXCEED 414 kPa (60
psi).
DOES PRESSURE RISE ABOVE
325 kPa (47 psi)?
FUEL PRESSURE ABOVE

325 kPjl (47 psi).
Cv
DISCONNECT QUICK-CONNECT
FITTING AT ENGINE FUEL RETURN
PIPE, REFER TO PAGES 3 OF 3 AND
FACING PAGE ILLUSTRATION.
ATTAC!-1 A LENGTH OF FLEXIBLE
FUEL HOSE TO ENGINE FUEL
RETURN PIPE. PLACE OPEN END OF
HOSE INTO AN APPROVED
GASOLINE CONTAINER.
IGNITION "OFF" FOR 10 SECONDS.
IGNITION "ON." NOTE FUEL
PRESSURE WITH PUMP RUNNING.
PRESSURE SHOULD BE 284-325 kPa
(41-47 psi).
IS IT?
NO
CHECK FOR:
RESTRICTED FUEL PUMP STRAINER.
LEAKING FUEL PUMP FLEX PIPE.
WRONG FUEL PUMP.
PRESSURE
REGULATOR IS
FAULTY.
CHECK FOR RESTRICTED

ENGINE FUEL RETURN
PIPE OR FUEL RAIL
OUTLET PASSAGE.
IS THERE A RESTRICTION?
FUEL PUMP IS
FAULTY.
LOCATE AND
CORRECT
RESTRICTION IN
FUEL RETURN
LINE TO FUEL
TANK.
SERVICE AS
REQUIRED
AND
RECHECK.
6-17-93
NS 16049-6E
6E3-A-36 3.4L (L32) {VIN S) (SFI) DRIVEABILITY AND EMISSIONS
CHART A-7
(Page 3 of 3)

FUEL SYSTEM PRESSURE RELIEF PROCEDURE

Engines With Fuel Pressure Connection
(Must Be Performed Before Disconnecting Fuel Line Fittings)
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve fuel system
pressure before disconnecting fuel line fittings.
After relieving system pressure, a small amount of fuel may be released when
disconnecting fuel line fittings. In orc;ter to reduce the chance of personal injury,
cover fuel line fittings with a shop towel before disconnecting, to catch any fuel
that may leak out. Place the towel in an approved container when disconnect is
completed.
Tool Required: J 34730-1 Fuel Pressure Gage
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Ignition "OFF."
Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to
start the engine.
Loosen fuel filler cap to relieve tank vapor pressure.
Connect gage J 34730-1 to fuel pressure connection. Wrap a shop towel around fitting while connecting
gage to avoid spillage.
Install bleed hose into an approved container and open valve to bleed system pressure. Fuel line fittings
are now safe for servicing.
Drain any fuel remaining in gage into an approved gasoline container.
Perform service required.
Tighten fuel filler cap.
Ignition "OFF."
Connect negative battery cable.
Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks.
11-11-92
NS 14624
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-.A-37
CHART A-7
rn
Pa e 3 of 3
FU EL SYSTEM DIAGNOSIS
Important
In order to install fuel system diagnostic equipment on vehicles equipped with plastic quick-connect
fittings, fuel line separator tools must be used to disconnect the fittings. Using the separator tools to
release the fittings will cause the plastic retainer to remain inside the female connector allowing
diagnostic equipment to be connected.
Tools required:
J 37088-A tool set, fuel line quick-connect separator;
J 39504 tool set, fuel line quick-connect separator (restricted access).
l++I Remove or Disconnect

1. Relieve fuel system pressure (see "Fuel System Pressure Relief'').
2. If equipped, slide dust cover back to access quick-connect fitting.
3. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt
particles may cause eye injury.
4. Using compressed air, blow dirt out of fitting.
5. Choose correct tool from J 37088-A or J 39504 tool set for size of fitting.
connector, then push/pull inward to release locking tabs.
6. Pull connection apart. . .. . .... -
Insert tool into female
ILI Clean and Inspect
NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring sealing surface.
Using a clean shop towel, wipe off male pipe end.

Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.
l++I Install or Connect

CAUTION: To Reduce the Risk of Fire and Personal Injury:
Before connecting fitting, always apply a few drops of clean engine oil to the
male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off
adapter. This will ensure proper reconnection and prevent a possible fuel leak.
{During normal operation, the 0-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.)
Apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or
fuel line shut-off adapter.
2. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make sure connection is secure.
4. If equipped, reposition dust cover over quick-connect fitting.
1.
11-21-92
NS 14628

PCM
LEFT (BANK 2) OXYGEN
SENSOR (025)1
l ~ - l - - - - - - - - - - - - - - c ( ( - 1 6 6 5 PPL/WHT
1 351
-*-
LEFT 025 GROUND

BLK/WHT
RIGHT 025 GROUND
ENGINE
GROUND~
6-16-93
NS 15602
OTC 13
LEFT (BANK 2)0XYGEN SENSOR (025) CIRCUIT
(OPEN CIRCUIT)

The PCM supplies a voltage of about .45 volt between terminals "B20" and "B21". (If measured with a 10
megohm digital voltmeter, this may read as low as .35 volt.) The Oxygen Sensor (02S) varies the voltage within
a range of about 1 volt. If the left (Bank 2) exhaust is rich, the 02S will display close to 1000 millivolts and when
the exhaust is lean the 02S will display close to 100 millivolts.
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open 02S
circuit or cold 02S causes "Open Loop" operation.
OTC 13 Will Set When: The engine is in "Closed Loop," ECT is greater than 85C (185F), 02S voltage is
between 350 and 550 millivolts, throttle angle is greater than 3% with all conditions met for 30 seconds.
Action Taken (PCM will default to): The PCM will default to "Open Loop" operation and the MIL will
become illuminated.
OTC 13 Will Clear When: A current DTC 13 will clear when the 02S voltage begins to vary outside of the 350
to 550 millivolt window. A history DTC 13 will clear after 50 ignition key cycles without a current DTC 13 being
stored.
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. If the conditions for a DTC 13 exist, the system will
not go "Closed Loop."
2. This will determine if the sensor is at fault, or the
wiring or PCM is the cause of the DTC 13.
3. In doing this test use only a high impedance digital
volt ohmmeter. This test checks the continuity of
CKT 1665 and CKT 351 because if CKT 351 is
open, the PCM voltage on CKT 1665 will be over .6
volt (600 m V).
Diagnostic Aids: Normal Tech 1 scan voltage

varies between 100 mV to 999 mV (.1 and 1.0 volt)
while in "Closed Loop." DTC 13 sets if voltage remains
between .35 and .55 volt, but the system will go "Open
Loop" in about 15 seconds. Refer to "lntermittents," in
"Symptoms," Section "6E3-B".
DTC 13
(OPEN CIRCUIT)
G)
ENGINE AT NORMAL OPERATING TEMPERATURE (ABOVE 80C/176F);

RUN ENGINE ABOVE 1200 RPM FOR TWO MINUTES.
DOES SCAN TOOL INDICATE cLOSED LOOP .. ?
G)
DISCONNECT 025 CONNECTOR.

JUMPER HARNESS CKT 1665 (PCM SIDE) TO GROUND.
SCAN TOOL SHOULD DISPLAY OXYGEN SENSOR VOLTAGE
BELOW .2 VOLT (200 mV) WITH ENGINE RUNNING.
DOES IT?
OTC 1315 INTERMITTENT. IF NO ADDITIONAL

DTC(s) WERE STORED, REFER TO "DIAGNOSTIC
AIDS .. ON FACING PAGE.
REMOVE JUMPER.
IGNITION oN," ENGINE "OFF."
CHECK VOLTAGE OF CKT 1665(PCM SIDE)AT
025 HARNESS CONNECTOR USING A DVM.
FAUL TY 025 CONNECTION

OR
SENSOR.
.3-.6VOLT
(300 - 600 mV)
FAULTY PCM.
GREATER THAN
.6 VOLT (600 mV)
OPENCKT351
OR
FAUL TY CONNECTION
OR
FAULTY PCM.
LESS THAN .3
VOLT(300 mV)
OPEN CKT 1665
OR
FAULTY PCM CONNECTION
OR
FAULTY PCM.
..AFTER REPAIRS/' REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-16-93
NS 15603
PCM
10-WA Y INJ/PCM CONN. (BLACK)
ENGINECOOLANT ~ 4 1 0 Y E L
TEMPERATURE (ECT)
SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
SIGNAL
-------1
:--K--1-,+-:
1
sv
470 BLK/PNK - f i l - + 4 7 0 BLK - e - - - - - 1

I
SENSOR GROUND
TOTPSENSOR
7-2-93
NS 15607
OTC 14
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)

The Engin.e Coolant Temperature (ECT) sensor is a thermistor which varies the signal voltage at the PCM.
The PCM applies 5 volts to sensor on CKT 410. The sensor's resistance is inversely proportio.nal to the
temperature it is sensing.
As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine operating
temperature, the voltage will measure about 1.5 to 2.0 volts at the PCM terminal "A31".
Engine coolant temperature is one of the inputs used to control:
Fuel delivery.
EVAP canister purge.
Ignition Control (IC).
Exhaust Gas Recirculation (EGR).
Idle Air Control (IAC).
Cooling fan operation.
Torque Converter Clutch (TCC).
OTC 14 Will Set When: The signal voltage indicates engine coola11t temperature is greater than 135C
(275F). Engine must be running for greater than 20 seconds before this test will begin.
Action Taken (PCM will default to): The PCM will use a default value of 90C (194F) for fuel delivery
calculations. The cooling fans will be enabled and the MIL will become illuminated.
OTC 14 Will Clear When: Current OTC 14 will clear when the failure is no longer detect~d (temperature
falls below 135C (275F) threshold). A history OTC 14 will clear after 50 consecutive ignition key cycles without
a current DTC 14 being stored.
DTC Chart Test Description: Number(s) below

1. This check is to determine if a DTC 14 is
intermittent or a current malfunction.
2. This test will determine if CKT 410 is shorted to
ground which will cause the conditions for DTC 14.
Diagnostic Aids:
Check harness routing for a

potential short to ground in CKT 410. This circuit is
routed from the PCM to the 10-way !NJ/PCM
connector, and then to the Engine Coolant
Temperature (ECT) sensor.
Tech 1 scan tool displays engine coolant

temperature in degrees centigrade. After the engine is
started, the temperature should rise steadily to about
90C (194F) then stabilize when the thermostat opens.
Refer to "lntermittents" in "Symptoms," Section "6E3B".
Verify that engine is not overheating and has not

been subjected to conditions which could create an
overheating condition (i.e. overload, trailer towing,
hilly terrain, heavy stop and go traffic, etc.). The
"Temperature to Resistance Value" scale at the right
may be used to test the engine coolant temperature
sensor at various temperature levels to evaluate the
possibility of a "shifted" (mis-scaled) sensor. A
"shifted" sensor could result in poor driveability
complaints.
DTC 14
DOES SCAN TOOL DISPLAY ENGINE COOLANT

TEMPERATURE OF 130C (266F) OR HIGHER?
DISCONNECT ENGINE COOLANT

TEMPERATURE SENSOR.
SCAN TOOL SHOULD DISPLAY ENGINE
COOLANT TEMPERATURE BELOW-30C
(-22F).
DOES IT?
REPLACE ENGINE COOLANT

TEMPERATURE SENSOR.
OTC 14 IS INTERMITTENT. IF NO
ADDITIONAL DTC(s) WERE STORED, REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE.
CKT 410 SHORTED TO GROUND

OR
CKT 410 SHORTED TO SENSOR GROUND CIRCUIT
OR
FAULTY PCM.
DIAGNOSTIC AID
ENGINE COOLANT TEMPERATURE SENSOR
TEMPERATURE VS. RESISTANCE VALUES
(APPROXIMATE)
OF
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
17
68
59
50
41
32
23
14
5
-4
-22
-40
OHMS
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670.
7280
9420
12300
16180
21450
28680
52700
100700
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-2-93
PS 18353
6E3-A-42 3.4L (L32). {VIN S) (SFI) DRIVEABILITY AND EMISSIONS
PCM
10-WAY INJ/PCM CONN. (BLACK)
ENGINE COOLANT
TEMPERATURE SENSOR
SIGNAL
sv
ENGINE COOLANT ~ 4 1 0 YEL----:....1- -K--:

TEMPERATURE (ECT)
1
1
SENSOR
470BLK/PNK----+0+470BLK-e----I
SENSOR GROUND
TOTPSENSOR
7-2-93
NS 15607
DTC 15
(LOW TEMPERATURE INDICATED)

The Engine Coolant Temperature (ECT) sensor is a thermistor which varies the signal voltage at the PCM,
The PCM applies 5 volts to the sensor on CKT 410. The sensor's resistance is inversely proportional to the
temperature it is sensing.
As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine operating
temperature the voltage will measure about 1.5 to 2.0 volts at the PCM terminal "A31".
Coolant temperature is one of the inputs used to control:
Fuel delivery.
EVAP canister purge.
Ignition Control (IC).
Cooling fan operation.
Torque Converter Clutch (TCC).
OTC 15 Will Set When: A DTC 15 will set when the ECT sensor indicates an engine coolant temperature less
than -38C (-37F).
Action Taken (PCM will default to): The PCM will use a default value of 90C (194F) for fuel delivery
calculations. The cooling fans will be enabled and the MIL will become illuminated.
OTC 15 Will Clear When: A current DTC 15 will clear when the low temperature failure is no longer
detected [temperature rises above -38C (-37F) threshold]. A history DTC 15 will clear after 50 consecutive
ignition key cycles without a current DTC 15 being stored.
temperature should rise steadily to about 95C (203F)
then stabilize when the thermostat opens. CKT 410 is
1. This is to verify that the temperature fault is not
routed from the PCM to a mini harness connector, and
intermittent.
then to the Engine Coolant Temperature (ECT) sensor.
2. This test simulates a DTC 14. If the PCM
A faulty connection, or an open in CKT 410 or 470
recognizes the low signal voltage (high
willresultinaOTC15.
temperature), and the Tech 1 scan tool reads 130C
DTCs 15 and 21 stored at the same time could be
(266F), the PCM and wiring are OK.
the result of an open CKT 470 which would also turn
3. This test will determine if CKT 410 is open. There
the temperature warning indicator "ON."
should be 5 volts present at sensor connector if
The "Temperature to Resistance Value" scale at
measured with a DVM.
the right may be used to test the engine coolant
Diagnostic Aids: Check harness routing for a
temperature sensor at various temperature levels to
potential open in CKT 410. This circuit is routed from
evaluate the possibility of a "shifted" (mis-scaled)
the PCM through the 10-way INJ/PCM connector and
sensor. A "shifted" sensor could result in poor
then to the engine coolant temperature sensor.
driveability complaints.
Refer to "Intermittents" in "Symptoms," Section
A Tech 1 scan tool reads engine temperature in
"6E3-B".
degrees centigrade. Mter the engine is started, the
OTC 15
DOES TECH 1 SCAN TOOL DISPLAY ENGINE COOLANT TEMPERATURE OF -38C (-37F) OR LESS?
DISCON.HECT ENGINE COOLANT TEMPERATURE SENSOR.

JUMPER HARNESS TERMINALS TOGETHER.
TECH 1 SCAN TOOL SHOULD DISPLAY 130C (266F) OR MORE.
DOESIT?
DTC 15 IS INTERMITTENT. IF NO
JUMPER CKT 410 TO GROUND.

TECH 1 SCAN TOOL SHOULD DISPLAY OVER 130C (266F).
DOESIT?
FAUL TY CONNECTION OR ENGINE

COOLANT TEMPERATURE SENSOR.
OPEN ENGINE COOLANT TEMPERATURE SENSOR GROUND

CIRCUIT, FAULTY CONNECTION OR FAULTY PCM.
dPEN CKT 410, FAULTY

CONNECTION AT PCM, OR
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
OHMS
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
3-10-93
NS 15052

PCM
10-WAY IN-LINE
1/P CONNECTOR
# 2 {BLUE)
1/P FUSE #5
-----<V"-----..ir--------11(IJ..----439 PNK ---c::

15 AMP
TO IGN ....
SWITCH
SEE SECTION SA
{ELECTRICAL DIAGNOSIS)
FOR COMPLETE CIRCUIT
DETAILS
IGNITION FEED
6-16-93
NS 15601
DTC 16
SYSTEM LOW VOLTAGE
The PCM will perform a test of the ignition voltage applied to pin "C3" of the PCM. A comparison is done
between the voltage applied to the input and a calibrated voltage value.
During the time a low voltage failure is present, all PCM outputs will become disabled. This may result in
the additional setting of other seemingly unrelated DTCs.
OTC 16 Will Set When: The PCM detects 8 volts or less on the ignition feed CKT 439, engine speed is greater
than 1000 RPM with both conditions met for 2 seconds.
Action Taken {PCM will default to): The MIL will become illuminated.
OTC 16 Will Clear When: A current DTC 16 will clear when ignition feed voltage is detected above 8 volts. A
history OTC 16 will clear after 50 consecutive ignition key cycles without a current DTC 16 being stored.
1. Test generator output as outlined in SECTION
603 to determine proper operation of the voltage
regulator. Run engine at moderate speed and
measure voltage across the battery. If less than 8
volts, repair generator as outlined in SECTION
603.
Diagnostic Aids: An intermittent may be caused

by poor connections, chaffed insulation, a wire broken
inside the insulation or poor PCM grounds.
Intermittent test. Monitor "System Volts" display
with a Tech 1 while moving related connectors. If
the failure is induced, the display will abruptly
change. This may help to isolate the location of the
malfunction.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) {SFI) 6E3-A-45
DTC 16
INSTALL TECH 1.
START ENGINE, WITH ENGINE RUNNING ABOVE 1000 RPM.
SCAN SYSTEM VOLTAGE.
BETWEEN 9 AND 14 VOLTS
INSTALLDVMACROSSBATTERY.
RUN ENGINE ABOVE 1000 RPM.
DOES DVM SHOW BATTERY
VOLTAGE ABOVE 12 VOL TS OR
LESS THAN 8 VOL TS.?
LOAD ELECTRICAL SYSTEM WITH

HEADLAMPS AND HIGH A/C BLOWER.
RAISE ENGINE RPM TO 2000.
NOTE SYSTEM VOLTAGE ON TECH 1.
BETWEEN 8 AND 14 VOL TS
SEE SECTION 6D
FOR REPAIR.
FAULT IS NOT PRESENT.

REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.
BELOW 8 VOL TS

HEADLAMPS AND HIGH A/C BLOWER.
NOTE BATTERY VOLTAGE AT BATTERY.
SEE SECTION 6D FOR REPAIR.
LESS THAN 8 VOL TS
COMPARE TECH 1 READING OF SYSTEM

VOLTAGE WITH DVM READING.
SEE SECTION 6D FOR REPAIR.
TECH 1 DATA DOES NOT

REFLECT DVM VALUES.
BOTH ABOVE 12 VOL TS
FAULTY PCM CONNECTOR

OR FAULTY PCM.
FAULT IS NOT PRESENT. REFER TO

"DIAGNOSTIC AIDS" ON FACING PAGE.
3-8-93
NS 15043
6E3-A-46 3.4l (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

PCM
PIGTAIL
CONNECTOR
- - - - - 633 BRN/WHT
CAMSHAFT
POSITION
SENSOR
-------1
CAM REFERENCE
SIGNAL
- - - - - 632 PNK/BLK - - - - - - - - ,
FUSE #11
1O AMP
I G N I T I O N ~ 239 PNK
10-WA Y FWD LAMP

HARNESS CONNECTOR
(BLACK)
-----11 G
TO IGNITION
CONTROL MODULE
(ICM)
11-----------'
RED
24X(CKP) ---BLK
SENSOR
---GRN
HIGH RESOLUTION
632PNK/BLK
--------11
B -----1800LTBLU/WHT-------1
PIGTAIL
CONNECTOR
REFERENCE LOW CAMSHAFT

AND 24X SIGNALS
24X REFERENCE
SIGNAL
7-2-93
NS 15617
DTC 17
CAMSHAFT POSITION SENSOR CIRCUIT ERROR
The camshaft position sensor is a "Hall-effect" switch, located on the front of the engine. The camshaft
position sensor sends a signal to the PCM when the #1 cylinder is on the intake stroke. This signal is used by th~
PCM to synchronize Sequential Fuel Injection (SFI) mode of operation with each intake valve opening. If the cam
reference signal is not received by the PCM, the PCM will still pulse the fuel injectors sequentially, but.the fuel
injectors may not be in synch with each intake valve opening. That is, fuel injector timing may not be as accurate
because the PCM does not know the exact time each intake valve is opening. A loss of this signal or extra (false)
cam reference signals, above 500 RPM, will set a OTC 17.
OTC 17 Wi 11 Set When: Cam reference pulses are not detected by the PCM for 3 seconds while the engine is
running, or CAM pulse is missing on the first pass through the internal PCM self test of the camshaft position
sensor.
Action Taken (PCM will default to): The PCM will pulse the injectors sequentially though possibly not in
the correct sequence. The malfunction indicator lamp will not be illuminated.
OTC 17 Will Clear When: A current OTC 17 will clear when the cam signal begins to toggle. A history OTC
17 will clear after 50 consecutive ignition key cycles without a current OTC 17 being stored.
1. The PCM performs a test for OTC 17 when the
engine is running or during cranking.
2. By repeatedly "bumping" the starter, the camshaft
timing mark and the camshaft position sensor will
align with each other. At this point, the voltage
from the sensor applied to the PCM should drop to
near zero temporarily. This indicates that the
camshaft position sensor is capable of sending a
signal to the PCM.
3. Before replacing the camshaft position sensor,

inspect the sensor for proper installation.
Diagnostic Aids: An intermittent cam reference

signal can be caused by poor connections, cracked
sensor or internal engine problem.
DTC 17
IF ENGINE CRANKS BUT WON'T RUN, USE CHART A-3.

IGNITION "ON" ENGINE IDLING. TECH 1 SCAN TOOL SHOULD
DISPLAY CAM SIGNAL PULSES CONSTANTLY CHANGING "O" TO "1".
DOESIT?
IGNITION "OFF."
DISCONNECT PCM HARNESS CONNECTOR "C".
IGNITION "ON."
PROBE PCM HARNESS PIN "C25" WITH A DVM TO GROUND (SET
DVM TO DC VOLTAGE).
DOES DVM DISPLAY APPROXIMATE SYSTEM VOLTAGE?
WITH KEY IN THE "ON" POSITION, CYCLE IGNITION TO

CRANK POSITION MOMENTARILY SEVERAL TIMES
WHILE OBSERVING DVM.
~ VOLTAGE SHOULD TEMPORARILY DROP TO NEAR ZERO
EACH TIME THE CAMSHAFT TIMING MARK ALIGNS
WITH THE CAMSHAFT POSITION SENSOR.
DOESIT?
IGNITION "OFF."
RECONNECT PCM HARNESS
CONNECTOR "C".
DISCONNECT CAM SENSOR 3-WA Y
HARNESS.
IGNITION "ON."
PROBE TERMINAL "C" (PCM HARNESS
SIDE) WITH A TEST LIGHT TO BATTERY
VOLTAGE.
IS TEST LIGHT "ON"?
FAUL TY HARNESS CONNECTION

OR
OPEN CAMSHAFT POSITION SENSOR
GROUND WIRE
OR
FAULTY CAMSHAFT POSITION SENSOR.
FAULTY PCM
CONNECTION
OR
FAULTY PCM.
OPEN HARNESS
GROUND
CIRCUIT.
DTC 17 IS INTERMITTENT. REFER TO

"DIAGNOSTIC AIDS" ON FACING PAGE .
IGNITION "OFF."
DISCONNECT CAMSHAFT POSITION SENSOR
PIGTAIL HARNESS CONNECTOR.
IGNITION "ON."
CONNECT DVM BETWEEN TERMINAL A" (PCM
HARNESS SIDE) AND GROUND.
DOES DVM DISPLAY APPROXIMATE BATTERY
VOLTAGE?
WITH A FUSEDJUMPER,JUMP
CAM SENSOR PIGTAIL TERMINAL
"A" TO BATTERY VOLTAGE.
PROBE TERMINAL "B" WITH
DVM TO GROUND.
DOES DVM DISPLAY
APPROXIMATE BATTERY
VOLTAGE?
OPEN OR SHORTED CAMSHAFT

POSITION SENSOR IGNITION FEED
WIRE TO SENSOR
OR
OPEN OR SHORTED CAMSHAFT
POSITION SENSOR PIGTAIL
SIGNAL WIRE FROM SENSOR
OR
FAULTY CAMSHAFT POSITION
SENSOR.
FAULTY HARNESS
IGNITION FEED
CIRCUIT.
FAULTY
CAMSHAFT
PIGTAIL
CONNECTION
OR
FAULTY PCM
CONNECTION
OR
OPEN CAMSHAFT
POSITION SENSOR
SIGNAL WIRE TO
PCM.
3-9-93
NS 15255
PCM
TO ECT SENSOR
It
-----
THROTTLE
POSITION {TP)
SENSOR
~CAB.___ _ 416 GRY

~
417 DK BLU
- - - 470 BLK
--------::11~----------1
SENSOR GROUND
TO A/C REFRIGERANT
PRESSURE SENSOR & A/C EVAPORATOR
TEMPERATURE SENSOR
TO MAP SENSOR
6-16-93
NS 15609
DTC21
THROTTLE POSITION (TP) SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH}

The Throttle Position (TP) sensor provides a voltage signal to the PCM that increases as the throttle blade
angle increases. This signal voltage will vary from approximately .5 volt at idle to 4.8 volts at Wide Open
Throttle (WOT). The TP sensor is one of the most important inputs to the PCM for governing fuel control of the
engine.
DTC 21 Will Set When: No DTC 33 or DTC 34, TP sensor voltage is greater than 3.8 volts, engine speed is
above 600 RPM, both conditions met for 10 seconds under steady throttle, road load conditions, or with throttle
closed, the TP sensor should read less than .98 volt. If it doesn't, make sure cruise control and throttle cables are
not being held open.
Action Taken (PCM will default to): The PCM will determine fuel and air calculations using calibrated
values from a default table. The transmission will have maximum line pressure, no TCC and no 4th gear in hot
mode. The MIL will become illuminated.
OTC 21 Will Clear When: A current DTC 21 will clear when a high signal voltage above the calibrated
threshold is no longer detected. A history DTC 21 will clear after 50 consecutive ignition key cycles without a
current DTC 21 being stored.
1. With throttle closed, the TP sensor should read
less than .98 volt. If it doesn't, ma.ke sure cruise
control and throttle cables are not being held open.
2. With the TP sensor disconnected, the TP sensor
voltage should go low, if the PCM and wiring are
OK.
3. Probing CKT 470 with a test light checks the 5 volt
return circuit. A faulty sensor ground circuit will
cause a DTC 21. DTC 33, 66 or 71 may also be set.
Diagnostic Aids: A Tech 1 scan tool reads throttle

position in volts. Voltage should increase at a steady
rate as throttle is moved toward WOT.
Also some scan tools will read: throttle angle 0%
= closed throttle, 100% = WOT.
An open in CKT 470 will result in a DTC 21.
Scan TP sensor while depressing accelerator pedal
with engine stopped and ignition "ON." Display
should vary from about .5 volt when throttle was
closed, to about 4.8 volts when throttle is held at Wide
Open Throttle (WOT) position.
"6E3-B".
DRIVEABILITY AND EMISSIONS 3.4L (L32) {VIN S) (SFI) 6E3-A-49
DTC21
(SIGNAL VOLTAGE HIGH)
THROTTLE CLOSED.
DOES TECH 1 SCAN TOOL DISPLAY
THROTTLE POSITION OVER 2.5 VOLTS?
DISCONNECT THROTTLE POSITION SENSOR.

TECH 1 SCAN TOOL SHOULD DISPLAY
THROTTLE POSITION BELOW .2 VOLT (200 mV).
DOESIT?
OTC 21 IS INTERMITTENT. IF NO ADDITIONAL DTC(s) WERE

STORED, REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
PROBE SENSOR GROUND CIRCUIT

WITH A TEST LIGHT CONNECTED TO
BATTERY VOLTAGE.
TP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

OR
FAULTY PCM.
FAULTY CONNECTION
OR
THROTTLE POSITION SENSOR.
OPEN SENSOR GROUND CIRCUIT

OR
FAULTY PCM.
6-4-93
PS 18379
PCM
TO ECT SENSOR
Priff!~rP)I.._~___fsi......--. . ::::::LU
~Bt - - - -
470 BLK
--------:;:jl~----------1
SENSOR GROUND
TO A/C REFRIGERANT
PRESSURE SENSOR & A/C EVAPORATOR
TEMPERATURE SENSOR
TO MAP SENSOR
6-16-93
NS 15609
DTC22
(SIGNAL VOLTAGE LOW)

The Throttle Position (TP) sensor provides a voltage signal to the PCM that increases as the throttle blade
angle increases. This signal voltage will vary from approximately .5 volt at idle to 4.8 volts at Wide Open
Throttle (WOT). The TP sensor is one of the most important inputs to the PCM for governing fuel control of the
engine.
OTC 22 Will Set When: TP sensor signal is less than .2 volt with engine running, and RPM greater than 400.
Condition must be met for 3 seconds.
Action Taken (PCM will default to): The PCM will determine fuel and air calculations using calibrated
values from a default table. The transmission will have maximum line pressure, no TCC and no 4th gear in hot
mode. The MIL will become illuminated.
OTC 22 Will Clear When: A current DTC 22 will clear when a low signal voltage below the calibrated DTC
22 threshold is no longer detected. A history DTC 22 will clear after 50 consecutive ignition key cycles without a
OTC Chart Test Description:
Number(s) below
1. Simulates DTC 21 (high voltage): If the PCM
recognizes the high signal voltage, the PCM and
wiring are OK.
2. TP sensor check: The TP sensor has an auto
zeroing feature. If the voltage reading is within
the range of 0.29 to 0.98 volt, the PCM will use
that value as closed throttle. If the voltage reading
is out of the auto zero range on an existing or
replacement TP sensor, check for cruise control
and throttle cables for being held open.
3. This simulates a high signal voltage to check for
an open in CKT 417.
4. CKT 416 is a 5 volts buffered reference signal. If
CKT 416 is shorted to ground, DTC 22 will set. To
determine if the MAP sensor is causing the DTC
22 problem, disconnect it to see if DTC 22 resets.
Be sure TP sensor is connected and clear DTC(s)
before testing.
Diagnostic Aids: A Tech 1 scan tool reads throttle

position in volts. Voltage should increase at a steady
rate as throttle is moved toward WOT.
= closed throttle, 100% = WOT.
An open or short to ground in CKTs 416 or 417 will
result in a DTC 22.
Scan TP sensor while depressing accelerator pedal
with engine stopped and ignition "ON." Display
should vary from about .5 volt when throttle was
closed, to about 4.8 volts when throttle is held at Wide
Open Throttle (WOT) position.
= closed throttle, 100% = wide open throttle.
If DTC 22 is set, check CKT 416 for faulty wiring
or connections.
"6E3-B".
DTC22
G)
0
(v
THROTTLE CLOSED.
DOES TECH 1 SCAN TOOL DISPLAY TP SENSOR :2v (200 mV)OR,BELOW1
DISCONNECT TP SENSOR.
JUMPER HARNESS CKTs416 AND417 TOGETHER.
TECH 1 SCAN TOOL SHOULD DISPLAV TP SENSOR OVER 4.0V.
DOESIT1
DTC 22 IS INTERMITTENT. If NO ADDITIONAL

DTCs WERE STORED, REFER TO uDIAGNOSTIC
PROBE CKT 417WITH A TEST LIGHT CONNECTED TO B+.

TECH 1 SCAN TOOL SHOULD DISPLAY TP SENSOR OVER .4.0V.
DOESIT1
CKT 416 OPEN, SHORTED TO GROUND.

IF OK, IT IS A FAULTV CONNECTION
OR
FAULTY PCM.
CKT 417 OPEN, SHORTED TO GROUND,

FAUL TY CONNECTION
OR
FAULTY PCM.
7-3-93
NS 15387
PCM
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
...,....---1
1------------------ 472TAN
SENSOR GROUND
TO MAP
SENSOR
TO A/C REFRIGERANT
PRESSURE SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
6-16-93
NS 15610
DTC23
INTAKE AIR TEMPERATURE {IAT) SENSOR CIRCUIT

The Intake Air Temperature (IAT) sensor is a thermistor that controls a signal voltage to the PCM. The PCM
applies approximately 5 volts to the sensor on CKT 472. When the intake air is cold, the sensor resistance is high,
therefore the voltage sensed at the input "C29" is high. If the air is warm, the sensor resistance will be low, and
the voltage input to the PCM will be low.
DTC 23 Will Set When: A signal voltage indicates an Intake Air Temperature (IAT) less than -35.5C
(-35.9F), a signal voltage indicates that engine coolant temperature is greater than -35.5C (-31.9F), time since
engine start is 4 minutes or longer, vehicle speed is less than 1 mph with all conditions met for 25 seconds
Action Taken (PCM will default to): The PCM will use an IAT default value of 37C (108F) and the MIL
will become illuminated.
DTC 23 Will Clear When: A current DTC 23 will clear when the intake air temperature is indicated above
the DTC 23 threshold. A history DTC 23 will clear after 50 consecutive ignition key cycles without a current DTC
23 being stored.
Number(s) below
1. A DTC 23 will set due to an open sensor, wire, or
connection. This test will determine if the wiring
and PCM are OK.
2. This will determine if the signal CKT 472 or the 5
volts return CKT 802 is open.
Diagnostic Aids: A Tech 1 scan tool reads the

temperature of the air entering the engine, and should
read close to ambient air temperature when the engine
is cold. IAT values will rise as underhood temperature
increases.
A faulty connection, or an open in CKT 472 or CKT

452 will result in a DTC 23.
DTCs 23 and 34 stored at the same time could be
the result of an open CKT 452. A faulty connection
could result in intermittent failures. The
"Temperature to Resistance Values" scale at the right
may be used to test the IAT sensor at various
temperature levels to evaluate the possibility of a
"shifted" (mis-scaled) sensor. A "slewed" sensor could
result in poor driveability complaints.
"6E3-B".
DTC23

DOES TECH 1 SCAN TOOL DISPLA V IAT 37C (-32F) OR COLDER?
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS
TOGETHER.
TECH 1 SCAN TOOL SHOULD
DISPLAY TEMPERATURE OVER
14oc (284F) .
DOESIT?
ADDITIONAL DTC(s) WERE
STORED, REFER TO "DIAGNOSTIC
DIAGNOSTIC AID
INTAKE AIR TEMPERATURE SENSOR
(APPROXIMATE)
OF
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
so
41
32
23
14
5
-4
-22
-40

TECH 1 SCAN TOOL SHOULD
DISPLAY TEMPERATURE OVER
14oc (284F).
DOESIT?
OPEN SENSOR
GROUND CIRCUIT,
FAULTY CONNECTION
OR FAUL TV PCM.
OPEN CKT 472,

FAULTY CONNECTION
OR FAUL TV PCM.
OHMS
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
3-9-93
PS 17146
PCM
~ ffi=================~.:.::L
r:1
---.-1:
111
LOCATED ON TRANSMISSION
TO ...
SPEEDOMETER
~1-i:------ 817 DK GRN/WHT

'-'- - '-'
VSS SIGNAL (LOW)
VSS SIGNAL (HIGH)

VSS OUTPUT
(4000 PPM)
10-WAY INLINE
1/P CONNECTOR
#1
(NATURAL)
7-8-93
NS15611
DTC24
'
VEHICLE SPEED SENSOR (VSS) CIRCUIT

Vehicle speed information is provided to the Powertrain Control Module (PCM) by the Vehicle Speed Sensor
(VSS), which is a Permanent Magnet (PM) generator mounted in the transmission. The PM generator produces a
pulsing voltage whenever vehicle speed is over about 3 mph. The AC voltage level and the number of pulses
increases with vehicle speed. The PCM then converts the pulsing voltage to mph, which is used for calculations.
The vehicle speed can be displayed with a Tech 1 scan tool.
The PCM supplies a signal, on CKT 817, to operate the speedometer and the odometer. The VSS signal is also
sent to the cruise control module.
DTC 24 Will Set When: Engine speed is between 2200 and 4400 RPM, TP sensor voltage less than 290, low
load condition (low MAP voltage), high manifold vacuum, transaxle not in park or neutral, VSS less than or equal
to 3 mph. All conditions met for 4 seconds.
Action Taken (PCM will default to): The vehicle will default to 3rd gear, the transmission will have
maximum line pressure and the MIL will become illuminated.
DTC 24 Will Clear When: A current DTC 24 will clear after each ignition key cycle. A history DTC 24 will
clear after 50 consecutive ignition key cycles without a current DTC 24 being stored.
1. Disregard DTC 24 that sets when drive wheels are
not turning. This can be caused by a faulty PNP
switch circuit.
The sensor only produces a signal if drive wheels
are turning faster than 3 mph.
2. If CKTs 400, 401 and 817 are OK, and if the
speedometer works properly, DTC 24 is being
caused by a faulty PCM, or an incorrect program.
If the PCM is faulty and must be replaced, the new
PCM must be programmed, also, note that the ESC
module will have to be transferred when replacing
the PCM. Refer to "PCM Replacement and
Programming Procedures" in Section "6E3-Cl".
Diagnostic Aids: Tech 1 scan tool should indicate a

vehicle speed whenever the drive wheels are turning
greater than 3 mph.
A problem in CKT 817 will not affect the VSS
input or the readings on a Tech 1 scan tool.
Check CKT 400 and CKT 401 for proper
connections to be sure they are clean and tight, and
that the harness is routed correctly. Refer to
"Intermittents" in "Symptoms," Section "6E3-B".
A faulty or misadjusted Park/Neutral Position
(PNP) switch can result in a false DTC 24. Use a
scan tool to check for the proper signal while in a
drive range. Refer to CHART C-lA for the PNP
switch check.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN. S) (SFI) 6E3-A-55
DTC24
DISREGARD OTC 24 IF SET WHILE DRIVE WHEELS ARE NOT TURNING.
G)
RAISE DRIVE WHEELS.

.
.
WITH ENGINE IDLING IN GEAR, SCAN TOOL SHOULD DISPLAY VEHldE SPEED ABOVE O MPH.
DOESIT?
DOES SPEEDOMETER WORK PROPERLY?
IGNITION "OFF.
DISCONNECT VSS HARNESS CONNECTOR AT TRANSAXLE.
CONNECT SIGNAL GENERATOR TESTER J 33431-8 OR EQUIVALENT
TO VSS HARNESS CONNECTOR.
IGNITION "ON; TOOL "ON AND SET TO GENERATE A VSS SIGNAL.
SCAN TOOL SHOULD DISPLAY VEHICLE SPEED ABOVE OMPH.
DOESIT?
CKT400
OR,
401 OPEN, SHORTED TO GROUND, SHORTED
TOGETHER, FAULTY CONNECTIONS
OR
FAULTY PCM.
AFTER REPAIRS, n REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
6-16-93
NS 15612
PCM
INTAKE AIR
TEMPERATURE
(IAT) SENSO!t
SVOLTS
B - - - - - - - - - - - - - - - - - - 472TAN
TO MAP
SENSOR
TO A/C REFRIGERANT
PRESSURE SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
6-16-93
NS 15610
DTC25
INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT

The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the PCM. The
PCM applies a voltage (about 5 volts) on CKT 472 to the sensor. When the air is cold, the sensor (thermistor)
resistance is high, therefore the PCM will see a high signal voltage. If the air is warm the sensor resistance is
low, thetefore the PCM will see a low voltage.
The IAT sensor is located in the rear air intake duct.
OTC 25 Will Set When: Vehicle speed is greater than 1 mph and intake air temperature indicates 145C
(297F) for 2 seconds.
Action Taken (PCM will default to): The PCM will use an IAT default value of 37C (108F) and the MIL
will become illuminated.
OTC 25 Will Clear When: A current DTC 25 will clear when the intake air temperature is indicated below
the high temperature threshold. A history OTC 25 will clear after 50 consecutive ignition key cycles without a

1. This test is a verification that the OTC is not
intermittent.
2. This test helps determine between a circuit fault
and a faulty sensor.
Diagnostic Aids: A Tech 1 scan tool reads the
temperature of the air entering the engine and should
read close to ambient air temperature when engine is
cold. IAT values will rises as underhood temperature
increases.
A short to ground in CKT 472 will result in a OTC

25.
The "Temperature to Resistance Values" scale at
the right may be used to test the IAT sensor at various
temperature levels to. evaluate the possibility of a
"shifted" (mis-scaled) sensor. A "slewed" sensor could
result in poor driveability complaints.
"6E3-B".
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-,57
DTC25
(HIGH TEMPERATURE INDICATE!))
G)
DOES TECH 1 SCAN TOOL DISPLAY

IA T OF 145C (293F) OR HOTTER?
DISCONNECT SENSOR.
TECH 1 SCAN TOOL SHOULD DISPLAY
TEMPERATURE BELOW 30C (22F).
DOES IT?.
OTC 2515 INTERMITTENT. If NO ADDITIONAL

DTCs WERE STORED, REFER TO "DIAGNOSTIC

OR
TO SENSOR GROUND
OR
PCM IS FAUL TY .
. DIAGNOSTIC AID
(APPROXIMATE)
"F
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
5
10
15
20
30
40
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
-4
-22
-40
4-2993
PS 17699

PCM
TRANSMISSION RANGE
PRESSURE SWITCH ASSEMBLY
- - - - - - - - 1225 DK BLU
B+
1226 RED
1
I
TRANSMISSION
CONNECTOR
...._
...' - - - - - - - 1227 BLK/YEL
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
...-.__,,,,.11,,...._5y
- - - TFT SIGNAL
MAP
SENSOR
6-16-93
PS 18513
DTC28
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY FAULT
3.4L (VIN S) ''F" CARLINE (Sfl)
The TR pressure switch assembly consists of five pressure switches (2 normally closed and 3 normally open),
and a TFT sensor combined into one unit and mountecI on the valve body. The PCM supplies battery voltage to
each range signal. By grounding one or more of these circuits through various combinations of the pressure
switches, the PCM detects which manual valve position has been selected by the vehicle operator. With ignition
"ON" and engine "OFF," PIN will be indicated.
DTC 28 Will Set When: Range signals "A;, and "C" are both Ovolts ("ON"), for two seconds.
Action Taken (PCM will default to): Drive Range 4 for shift pattern control, harsh shifts. TCC will be
inhibited, and if in hot mode, no fourth gear will occur. DTC 28 will be stored in the PCM memory but will not
turn "ON" the Malfunction Indicator Lamp (MIL) .
DTC 28 Will Clear When: The fault condition(s) no longer exist, and the ignition switch cycled "OFF" then
"ON."
DTC Chart Test Description:
Number(s) below
1. This test checks the indicated range signal to the
valve position signal actually selected.
2. This test checks for correct voltage from the PCM
to the transmission external connector.
3. This test checks a short to ground in any one of the
three valve position circuits.
"ON"
=Zero Volt/"OFF" =B +
A
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
ON
Expected Readings
ON
Range Signal
ar
Rev
Neutral
04
03
02
01
ega
Ille al
Diagnostic Aids: DTC 28 will set if the PCM

detects one of two "illegal" combinations.
Refer to accompanying chart for various
combinations.
Check all connectors for good contact.
Refer to "TR Pressure Switch Assembly Resistance
Check" or "Functional Test Procedure" in SECTION
7Al 4A of the appropriate service manual for further
information.
DTC28
SWITCH ASSEMBLY FAULT
THIS CHART ASSUMES THAT:

THE TRANSMISSION LINKAGE FROM THE SELECT LEVER TO
THE MANUAL VALVE IS ADJUSTED PROPERLY.
OBD SYSTEM CHECK HAS BEEN PERFORMED.
FLUID CHECKING PROCEDURE HAS BEEN PERFORMED.
ALL DTC{s) HAVE BEEN RECORDED AND THEN CLEARED.
SCAN TOOL STILL INSTALLED.
ENGINE IDLING AT NORMAL OPERATING TEMPERATURE.

PARKING BRAKE APPLIED AND WHEELS BLOCKED.
APPLY BRAKE PEDAL AND SELECT EACH TRANSMISSION RANGE 01, 02, 03, 04, N, R, P.
DOES EACH SELECTED TRANSMISSION RANGE MATCH THE SCAN TOOL "TRANS RANGE SW" DISPLAY?
IGNITION "OFF."
DISCONNECT TRANSMISSION WIRING CONNECTOR ASM.
INSTALL J 39775-JUMPER HARNESS/PROBE KIT ON THE
EXTERNAL WIRING CONNECTOR.
WITH J 39200TO GROUND,CHECKVOLTAGE AT HARNESS
CONNECTOR TERMINALS "N", "R" AND "P".
DOES J 39200 DISPLAY B + AT ALL THREE CIRCUITS?
ON CIRCUIT{S) THAT DID NOT INDICATE B +, CHECK FOR AN

OPEN OR SHORT TO GROUND. IF OK, CHECK CONTROL
MODULE CONNECTOR TERMINAL TENSION ON THESE
CIRCUITS. IF OK, REPLACE CONTROL MODULE.
(D
VERIFY THAT CKT{s) 1224, 1225, OR 1226 ARE NOT

SHORTED TOGETHER. IF OK, REFER TO "FLUID
PRESSURE SWITCH ASSEMBLY RESISTANCE
CHECK" SECTION 7A14A {4L60E) OR7A17A
{4LSOE) OF THE APPROPRIATE SERVICE MANUAL.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RES'ET.
4-27-93
PS 17065
PCM
TO A/C EVAPORATOR
TEMPERATURE SENSOR
MANIFOLD
ABSOLUTE
PRESSURE
{MAP)
SENSOR
TOA/C
REFRIGERANT
PRESSURE SENSOR
I - - - - _ _ ; ~ - - - - 452 BLK
SENSOR GROUND
1 - - - - - - - - - - 432LT GRN
r - - - - - - - : ; ~ - - - - 416 GRY
MANIFOLD
VACUUM
5VOLT
REFERENCE
TOT/P
SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
616-93
NS 15613
DTC33
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
{SIGNAL VOLTAGE HIGH- LOW VACUUM)

The Manifold Absolute Pressure (MAP) sensor responds to changes in the intake manifold pressure. MAP is
the inverse of vacuum, so as MAP increases such as during WOT, vacuum decreases.
The MAP sensor should indicate approximately 1-2 volts at idle, and between 4 and 5 volts at Wide Open
Throttle (WOT). MAP is one of the most important inputs for calculating fuel delivery.
OTC 33 Will Set When: No current DTC 21 or 22 is present, engine running, MAP is greater than 74 kPa
(AIC "OFF") 84 kPa (A/C "ON"), throttle angle is between 3% and 30% and held steady. All conditions met for 4
seconds.
Action Taken {PCM will default to): A default table of MAP values will be used by the PCM to calculate
air flow. The MIL will become illuminated and MAP values on the Tech 1 will become maximum (5 volts).
OTC 33 Will Clear When: A current DTC 33 will clear when the MAP value falls below the calibrated high
MAP threshold. A history DTC 33 will clear after 50 consecutive key cycles without a current DTC 33 being
stored.
Comparison of this reading with a known good vehicle
with the same sensor is a good way to check accuracy
of a "suspect" sensor. Readings should be the same
1. Engine misfire or a low unstable idle may set DTC
.4 volt.
33.
Check all connections .
2. With the MAP sensor disconnected, the PCM
should see a low voltage if the PCM and wiring are
Important
OK.
Make sure electrical connector remains
Diagnostic Aids: If idle is rough or unstable, refer
securely fastened.
to "Symptoms," Section "6E3-B" for items which can
cause an unstable idle.
Disconnect sensor from bracket and twist sensor
An open in CKT 452 or the connection will result
by hand (only) to check for intermittent
ina DTC 33.
connections. Output changes greater than .1 volt
With the ignition "ON" and engine stopped, the
indicates a bad connector or connections. If OK,
manifold pressure is equal to atmospheric pressure
replace sensor.
and the signal voltage will be high. This information
Refer to "MAP Sensor Voltage Output Check,"
is used by the PCM as an. indication of vehicle altitude.
CHART C-1 D, for further diagnosis.
"6E3-B".
[I]
DTC33
(SIGNAL VOLTAGE HIGH - LOW VACUUM)
3.4L (VIN S) ''F" CARLINE (SFI)
.0
IF ENGINE IDLE IS ROUGH, UNSTABLE OR INCORRECT, CORRECT BEFORE USING CHART.

REFER TO "SYMPTOMS," SECTION "B".
ENGINE IDLING.
DOES TECH 1 SCAN TOOL DISPLAY A MAP OF 3.75 VOLTS OR GREATER?
IGNITION "OFF."
DISCONNECT MAP SENSOR ELECTRICAL CONNECTOR.
IGNITION "ON."
TECH 1 SCAN TOOL SHOULD DISPLAY A VOLTAGE OF 1 VOLT OR LESS.
DOES IT?
DTC 33 IS INTERMITTENT. IF NO ADDITIONAL

PROBE MAP SENSOR GROUND CIRCUIT WITH A TEST LIGHT TO B +.

TEST LIGHT SHOULD LIGHT.
DOESIT?
MAP SENSOR SIGNAL CIRCUIT

SHORTED TO VOLTAGE, SHORTED
TO 5 VOLT REFERENCE CIRCUIT
OR
FAULTY PCM.
PLUGGED OR LEAKING
SENSOR VACUUM HOSE
OR
FAUL TY MAP SENSOR.
7-3-93
NS 15614
PCM
TOA/C
REFRIGERANT
PRESSURE SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
11-------'----- 452 BLK

11---------- 432 LT GRN
MANIFOLD
ABSOLUTE
PRESSURE
{MAP)
SENSOR
SENSOR GROUND
t - - - - - - - : ; t " - : : - - - - - 416 GRY
MANIFOLD
VACUUM
SVOLT
REFERENCE
TOT/P
SENSOR
TO A/C EVAPORATOR
TEMPERATUfU SENSOR
6-16-93
NS15613
DTC34
(SIGNAL VOLTAGE LOW - HIGH VACUUM)

The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure. MAP is the
inverse of vacuum, so as MAP increases such as during WOT, vacuum decreases.
The MAP sensor should indicate approximately 1-2 volts at idle, and between 4 and 5 volts at Wide Open
Throttle (WOT). MAP is one of the most important inputs for calculating fuel delivery.
OTC 34 Will Set When: Engine speed is less than 1200 RPM, throttle angle is greater than 2% and MAP is
less than 13 kPa. All conditions must be met for 2.5 seconds.
Action Taken (PCM will default to): A default table of MAP values will be used by the PCM to calculate
air flow. The MIL will become illuminated and MAP values on the Tech 1 will become minimum (11 kPa).
OTC 34 Will Clear When: A current DTC 34 will clear when the MAP value exceeds the minimum low MAP
threshold value. A history DTC 34 will clear after 50 consecutive ignition key cycles without a current DTC 34
being stored.
Number(s) below
1. This test is to see if the sensor is at fault for the low
voltage or if there is a PCM or wiring problem.
an open in CKT 432. If the test light is bright
during this test, CKT 432 is probably shorted to
ground. If Tech 1 scan tool reads over 4 volts at
this test, CKT 416 can be checked by measuring
the voltage at terminal "C" (should be 5 volts).
Diagnostic Aids: An intermittent open in CKT 432

or CKT 416 will result in a DTC 34.
With the ignition "ON" and engine stopped, the
is used by the PCM as an indication of vehicle altitude.
Comparison of this reading with a known good vehicle
with the same sensor is a good way to check accuracy
of a "suspect" sensor. Readings should be the same

.4 volt.
Check all connections.
rn
Important

securely fastened.
Disconnect sensor from bracket and twist sensor

by hand (only) to check for intermittent
connections. Output changes greater than .1 volt
indicates a bad connector or connections. If OK,
replace sensor.
Refer to "MAP Sensor Voltage Output Check,"
CHART C-lD, for further diagnosis.
Refer to "Inte.rmittents" in "Symptoms," Section
"6E3-B".
DTC34
(SIGNAL VOLTAGE LOW - HIGH VACUUM)

START ENGINE AND IMMEDIATELY NOTE MAP
VALUE ON TECH 1 SCAN TOOL.
.
DOES SCAN DISPLAY MAP BELOW .25 VOLT?
IGNITION "OFF."
JUMPER HARNESS TERMINALS "B" TO "C".
IGNITION "ON."
DOES MAP VOLTAGE READ OVER4 VOLTS?
OTC 34 IS INTERMITTENT. IF NO ADDITIONAL

DTC(s) WERE STOR.ED, REFER TO :'DIAGNOSTIC
.
.
IGNITION "OFF."
REMOVE JUMPER WIRE.
PROBE TERMINAL "B" (MAP SENSOR SIGNAL CIRCUIT) WITH
A TEST LIGHT TO B +.
IGNITION "ON."
DOES TECH 1 SCAN TOOL DISPLAY OVER 4 VOLTS?
FAUL TY CONNECTION
OR
SENSOR.
5 VOLT REFERENCE CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY PCM.
MAP SENSOR SIGNAL CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY PCM.
7-3-93
NS15615
PCM
1---------- 1747 LT BLU/WHT

~~=t:J.~1---------- 1748 LT BLU/BLK
IACCOIL "A" HIGH

IAC COIL "A" LOW
1 - - - - - - - - - 1749 LT GRN/WHT
IAC COIL "B" HIGH
1---------- 444 LT GRN/BLK
IAC COIL "B" LOW

6-16-93
NS 15616
DTC35
IDLE SPEED ERROR
The IAC i:noto~ will constantly_adjust its valve positio~ to maintain the desired idle speed. If idle speed is
below ~he desired idle, th~ v~lVf: will open to allow mor~ air flow and increase RPM. If the idle is too high, the
IAC will slowly close to hmit ~nrflow and therefore E:ngme RPM will decrease. If engine RPM becomes out of
control for a long enough period, then a OTC 35 will be set. Review the "General Description" of the IAC
QP.eration in_ "Fuel Metering System," Section "6E3-C2".
DT<; 35 W111 Set When~ Closed throttle engine speed is 300 RPM above or below desired idle for 50 seconds.
Action Taken (PCM will default to): The PCM will turn the MIL "ON" and set a OTC 35. The RPM will
remain cont:rolling erratically until the problem is corrected.
OTC 35 Will Clear When: A current DTC 35 will clear when the engine speed controls within a 350 RPM
range of desired idle. A history DTC 35 will clear after 50 consecutive ignition key cycles without a current OTC
35 being stored.

1. The Tech 1 RPM control mode is used to extend
and retract the IAC valve. The valve should move
smoothly within the specified range. If the idle
speed is commanded (IAC extended) too low (below
700 RPM), the engine may stall. This may be
normal and would not indicate a problem.
Retracting the IAC beyond its controlled range
(above 1500 RPM) will cause a delay before the
RPMs start dropping. This too is normal.
2. This test uses the Tech 1 scan tool to command the
IAC controlled idle speed. The PCM issues
commands to obtain commanded idle speed. The
node lights each should flash red and green to
indicate a good circuit as the PCM issues
commands. While the sequence of color is not
important if either light is "OFF" or does not flash
red and green. check the circuits for faults
. beginni_ng 'A'.ith poor terminal contacts.
D1agnost1c Aids: A slow, unstable, or fast idle may
be caused by a non-IAC system problem that cannot be
overcome by the IAC valve. Out of range IAC counts
will be above 60 if idle is too low and zero counts if idle
is too high. If idle speed is above 600-700 RPM in drive
with an AJT, locate and correct vacuum leak. If RPM
is below spec., check for foreign material around
throttle plates. Refer to "Fuel Metering System,"
Section "6E3-C2". The following checks should be
made to repair a non-IAC system problem.
Vacuum leak (high idle). If idle is too high, stop
the engine. Fully extend IAC with tester. Start
engine. If idle speed is above 800 RPM, locate and
correct vacuum leak including crankcase
ventilation system. Also check for binding of
throttle blade or linkage.
System too lean (high air/fuel ratio). The idle

speed may be too high or too low. Engine speed
may vary up and down and disconnecting the IAC
valve does not help. OTC 44 may set. Tech 1 028
voltage will be less than 300 m V (.3 volt). Check
for low regulated fuel pressure, water in the fuel or
a restricted injector.
S stem too rich low air/fuel ratio . The idle speed
wi 1 be too low. Tech 1 IA counts will usually be
above 80. System is obviously rich and may
exhibit black smoke in exhaust. DTC 45 may set.
Tech 1 scan tool 028 voltage will be fixed above
800 mV (.8 volt).
Check for high fuel pressure, leaking or sticking
injector. Silicone contaminated 02S will cause
sluggish voltage variations on Tech 1 scan tool.
Throttle body. Remove IAC valve and inspect bore
for foreign material.
IAC valve electrical connections. IAC valve
connections should be carefully checked for proper
contact.
Crankcase ventilation valve. An incorrect or
faulty valve may result in an incorrect idle speed.
Refer to "Rough, Unstable, Incorrect Idle, or
Stalling" in "Symptoms" Section "'6E3-B".
If intermittent poor driveability or idle symptoms
are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance, or
replace IAC.
AJC compressor or relay failure. Refer to CHART
C-10 if the A/C control re lay drive circuit is
shorted to ground or if the relay is faulty, an idle
problem may exist.
If above are OK, see "Rough, Unstable, Incorrect
Idle, or Stalling" in "Symptoms," Section "6E3-B".
DTC35
fi'\ .
\V
3.4L (VIN S) "F" CA,RLINE (SFI)

ENGINE AT NORMAL OPERATING TEMPERATURE
IN PARK/NEUTRAL WITH PARKING BRAKE SET.
A/C "OFF."
SELECT RPM CONTROL. (MISC. TESTS)
CYCLE IAC THROUGH ITS RANGE FROM 700 RPM
UP TO 1500 RPM.
RPM SHOULD CHANGE SMOOTHLY.
DOES IT?
INSTALL IAC NODE LIGHT* IN IAC HARNESS.

ENGINE RUNNING. CYCLE IAC WITH TECH 1 SCAN TOOL.
EACH NODE LIGHT SHOULD CYCLE RED AND GREEN BUT
NEVER "OFF."
DO THEY?
IF CIRCUIT(S) DID NOT TEST RED AND

GREEN, CHECK FOR:
FAUL TY CONNECTOR TERMINAL
CONTACTS.
OPEN CIRCUITS INCLUDING
CONNECTORS.
CIRCUITS SHORTED TO GROUND OR
VOLTAGE.
FAUL TY PCM CONNECTIONS OR
REPLACE PCM.
REPAIR AS NECESSARY AND RETEST.
CHECKIAC
CONNECTIONS.
CHECKIAC
PASSAGES.
IF OK, REPLACE IAC.
USING THE IAC DRIVER * OR OTHER

CONVENIENT CONNECTOR, CHECK
RESISTANCE ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN
IAC TERMINALS "A" TO "B" AND "C"
TO"D".
CHECK RESISTANCE BETWEEN IAC

TERMINALS "B" AND"(" AND
"A" AND"D".
SHOULD BE INFINITE.
IDLE AIR CONTROL CIRCUIT OK.

REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
REPLACE IAC
VALVE AND
RETEST.
REPLACE IAC
VALVE AND
RETEST.
IAC DRIVER AND NOOE LIGHT REQUIRED KIT

222-L FROM: CONCEPT TECHNOLOGY, INC.
J 37027 FROM: KENT-MOORE, INC.
CLEAR DIAGNOSTIC TROUBLE CODES, CONFIRM "CLOSED LOOP"

OPERATION, NO MALFUNCTION INDICATOR LAMP(MIL) "SERVICE
ENGINE SOON." PERFORM IAC RESET PROCEDURE PER APPLICABLE
SERVICE MANUAL AND VERIFY CONTROLLED IDLE SPEED IS CORRECT.
3-8-93
PS 17150

PCM
PIGTAIL
CONNECTOR
- - - - - 633 BRN/WHT
CAMSHAFT
POSITION
SENSOR
1--------11
CAM REFERENCE
SIGNAL
- - - - - 632 PNK/BLK - - - - - - - - ,
10-WAY FWD LAMP

FUSE #11
HARNESS CONNECTOR
(BLACK)
1O AMP
I G N I T I O N ~ 239 PNK - - - - G
TO IGNITION
CONTROL MODULE
(ICM)
t---..._____,
RED
24X (CKP) 11---- BLK

SENSOR
t----GRN
HIGH RESOLUTION
1------ 632 PNK/BLK
--------1
11------1800LTBLU/WHT
--------1
PIGTAIL
CONNECTOR
REFERENCE LOW CAMSHAFT

AND 24X SIGNALS
24X REFERENCE
SIGNAL
7-2'-93
NS15617
DTC36
24X SIGNAL CIRCUIT ERROR
The 24X Crankshaft Position (CKP) sensor is used to improve idle spark control at low engine speeds. The
24X CKP sensor is located behind the harmonic balancer on the front of the engine where it picks up pulses from
a reluctor wheel on the crankshaft. Its signal is conditioned by the PCM and used to more accurately control
spark at lower engine speeds up to approximately 2000 RPM.
OTC 36 Will Set When: The PCM determines that 6 or more consecutive 24X crankshaft position sensor
reference pulses have not occurred. This test is executed once per ignition key cycle immediately after startup.
Action Taken {PCM will default to): The PCM will disregard the 24X sensor input and base timing from
the 3X low resolution CKP sensor. The MIL will not become illuminated.
OTC 36 Will Clear When: A current DTC 36 will clear after each ignition key cycle. A history DTC 36 will
1. The 24X signal RPM should be the same as engine
speed up to approximately 2000 RPM at which
time it stops. This test determines if the PCM is
putting out a 24X signal.
2. This test determines if signal voltage is present up
to the PCM.
3. This will determine if B + is present at the sensor
input.
4.
5.
By applying B + to the 24X crankshaft sensor

pigtail circuit, pigtail and sensor integrity can be
determined.
Ground path continuity is determined with this
test.
Diagnostic Aids: An intermittent 24X signal error

can be caused by poor connections. Ignition feed,
reference low and the signal circuits should all be
checked for poor connections.
DTC36
fs\ .
\V
IF ENGINE CRANKS BUT WON'T RUN, USE CHART A-3.

IGNITION "ON" ENGINE IDLING. MONITOR "IGNITION CONTROL 24X SIGNAL."
IS RPM INDICATED?
IGNITION "OFF."
DISCONNECT PCM HARNESS CONNECTOR "C".
IGNITION "ON."
PROBE PCM HARNESS PIN "C21" WITH A DVM TO
GROUND (SET DVM TO DC VOLTAGE).
DOES DVM DISPLAY APPROXIMATE SYSTEM VOLTAGE?
IGNITION "OFF."
RECONNECT PCM HARNESS CONNECTOR "C".
DISCONNECT 24X SENSOR 3-WAY PIGTAIL HARNESS.
IGNITION "ON."
PROBE TERMINAL "C" (PCM HARNESS SIDE)WITH A
TEST LIGHT TO B +.
IS TEST LIGHT "ON"?
FAUL TY HARNESS CONNECTION

OR
OPEN CRANKSHAFT POSITION
SENSOR PIGTAIL GROUND WIRE
OR
FAULTY 24X CRANKSHAFT
POSITION SENSOR.
OPEN PCM HARNESS

GROUND CIRCUIT
OR
FAULTY TERMINAL
CONNECTION
OR
FAULTY PCM.

IGNITION "OFF."
DISCONNECT 24X CRANKSHAFT POSITION
SENSOR PIGTAIL HARNESS CONNECTOR.
IGNITION "ON."
CONNECT DVM BETWEEN TERMINAL" A"
(PCM HARNESS SIDE) AND GROUND.
DOES DVM DISPLAY APPROXIMATE BATTERY
VOLTAGE?
WITH A FUSED JUMPER, JUMP 24X

SENSOR PIGTAIL TERMINAL "A" TO
B+.
PROBE TERMINAL "B" WITH DVM

TO GROUND.
DOES DVM DISPLAY APPROXIMATE
BATTERY VOLTAGE?
OPEN OR SHORTED 24X

IGNITION FEED PIGTAIL WIRE TO
SENSOR
OR
OPEN OR SHORTED CRANKSHAFT
POSITION SENSOR PIGTAIL
SIGNAL WIRE FROM SENSOR
OR
FAULTY CRANKSHAFT POSITION
SENSOR.
FAULTY
HARNESS
IGNITION FEED
CIRCUIT.
FAULTY CRANKSHAFT
SENSOR PIGTAIL
CONNECTION
OR
FAULTY PCM
CONNECTION
OR
OPEN CRANKSHAFT
POSITION SENSOR
SIGNAL WIRE TO PCM.
7-2-93
PS 18387
BRAKE SWITCH
(NORMALLY CLOSED)
PCM
ro
IGNITION
SWITCH
9
~,_Es--39 PNKJBLK _ _
10 AMP
___.f T.--.. . .- - - - ~ s s 3 LT BLU/BLK-r;j'i"
BRAKE SIGNAL
l..!!..!!.,
BRAKE TRANSMISSION
SHIFT INTERLOCK
6-16-93
PS 18512
DTC37
TCC BRAKE SWITCH ERROR
The TCC brake switch is used to indicate brake pedal status. The normally closed brake switch supplies a
B + signal on CKT 420 to the PCM. The signal voltage is opened when the brakes are applied. The PCM uses
this signal to de-energize the TCC solenoid when the brake pedal is applied.
DTC 37 Will Set When:
No DTC(s) 24 or 72.
No change in the TCC brake signal to the PCM when:
Vehicle speed is greater than 35 mph for greater than 10 seconds.
Then vehicle speed is Omph.
For a total of 4 times.
Action Taken (PCM will default to): An incorrect brake signal can affect TCC scheduling. Also, an
incorrect brake signal can inhibit fourth gear operation, if in hot mode. OTC 37 will be stored in PCM memory,
but, will not turn "ON" the Malfunction Indicator Lamp (MIL).
DTC 37 Will Clear When: Fault condition no longer exists.

1. This test checks for voltage at brake switch.
2. This test checks the brake switch.
3. This test checks CKT 420 at the PCM.
Diagnostic Aids:
Check customer driving habits and/or unusual

traffic conditions (i.e. stop and go expressway
traffic).
G)
INSTALL SCAN TOOL.

IGNITION SWITCH "ON," ENGINE "OFF."
RECORD THEN CLEAR DTC(s).
APPLY THEN RELEASE BRAKE PEDAL,
DOES SCAN TOOL DISPLAY TCC BRAKE SW "OPEN"
WITH BRAKE PEDAL APPLIED, AND THEN DISPLAY
"CLOSED" WHEN RELEASED?
DTC37
WITH A TEST LIGHT CONNECTED TO GROUND,

BACKPROBE IGNITION FEED CIRCUIT ON BRAKE SWITCH.
IS TEST LIGHT "ON"?
NO TROUBLE FOUND. REFER TO

"DIAGNOSTIC AIDS."
WITH TEST LIGHT CONNECTED TO GROUND,

BACKPROBE HARNESS CKT 420 AT BRAKE SWITCH.
IS TEST LIGHT "ON"?
REPAIR OPEN IN THE IGNITION FEED CIRCUIT TO

THE BRAKE SWITCH. IF THE IGNITION
VOLTAGE FEED FUSE IS OPEN, ALSO CHECK
CKT 420 F()R A SHORT TO GROUND.
APPLY BRAKE PEDAL.

IS TEST LIGHT "OFF" WHEN BRAKE PEDAL IS APPLIED?
BRAKE SWITCH OUT OF ADJUSTMENT

OR
FAULTY BRAKE SWITCH.
IGNITION "OFF."
DISCONNECT CONTROL MODULE CONNECTORS.
WITH A TEST LIGHT CONNECtEO TO GROUND, PROBE
CONTROL MODULE CKT 420 HARNESS CONNECTOR.
IS TEST LIGHT "ON"?
CHECK CKT 420 FOR SHORT TO B +.

IF OK, REPLACE BRAKE SWITCH.
IGNITION "OFF."
RECONNECT CONTROL MODULE CONNECTIONS.
IGNITION "ON."
APPLY THEN RELEASE BRAKE PEDAL.
WITH BRAKE APPLIED, AND THEN DISPLAY "CLOSED"
WHEN RELEASED?
REPAIR OPEN CKT 420 FROM TCC BRAKE

SWITCH TO PCM.
ELECTRICAL SYSTEM CHECKS OK AT THIS TIME.

THE MALFUNCTION MAY BE INTERMITTENT OR
MAY HAVE BEEN CORRECTED DURING THIS
DIAGNOSTIC PROCEDURE.
REFER TO DIAGNOSTIC AIDS.
S-3-93
PS 17053
PCM
CLUTCH SW. CLOSED

WHEN CLUTCH PEDAL
IS AT REST
CLUTCH ANTICIPATE
SIGNAL
10 WAY 1/P
CONNECTOR
48GRY
>
cRL?sE
CONTROL
451 BLKIWHT
I
I
I
~
LL:=-J.J
j_
ENGINE
GROUND
6-16-93
NS 15890
DTC39
CLUTCH SWITCH ERROR
The clutch switch is normally closed when the clutch pedal is at rest. When the clutch pedal is depressed
(clutch disengaged), the switch will change from ''OFF" to "ON." The PCM runs a diagnostic check that looks for
a change of state in the switch logic. If there is a failure in the clutch switch circuit, a DTC 39 will be stored in
memory and the MIL (Service Engine Soon) will be illuminated.
OTC 39 Will Set When: Engine temperature above 90C (194F), vehicle speed is greater than or equal to 40
mph, the PCM must see VSS from Oto 40 mph and back to O mph for the clutch diagnostic to run. The clutch
switch must fail four consecutive times per ignition cycle.
Action Taken {PCM will default to): DTC 39 will be stored and the MIL will become illuminated.
OTC 39 Will Clear When: A current DTC 39 will clear when the PCM recognizes a change of state in the
switch logic from "OFF" to "ON." A history DTC 39 will clear after 50 consecutive ignition key cycles without a
1. When the clutch pedal is depressed, the switch
should go from closed to open and the status on the
Tech 1 scan tool should change from "OFF" to
"ON."
2. This test will check for a poor ground to the clutch
switch.
3. This test will determine if the clutch switch is
being supplied with "B +" or if C KT 48 is shorted
to ground.
Diagnostic Aids: If DTC 39 was stored in

memory and no problem was found, make sure
clutch switch fastener is secure and is not sticking
or binding. The clutch and the cruise control share
the same switch.
DTC39

IGN "ON" ENG "OFF."
MONITOR "CLUTCH SWITCH" STATE USING TECH 1.
CLUTCH SWITCH SHOULD READ "OFF."
DOES IT?
DEPRESS CLUTCH PEDAL.

CLUTCH SWITCH SHOULD CHANGE
STATUS FROM "OFF" TO "ON."
DOES IT?
NO TROUBLE FOUND.
DISCONNECT CLUTCH.
SWITCH HARNESS CONNECTOR.
WITH TEST LIGHT CONNECTED TO "B + ",
PROBE CAVITY "D" OF HARNESS.
LIGHT SHOULD BE "ON."
ISIT?
DISCONNECT CLUTCH SWITCH

HARNESS CONNECTOR.
WITH FUSED JUMPER WIRE, JUMPER
CAVITIES "D" AND "C" TOGETHER.
TECH 1 SHOULD READ "OFF."
DOESIT?
CLUTCH SWITCH OUT OF

ADJUSTMENT
OR
FAUL TY SWITCH.
WITH TEST LIGHT CONNECTOR TO

GROUND, PROBE CAVITY "C".
IS IT?
CLUTCH SWITCH OUT OF ADJUSTMENT.

FAULTY CONNECTION
OR
FAULTY SWITCH.
OPEN OR SHORT TO GROUND IN CKT 48.

OR
FAULTY PCM.
6-16-93
MS 12599
6E3-A-72 3.4l (L32) (VIN S) (SFI) DRIVEABILITYAND EMISSIONS
PCM
10-WAY FWD LAMP

HARNESS CONNECTOR
(BLACK)
FUSE #11 *
10 AMP
IGNITION ....., . : - - - ~ - - - 239 PNK
G 11----111-------,TO HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK--=:.___
GND
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
: ~ ~. :_.I__
SIGNAL
MINIMUM
1 1 - - - - - - - - - 424 TAN/BLK - - - - - 1 1
1 1 - - - - - - - - - - 423 WHT - - - - - 1
IGNITION
CONTROL
MODULE
(ICM)
IGNITION CONTROL
BYPASS
IGNITION CONTROL
121 WHT --,.....TACH SIGNAL

D
E 1 1 - - - - - - - - 647 LT BLU/BLK
...___ _ _ _ F
453 RED/BLK - - - - - 1
3XREF HIGH
3XREFLOW
PRIMARY
WINDING
6-16-93
NS 15618
*LOCATED IN UNDERHOOD ELECTRICAL CENTER
DTC41
IGNITION CONTROL (IC) TIMING CIRCUIT ERROR
Ignition control spark timing is provided by the PCM on CKT 423. Inputs from a number of engine sensors
allow the PCM to correctly calculate optimum spark timing. Engine load is calculated from the MAP sensor,
engine RPM is derived from the 3X crankshaft position sensor, engine operating temperature from ECT and IAT
sensors and engine knock activity from the knock sensor. Other engine functions modify spark to a lesser degree
such as TCC engagement and EGR activity.
The bypass circuit controls an internal switch in the electronic Ignition Control Module (ICM). Unless the
vehicle is in backup spark (base timing mode), the bypass circuit will have 5 volts applied to it. This 5 volt signal
from the PCM allows a solid state switch to direct the IC timing pulses to the ICM for sequencing and energizing
the coil packs. If the bypass circuit is not energized, the IC pulses from the ICM are shunted to ground and the
electronic ICM uses its own base timing schedule to time and energize the coil packs.
OTC 41 Will Set When: Ignition Control CIC) pulses are detected on CKT 423 when the vehicle is in bypass
(no voltage applied to bypass should allow IC pulses to be grounded by the electronic ICM). The test will either
pass or fail within the first_ 1 second of engine running. If it passes, the test will not run until the next key cycle.
Action Taken (PCM will default to): The PCM will allow the electronic ignition control module to control
timing usin~ its own base timing schedule. The MIL will become illuminated.

1. This test confirms DTC 41 and that the fault
causing the DTC is present.
2. Checks for a normal IC ground path through the
ignition control module. An IC CKT 423 shorted to
ground will also read less than 500 ohms; however,
this should set a DTC 42.
Diagnostic Aids: The scan tool does not have any

ability to help diagnose a DTC 41 problem.
"6E3-B".
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-A-73
DTC41
G)
G)
CLEAR DTC(s).
IDLE ENGINE FOR 5 SECONDS
OR UNTIL DTC41 SETS.
DOES DTC41 SET?
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C".
IGNITION "ON."
SET OHMMETER SELECTOR SWITCH IN THE 1000 TO
2000 OHMS RANGE.
GROUND THE BLACK(-) OHMMETER LEAD.
PROBE PCM HARNESS IGNITION CONTROL CKT 423
USING THE RED (+)OHMMETER LEAD. THE
OHMMETER SHOULD READ LESS THAN 500 OHMS.
DOESIT?
DTC41 INTERMITTENT. REFER TO

FAULTY CONNECTION AT THE PCM.

OR
FAULTY PCM.
OPEN CKT 423, FAULTY CONNECTION,

OR
FAULTY IGNITION CONTROL MODULE (ICM).
IF PCM IS FAULTY AND MUST BE REPLACED, THE NEW PCM MUST BE PROGRAMMED. REFER TO
PCM REPLACEMENT AND PROGRAMMING PROCEDURES IN SECTION "6E3-C1 ".
3-9-93
PS 17152
6E3-A-74 3.4L (L32) (VINS) (Sft) DRIVEABIUTY AND EMISSIONS
FUSE.#11 *
10 AMP
IGNITION
PCM
10-WAY FWD LAMP

HARNESS CONNECTOR
(BLACK)
..-,,c.-----tl/'9--- 239 PNK
G - - - - - - T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK
GND
-i
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
YEL-.m-r-1
SIGNAL
PPL-filj_J
MINIMUM
1--------- 424 TAN/BLK - - - - ~

IGNITION
CONTROL
MODULE
(ICM)
- - - - - - - - - - - 423 WHT - - - - - - - ~
121 WHT ----"TACH SIGNAL
IGNITION CONTROL
BYPASS
IGNITION CONTROL
D
E - - - - - - - 647 LT BLU/BLK - - - - ~
3XREF HIGH
-----t
3XREFLOW
" - - - - - - F - - - - - - - - 453 RED/BLK
PRIMARY
WINDING
6-16-93
NS 15618
DTC42
IGNITION CONTROL (IC) ERROR
Ignition control timing is provided by the PCM on CKT 423. Using inputs from both the 3X and 24X
crankshaft position sensors, spark timing is calculated and delivered to the electronic ignition control module to
sequence and energize the coil packs. If this ignition control circuit is grounded, the electronic ICM will control
spark timing from a preset base timing schedule and a DTC 42 will be set.
The ignition control bypass circuit should always have 5 volts applied to it. This input controls the solid state
switch internal to the ICM, which provides a complete circuit for timing signals delivered from the PCM to the
electronic ICM. If the bypass circuit is open or grounded, timing signals from the PCM on the ignition control
circuit are grounded inside the electronic ICM. The ICM will use its own base timing schedule and a DTC 42 will
be set.
OTC 42 Will Set When: No pulses are detected on the IC circuit by the PCM.
Action Taken (PCM will default to): The PCM will allow the electronic ignition control module to control
timing usin~ its own base timing schedule. The MIL will become illuminated.
OTC Chart Test Description: ~umber(s) below
will indicate above 5000 ohms. The important
thing is that the module "switched."
1. DTC 42 indicates the PCM has detected an open or
4. The module did not switch and this step checks for:
short to ground in the bypass circuit. This test
IC CKT 423 shorted to ground.
Bypass CKT 424 open.
confirms DTC 42 and that the fault causing the
DTC is present.
Faulty electronic ignition control module
2. Checks for a normal IC ground path through the
connection or module.
5. Confirms that DTC 42 is a faulty PCM and not an
ignition control module. An IC CKT 423 shorted to
ground will also read less than 500 ohms; however,
. interm~tten~ in CKT 423 or 424.
.
this will be checked later.
D1agnost1c Aids: The Tech 1 scan tool does not
3. As the test light voltage touches CKT 424, the
have any ability to help diagnose a DTC 42 problem.
module should swit.ch causing the ohmmeter to
"6E3-B".
"overrange" if the meter is in the 1000-2000 ohms
position. Selecting the 10-20,000 ohms position
DTC42
CLEAR DTC(s).
IDLE ENGINE FOR 1 MINUTE
OR UNTIL DTC 42 SETS.
DOES OTC 42 SET?
IGNITION "OFF."
DISCONNECT BLUE PCM CONNECTOR.
IGNITION "ON."
SET OHMMETER SELECTOR SWITCH IN THE 1000 TO
2000 OHMS RANGE.
GROUND THE BLACK(-) OHMMETER LEAD.
PROBE PCM HARNESS IGNITION CONTROL CKT 423
USING THE RED (+)OHMMETER LEAD. THE
OHMMETER SHOULD READ LESS THAN 500 OHMS.
DOES IT?
DTC 42 INTERMITTE'NT. REFER TO

PROBE PCM HARNESS CONNECTOR CKT 424 WITH A TEST

LIGHT TO BATTERY VOLTAGE AND OBSERVE LIGHT.
OPEN CKT 423, FAULTY CONNECTION, OR

FAULTY ELECTRONIC IGNITION CONTROL
MODULE (ICM).
I
LIGHT "ON"
G)
G)
'
WITH OHMMETER STILL CONNECTED TO PCM HARNESS

CKT 423 AND GROUND AS DESCRIBED :N STEP #2, AGAIN
PROBE PCM HARNESS CKT 424 WITH THE TEST LIGHT
CONNECTED TO BATTERY VOLTAGE. AS TEST LIGHT
CONTACTS CKT 424, RESISTANCE SHOULD SWITCH FROM
HUNDREDS TO THOUSANDS OHMS.
DOESIT?
DISCONNECT IGNITION CONTROL MODULE 6 PIN

CONNECTOR. NOTE OHMMETER THAT IS STILL CONNECTED
TO CKT 423 AND GROUND. RESISTANCE SHOULD HAVE
BECOME VERY HIGH (OPEN CIRCUIT).
DOES IT?
CKT 424 OPEN, FAUL TY CONNECTIONS,

OR
FAULTY IGNITION CONTROL MODULE.
'
DISCONNECT IGNITION CONTROL

MODULE 6 PIN CONNECTOR.
REPLACE IGNITION
CONTROL MODULE.
RECONNECT PCM AND IDLE

ENGINE FOR ONE MINUTE
OR UNTIL DTC42 SETS.
DOES OTC 42 SET?
DTC 42 INTERMITTENT.
6-16-93
NS 15395
PCM
KNOCK
SIGNAL
. - - - - - - - - 496 DK BLU - - - - - - 1 c 2 0
sv
KNOCK
SENSOR
6-15-93
NS15039
DTC43
KNOCK SENSOR (KS) CIRCUIT
3.4L (VIN S) f 11 CARLINE (Sfl)~
11
The Knock Sensor (KS) is used to detect engine detonation. The PCM receives the knock sensor signal and
will retard Ignition Control (IC) timing until knock is
aetected.
The circuitry within the KS will drop approximately half of the 5 volts applied to the sensor on CKT 496.
When engine detonation occurs, the sensor produces an A/C signal which rides on the 2.5 volt DC signal. The
voltage amplitude and frequency is dependent upon the knock level emitted from the engine combustion process.
not
DTC 43 Will Set When: The PCM detects above 4-6 volts or below .89 volt for 10 seconds, engine coolant
temperature is over 90C (194F), IAT temperature is over 0C (32F), high engine load based on air flow and
RPM between 3400 and 4400. This test will be performed continuously when all these conditions are met.
Action Taken (PCM will default to): The MIL will become illuminated. Knock retard will be fixed at 15 of
timing retard.
DTC 43 Will Clear When: A current DTC 43 will clear when the PCM senses the signal voltage level between
.89 and 4.6 volts. A history DTC 43 will clear after 50 consecutive ignition key cycles without a current DTC
being stored.
Nuinber(s) below
1. If the conditions for DTC 43, as described above,
are being met, the Tech 1 scan tool will al ways
indicate "YES" when the knock signal position is
selected. If an audible knock is heard from the
engine, repair the internal engine problem, as
normally no knock should be detected at idle.
2. The PCM applies a 5 volt signal to the sensor on
CKT496 ..
Diagnostic Aids: Check CKT 496 for a potential

open or short to ground.
"6E3-B".
If the customer's complaint is the MIL (Service
Engine Soon) comes "ON" when in acceleration. There
is a possibility that the electronic ignition system was
in bypass mode when the DTC 43 test was run. An
intermittent open in the IC circuit will put the ignition
control module in bypass which will not allow the
spark to be advanced so the DTC 43 test would fail. If
the PCM also had a DTC 42 stored, then the IC circuit
is likely the cause of the DTC 43.
DTC43
G)
INSTALL TECH 1.
ENGINE IDLING, ENGINE COOLANT TEMP ABOVE 67(.
DOES TECH 1 INDICATE A FIXED VALUE OF KNOCK
RETARD BETWEEN 4 AND 20 DEGREES?
DISCONNECT KNOCK SENSOR.

IGNITION "ON."
USING A DVM, MEASURE VOLTAGE BETWEEN
HARNESS CKT 496 AND GROUND.
VOLTAGE SHOULD BE 4-6 VOL TS.
IS IT?
MEASURE RESISTANCE OF KNOCK SENSOR BY

CONNECTING OHMMETER BETWEEN SENSOR
TERMINAL AND ENGINE BLOCK.
SHOULD BE BETWEEN 3.3kQ AND 4.SkQ.
ISIT?
CHECK HARNESS AND SENSOR CONNECTOR.

IFOK:
REMOVE PCM AND BE SURE KS MODULE IS
PROPERLY SEATED INTO PCM.
IFOK:
REPLACE MODULE.
DTC.43 IS .INTERI\IIITT~NT. SEE "DIAGNOSTIC AIDS"

ON ~ACING PAGE ..
LESS THAN 4 VOLTS

CHECK FOR CKT 496 BEING ROUTED TOO
CLOSE TO SECONDARY IGNITION WIRES
OR
CKT 496 SHORTED TO VOLTAGE
OR
FAULTY PCM.
CKT 496 OPEN,

SHORTED TO GROUND
OR
FAULTY PCM.
REMOVEKNOCKSENSORANDENSURETHATTHREADSON
SENSOR AND BLOCK ARE CLEAN AND FREE OF CORROSION,
TEFLON TAPE, ANTI-SEIZE COMPOUNDS, OR SEALANTS. IF
OK, REPLACE FAUL TY KNOCK SENSOR.
3-9-93
NS 15640
6E3-A-78 3.4L (L32) (VIN S) (SFI) DRIVEABIUTYAND EMISSIONS

PCM
SENSOR (02S)
l~-l------.......--------c(~1665PPLIWHT
LEFT 02S GROUND
-*-
351 BLKJWHT
RIGHT 02S GROUND
ENGINE
GROUND-=-
6-16-93
NS 15602
DTC44
LEFT (BANK 2) OXYGEN SENSOR (025) CIRCUIT
(LEAN EXHAUST INDICATED)

The Powertrain Control Module (PCM) supplies a voltage of about .45 volt between terminals "821" and
"820". (If measured with a 10 megohm digital voltmeter, this may read as low as .32 volt.)
When the 02S reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
lean) to about 900 millivolts (exhaust is tich).
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open sensor
circuit, or cold sensor, causes "Open Loop" operation.
DTC 44 Will Set When: Vehicle is operating in "Closed Loop" and CKT 1665 is below 280 millivolts for
greater than 60 seconds.
Action Taken (PCM will default to): Vehicle will operate in "Open Loop" and MIL will become
illuminated.
DTC 44 Will Clear When: A current DTC 44 will clear when the 02S voltage rises above the calibrated lean
exhaust voltage threshold. A history DTC 44 will clear after 50 consecutive ignition key cycles without a current
DTC 44 being stored.
Lean injector(s). Perform "Injector/Coil Balance
Test," CHART C-2A.
l. The engine must be operating in "Closed Loop" to
Fuel contamination. Water, even in small
amounts, near the in-tank fuel pump inlet can be
store DTC 44.
delivered to the injectors. The water causes a lean
Diagnostic Aids: Using the Tech 1 scan tool,
028 signal and can set a DTC 44.
observe the long term fuel trim at different RPM and
Fuel pressure. System will be lean if pressure is
air flow conditions. The Tech 1 scan tool also displays
too low. It may be necessary to monitor fuel
the fuel trim cells, so the long term fuel trim values
pressure while driving the vehicle at various road
can be checked in each of the cells to determine when
speeds and/or loads to confirm correct fuel
the DTC 44 ma,y have been set. If the conditions for
pressures. Refer to "Fuel System Diagnosis,"
CHART A-7.
DTC 44 exist, the long term fuel trim values will be
Exhaust leaks. If there is an exhaust leak, the
around 150.
engine can cause outside air to be pulled into the
02S wire. Sensor pigtail may be mispositioned
and contacting the exhaust manifold.
exhaust and past the sensor. Vacuum or crankcase
Check for intermittent ground in wire between
leaks can cause a lean conciition.
If the above are OK, it is a faulty Oxygen Sensor
connector and sensor.
(02S).
DTC44
RUN WARM ENGINE (75C/167F TO 95C/203F) AT 1200 RPM.

DOES TECH 1 INDICAT. E LEFT 025 (BANK 2) VOLTAGE FIXED BELOW .28 v.OLT (280 mV)?
'
'
eJ DISCONNECTLEFT 025 (BANK 2) ELECTRICAL CONNECTOR.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY LEFT 025
(BANK2)VOLTAGE BETWEEN .28 VOLT AND .7 VOLT
(280 mV AND 700 mV).
DOES IT?
. ; OTC 44 IS INTERMITTENT. IF NO ADDITIONAL

AIDS" ON FAONG PAGE.
CKT 1665 SHORTED TO. GROUND

OR
FAULTY PCM.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND C9NFIRM DTC DOES NOT RESET.
6-16-93
NS 15620

PCM
SENSOR (02S)
1~~1------------c((--1665PPI.JWHT
1 351
LEFT 02S GROUND

BLK/WHT
RIGHT 02S GROUND
-*--
ENGINE
GROUND-=-
6-16-93
NS 15602
DTC45
LEFT {BANK 2) OXYGEN SENSOR{02S) CIRCUIT
(RICH EXHAUST INDICATED)
3.4L (VIN S) "F" CARLINE {SFI)

The Powertrain Control Module (PCM) supplies a voltage of about .45 volt between terminals "B21" and
"B20". (If measured with a 10 megohm digital voltmeter, this may read as low as .32 volt.)
When the 028 reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
lean) to about 900 millivolts (exhaust is rich).
circuit or cold sensor causes "Open Loop" operation.
OTC 45 Will Set When: Vehicle is operating in "Closed Loop," C.KT l6ij5 is above 750 millivolts, throttle
angle is between 6% and 20%, condition present for greater than 60 seconds.
Action Taken (PCM w1fl default to): Vehicle will operate in "Open Loop" and MIL will become
illuminated.
OTC 45 Will Clear When: A current DTC 45 will clear when the 028 signal voltage falls below the calibrated
rich exhaust voltage threshold. A history DTC 45 will clear after 50 consecutive ignition key cycles without a
Diagnostic Aids: Using the Tech 1 scan tool,

observe the long term fuel trim values at different
RPM and air flow conditions. The Tech 1 scan tool also
displays the fuel trim cells, so the long term fuel trim
values can be checked in each of the cells to determine
when the DTC 45 may have been set. If the conditions
for DTC 45 exist, the long term fuel trim values will be
around 115.
Fuel pressure. System will go rich if pressure is
too high. The PCM can compensate for some
increase. However, if it gets too high, a DTC 45
may be set. Refer to "Fuel System Diagnosis,"
CHART A-7.
Rich injector. Perform "Injector/Coil Balance
Test," CHART C-2A.
Leaking injector. Refer to CHART A-7.
Crankcase oil. Check for fuel contaminated oil.
02S contamination. Inspect Oxygen Sensor (028)
for silicone contamination from fuel, or use of
improper RTV sealant. The sensor may have a
white, powdery coating and result in a high but
false signal voltage (rich 028 signal indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe surge
driveability problem.
An open ground CKT 351 - May result in EMI, or
induced electrical "noise." The PCM looks at this
"noise" as reference pulses. The additional pulses

result in a higher than actual engine speed signal.
The PCM then delivers too much fuel, causing
system to go rich. Engine tachometer will also
show higher than actual engine speed, which can
help in diagnosing this problem.
EVAP canister purge. Check for fuel saturation .
If full of fuel, check canister control and hoses.
Refer to "Evaporative Emission Control System,"
Section "6E3-C3".
Check for leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for fuel.
Throttle Position (TP) sensor. An intermittent
Throttle Position (TP) sensor output will cause the
system to go rich, due to a false indication of the
engine accelerating.
EGR. An EGR staying open (especially at idle)
will cause the Oxygen Sensor (028) to indicate a
rich 02S signal and this could result in a DTC 45.
MAP sensor - An output that causes the PCM to
sense a higher than normal manifold pressure (low
vacuum) can cause the system to go rich.
Disconnecting the Manifold Absolute Pressure
(MAP) sensor will allow the PCM to set a fixed
value for the MAP sensor. Substitute a different
MAP sensor if the rich condition is gone, while the
sensor is disconnected.
DTC45
RUN WARM ENGINE {75C/167F TO 95C/203F)AT 1200 RPM.

DOES TECH ONE DISPLAY LEFT 02S{BANK 2)VOLTAGE FIXED ABOVE .7 VOLT (700 mV)?
DISCONNECT LEFT 025 {BANK 2) AND

JUMPER HARNESS cKr 1665 TO GROU!l,ID.
TECH ONE SHOULD DISPLAY LEFT 025
{BANK 2) LESS rHAN .28 VOLT (280 mV).
DOES IT?
DTC45 IS INTERMITTENT.
IF NO ADDITIONAL DTCs WERE STORED,
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
CKT 1665 SHORTED

TO VOLTAGE
OR
FAULTY PCM.
7-2-93
NS 15621
PCM
B+
BATTERY
JUNCTION
BLOCK
1/PFUSE #4
10AMP
4-WAY IN-LINE
1/P CONNECTOR #3
(BLACK)
r- ____ ._--.
I PASS-KEY II A1 t - - - - - - - - w - - - - - 1 1
I DECODER
I MODULE
A3 - - - - - - - - - - - 1
L----
340 ORN - * ' - - - - I
229 DK BLU
-----1
10-WAY 1/P
CONNECTOR
(BLUE)
KEEP ALIVE
MEMORYB+
VEHICLE ANTI-THEFT
SYSTEM INPUT
(FUEL ENABLE SIGNAL)
6-16-93
NS 15647
DTC46
PERSONAL AUTOMOTIVE SECt.)ftlTY ~YST~IVI (PASS-~eyII) CIRCUIT
,
The PASS-KeyII system is designed to disable vehicle operation if the incorrect key or starting procedure is
used. The PASS-Key II decoder module sends a signal to the PCM if the correct key is being used. If the proper
signal does not reach the PCM on CKT 229, the PCM will not pulse the injectors "ON'' and' thus not allow the
vehicle to be started.
OTC 46 Will Set When: The PCM does not receive the proper signal on CKT 229 when the ignition is turned
"ON."
.
Action Taken (PCM will default to): The malfunction indicator lamp will not be illuminated. A
PASS-Key@II fault will be stored in the PCM memory; engine will crank but will not start.
OTC 46 Will Clear When: A current DTC 46 will clear when the PCM receives a proper signal on CKT 229, a
history DTC 46 will clear after 50 consecutive key cycles without a current DTC 46 being ~tored.

1. If the engine cranks, but doesn't start. It indicates
that the portion of the module which generates the
signal to the PCM is not operating or CKT 229 is
open or shorted to ground. If the decoder module is
found to be OK, as determined from SECTION SA,
the PCM may be at fault, but this is not a likely
condition.
2. If DTC 46 is stored, and the engine will not crank,

it indicates that there is a PASS-KeyII problem
or an incorrect key or starting procedure is being
used.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3,.A-83
DTC46
11
3.4L (VIN S), F" CARLINE (SFI)
IGNITION "ON."
DOES SCAN TOOL INDICATE PASS-KeyII STATUS AS "OK"?
PROBLEM IS INTERMITTENT. IF NO
OTHER DTC(s) IS STORED, REFER TO
"INTERMITTENTS" IN SECTION "B".
G)
CHECK FOR OPEN OR SHORT TO ~ROUND ,IN CKT 229

OR
FAULTY PCM.
PASS-KeyIISYSTEM PROBLEM. REFER TO

PASS-KeyII DIAGNOSIS" IN SECTION "SA"
AND"90".
5-13-93
PS 17827
6E3-A-84 3.4L (L32) (VIN S) (SFI) DRIVEABILITYAND EMISSIONS
PCM
10-WAY IN-LINE
1/P CONNECTOR
# 2 (BLUE)
...,..,-------,~,__--_,r _____--11[I)t----1/P FUSE #5
TO IGN
SWITCH
439 PNK
IGNITION FEED
15 AMP
SEE SECTION BA
(ELECTRICAL DIAGNOSIS)
FOR COMPLETE CIRCUIT
DETAILS
6-16-93
NS 15601
DTC53
SYSTEM VOLTAGE OVERCHARGE
(HIGH BATTERY VOLTAGE)

The PCM has the ability to determine if the ignition feed circuit has more than 16.5 volts applied to it. This
feature is to protect the PCM circuitry as well as components that have voltage applied to them by the PCM. The
circuit that is monitored for an over voltage condition is CKT 439 (ignition feed).
OTC 53 Will Set When: The ignition is "ON" and the PCM is sensing greater than J6.5 volts at PCM
terminal "C3" for 10 seconds.
Action Taken (PCM will default to): The MIL will become illuminatecj. and all .PCM outputs will be
disengaged. The transmission will default. to 3rd gear and have maximum line pressure.
OTC 53 Will Clear When: A current DTC 53 will clear when battery voltage is sensed below 16.5 volts. A
history DTC 53 will clear after 50 cons~cutive ignition key cycles without a current DTC 53 being stored.

1. Normal battery output is between 10 - 16.5 volts.
2. Checks to see if the high voltage reading is due to
the generator or PCM. With engine running,
check voltage at the battery with a DVM. If the
voltage is above 12.1 volts, the PCM is OK.
3. Checks to see if generator is faulty under load
condition. If the voltage is above 16.5 volts, refer
to SECTION 6D.
DTC53
(HIGH BATTERY VOLTAGE)
ENGINE RUNNING ABOVE 800 RPM.

NOTE SYSTEM VOLTAGE ON TECH 1 SCAN TOOL
I
ABOVE 16.5 VOL TS
I
CHECK SYSTEM VOLTAGE AT BATTERY.
ABOVE 16.5 VOL TS
REMOVE GENERATOR
FOR REPAIR.
REFER TO SECTION 60.
BELOW 16.5 VOLTS

I
FAULTY PCM
CONNECTOR OR
FAULTY PCM.
BELOW 16.5 VOL TS

I
G)
RAISE ENGINE RPM TO 2000 .

LOAD ELECTRICAL SYSTEM WITH HEADLAMPS
AND HIGH BLOWER "ON."
NOTE DATA VALUE .
ABOVE 16.5 VOLTS
BELOW 16.5 VOL TS

I
REMOVE GENERATOR
FOR REPAIR.

REFER TO NOTE ON
INTERMITTENTS."
"AFTER REPAIRS.'' REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
3-9-93
NS 15042
6E3-A-86 3.4L (L32) (VIN S) (SFI) ,DRIVEABILITY AND EMISSIONS
PCM
TO PASS-KeyII
DECODER MODULE
10-WAY INLINE 1/P

CONNECTOR #2
1/P FUSE #5
(BLUE)
TSWOIIGTCNH~~e------~-------,-~----~~
15AMP
439PNK
IGNITION FEED
439 PNK
10-WAY INLINE 1/P
CONNECTOR #1 {NATURAL)
,...,~:::::::1r:::"'1----f J
465 DK GRN/WHT
FUEL
PUMP
RELAY
451 BLKIWHT ~
FUEL PUMP
MOTOR IN
FUEL TANK
K
120 GRY
120GRY
-G--4!---01----.. . .
T--120GRY
FUEL TANK/ABS PASS

INLINE 1/P
THRU CONNECTOR
CONNECTOR #1
./',.
FUEL PUMP PRIME
CONNECTOR
6-16-93
NS 15619
DTC54
FUEL PUMP CIRCUIT
(LOW VOLTAGE)
3.4L {VIN S) "F" CARLINE (SFI)

The status of the fuel pump CKT 120 is monitored by the PCM at terminal "A6" and is used to compensate
fuel delivery based on system voltage. This signal is also used to store a diagnostic trouble code if the fuel pump
relay is defective or fuel pump voltage is lost while the engine is running. There should be about 12 volts on CKT
120 for 2 seconds after the ignition is turned "ON," or any time reference pulses are being received by the PCM.
This DTC is designed to detect a faulty relay causing extended crank time and the DTC will help the
diagnosis of an engine that "Cranks But Will Not Run."
OTC 54 Will Set When: Voltage at terminal "A6" is less than 7 volts for .3 second since the last reference
pulse was received.
Action Taken (PCM will default to): Ifafaultisdetectedduringstart-up, the MIL will become illuminated
until the ignition is cycled "OFF." If the voltage is detected below 7 volts with the engine running, the light will
remain "ON" while the condition exists.
OTC Will Clear When: A current DTC 54 will clear when voltage at the fuel pump monitor is sensed within
the calibrated voltage threshold. A history DTC 54 will clear after 50 consecutive ignition key cycles without a
DRIVEABILllY ANO. EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-87
DTCS4
P IRCUIT
(LOW VOLlAGE)
3.4L (VIN S) ..F" CARLINE (SFI)
CLEAR DTC(S),
IGNITION "ON."
IGNITION "ON."
LISTEN FOR IN-TANK FUEL PUMP.
PUMP SHOULD RUN FOR 2 SECONDS AFTER IGNITION "ON."
DOES IT?
IGNITION "OFF."
USING A 10 A!\IIP FUSED JUMPERWIRE, CONNECT
FUEL PUMP PRIME CONNECTOR TO 11 VOLTS.
DOES PUMP RUN?
IGNITION "OFF."
DISCONNECT FUEL
PUMP RELAY.
PROBE CKT 439 WITH A
TEST LIGHT TO GROUND.
CONNECT TEST
LIGHT BETWEEN
CKTs439 &451.
REPAIR.
OPEN IN
CKT439.
DISCONNECT FUEL
PUMPRElAY.
.
USING Tl-!E FUSED JUMP,ER
WIRE, CONNECT CKT 120 TO
12VOLTS.
DOES PUMP RUN?
FAULTY
CONNECTION
OR
FAULTY RELAY.
DISCONNECT PCM
0
CONNECTOR A".
WITH A DVM CHECK FOR
CONTINUITY FROM CKT 120
Of FUEL PUMP RELAY TO
PCMPIN"A6".
DO YOU HAVE CONTINUITY?
DTC541S
INTERMITTENT.
REFER TO
"INTERMITTENTS"
IN SECTION "B".
OPEN CKT 120,

FAULTY IN-TANK
PUMP OR FAUL TY
PUMP GROUND.
CONNECT TEST LIGHT BETWEEN HARNESS CKT 465 AND.GROUND.

.
IGNITION "OFF" FOR 10 SECONDS. ,
NOTE TEST LIGHT WITHIN 2 SECONDS AFTER IGNITION "ON."
REPLACE FAULTY FUEL PUMP RELAY.
CLEAR DTC(S).
START.AND RUN ENGlNE FOR30
SECONDS OR UNTIL OTC 54 SETS.
001!5 OTC SET?
REPAIR OPEN CKT 451.
CKT 465 OPEN, SHORTED TO GROUND

OR
FAULTY PCM.
6-16-93
NS 15623
6E3-A-88 3.4L (L32) (VIN S) (SFI)' DRIVEABILITYAND EMISSIONS

PCM
TRANSMISSION RANGE
B+
B+
- - - - - - - - 1225 DK BLU
B+
1226 RED
TRANSMISSION
,. _ CONNECTOR
I
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
. . , ' - - - - - - - 1227 BLK/YEL
SY
MAP
SENSOR
6-16-93
PS 18513
DTC58
TRANSMISSION FLUID T~MPERATURE (TFT) SENSOR CIRCUIT LOW

The TFT sensor is a thermistor within the TR pressure switch assembly, that controls the signal voltage to
the PCM. The PCM supplies a 5 volt reference signal to the sensor on CKT 1227. When the transmission fluid is
cold, the sensor resistance is high and the PCM will sense high signal volt~ge.
As the transmission fluid temperature warms to normal transmission operating temperature 100C (212F),
the sensor resistance becomes less and the voltage decreases to approximately 1.5 to 2.0 volts. With a DTC 79
also set, check the transmission cooling system.
OTC 58 Will Set When: Signal voltage indicates TFT greater than 151 C (306F) for at least 1 second.
Action Taken (PCM will default to): When DTC 58 is ~et, the transmission will use a warm value for
operation, but the scan tool will display the actual fluid temperature. DTC 58 will be stored in the PCM memory
but will not turn "ON" the Malfunction Indicator Lamp (MIL).
OTC 58 Will Clear When: The fault condition(s) no longer exist.

1. This test checks for a short to ground or a skewed
sensor.
2. This test checks for an internal fault within the
transmission by creating an open.
potential short to ground in CKT 1227.
Scan tool TFT displays should rise steadily to

about 100C (212F) then stabilize.
The temperature to resistance value scale in
SECTION 7A14A may be used to test the transmission
sensor at the various temperature levels to evaluate
th.e. possibility of a "skewed" sensor. A "skewed"
sensor could result in delayed garage shifts or TCC
enabled complaints.
DTC58
(TFT) SENSOR CIRCUIT LOW
HAS FLUID CHECKING PROCEDURE
IUN PERFORMED?
DOES SCAN TOOL DISPLAY TRANSMISSION FLUID

TEMPERATURE GREATER THAN 146C (295"F).
IGNITION .. OFF."
DISCONNECT TRANSMISSION WIRING
CONNECTOR. SCAN TOOL SHOULD DISPLAY
TEMPERATURE LESS THAN -33C (-27F).
REFER TO "INTERNAL WIRING HARNESS

CHECK .. SECTION 7A14A OR 7A17A OF
THE APPROPRIATE SERVICE MANUAL.
DTC IS INTERMITTENT.
IF NO ADDITIONAL DTC(s) WERE
STORED, REFER TO "DIAGNOSTIC AIDS."
CKT 1227 SHORTED TO GROUND OR

FAUL TV CONTROL MODULE OR
CONNECTIONS.
1-25-93
MS 13671
6E3-A-90 3.4L (L32},(V:IN S) (SFI) DRIVEABILIT'l AND EMISSIONS

PCM
TRANSMISSIOI\I RANGE
..,.__....,...._ _ _ _ _ _ 1224PNK
1226 RED
I
I
TRANSMISSION
: ~ CONNECTOR
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
- - - - - - - - 1227BLK/YEL
sv
- - - - - - - - - 470 BLK
6-16-93
PS 18513
MAP
SENSOR
DTC59
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT HIGH
(LOW TEMPERATURE INOlCATED)
3.4L (VIN S)
11
F" CARl:JNE (SFI)
'
The TFT sensor is a thermistor within the fluid.pressure switch assembly, that controls the signal voltage to
cold, the sensor resistance is high and the PCM will sense high signal voltage.
the sensor resistance becomes less and the voltage decreases to approximately 1.5 to 2.0 volts.
OTC 59 Will Set When: Signal voltage indicates TFT less tha:h'-40C(~40F'), for 1 se~ond.
Action Taken (PCM will default to): When DTC 59 is set, the transmission will use a warm value for
operation, but, the scan tool will display the actual fluid temperature.
When OTC is set, the TCC may not apply properly. DTC 59 will be stored in the PCM memory but will not
turn "ON" the Malfunction Indicator Lamp (MIL).

1. This test checks for a skewed sensor.
temperature), and the scan displays 146C (295F)
or greater, the PCM and wiring are OK.
3. This test checks if CKT 1227 is open. There should
be 5 volts present at the sensor connector if
measured with J 39200.
Diagnostic Aids: Scan tool displays fluid

transmission temperature in degrees. After
transmission is operating, .the temperature should rise
steadily to about 100C (212F) then stabilize.
A faulty connection or an open in CKT 455 or CKT
1227 can result in a DTC 59.
The "Temperature to Resistance Value" scale in
SECTION 7AHA may be used to check the TFT sensor
at various temperature levels to evaluate the
possibility of a "skewed" (mis-scaled) sensor. A
"skewed" sensor can result in firm shifts, or TCC
enabled.
DTC59
SENSOR CIRCUIT HIGH

BEEN PERFORMED?
IGNITION "OFF."
DISCONNECT TRANSMISSION WIRING CONNECTOR.
INSTALLJ 39775 ON THE EXTERNAL WIRING CONNECTOR.
INSTALL TEST LIGHT BETWEEN TERMINALS "L" AND "M".
IGNITION "ON" SCAN TOOL SHOULD DISPLAY
TEMPERATURE GREATER THAN 146C (295F).
OTC 59 IS INTERMITTENT.
IF NO ADDITIONAL DTC(s) WERE STORED,
REFER TO "DIAGNOSTIC AIDS."

SCAN TOOL SHOULD OISPLA Y TEMPERATURE
GREATER THAN 146C (295F).

CHECK" SECTION 7A14A OR 7A17A IN
OPEN CKT 1227, FAUL TY CONNECTION

AT CONTROL MODULE OR FAUL TY
CONTROL MODULE.
OPEN SENSOR GROUND CIRCUIT,

FAUL TY CONNECTION OR FAULTY
CONTROL MODULE.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM .OTC DOES NOT RESET.
1-25-93
MS 13451

TOIATAND
MAP SENSOR
A/C PRESSURE
SENSOR
452BLK--------'---.-----------------c..._------------____.
SENSOR GROUNDS
--------------------------+----------------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416 GRY ------------------,

A/C
EVAPORATOR
TEMPERATURE
SENSOR
452 BLK
-------------------+-----------'
732DKBLU-----------------t------------------------------t
1/P FUSE #3
PCM
416GRv-------------------------------------------------11
A/C
----;~ TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 B R N - - - - - - - - - - - - - - - - ~ r----------------762DKGRN/WHT
A/C EVAPORATOR
TEMPERATURE SIGNAL
SV REFERENCE
A/CREQUEST
IGNITION
25 AMP
FUSE #12 *
SWITC~139PNK--~
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
,--- .,
I
1--------------------------------rl
I.
459 DK GRN/WHT
o ~ A B1-59DKGRN _ _..____
_. ---'
A/C
COMPRESSOR
CLUTCH
1-e---450 BLK ----....1._~
.
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
7-2-93
NS 15598
DTC61
A/C SYSTEM PERFORMANCE
NC refrigerant charge is calculated by the inputs from the AJC refrigerant pressure and NC evaporator
temperature sensors. The PCM will calculate system charge when the AJC is selected "ON" by using three
variables. A/C evaporator temperature, NC refrigerant pressure and vehicle speed are factored together to yield
a minimum charge allowable for the NC system to operate. As ambient temperature falls, so does static (NC
"OFF") refrigerant pressure. This produces a sliding scale which requires temperature, pressure and vehicle
speed inputs to calculate a reliable system charge value that indicates when NC refrigerant charge is too low to
safely allow the compressor to operate.
OTC 61 Will Set When: The system charge falls below a given value for the temperature and vehicle speed
variables or if the status line is intermittently "OPEN" or grounded.
Action Taken (PCM will default to): The MIL will not become illuminated, the NC compressor will be
disabled, the cooling fan will not be enabled unless NC had been requested first and the vehicle speed is above 35
mph with a current OTC 61.
OTC 61 Will Clear When: A current OTC 61 will clear when NC charge falls within the calibrated threshold.
A history OTC 61 will clear after 50 consecutive ignition key cycles without a current OTC 61 being stored.

1. This test determines if OTC is intermittent and
will also check the AJC system for other failures.
Repair all other OTC(s) first before proceeding.
2. This test is to evaluate the A/C refrigerant
pressure sensor for accuracy. A reliable gage set
should be used and no more than 20 psi difference
in pressure between gages and Tech 1 is allowable.
3. The system is operating though OTC 61 is
intermittent. Hardware failures including worn
compressor, etc. are diagnosed in SECTION lB.
Diagnostic Aids: After a subsequent key cycle, the

NC will be enabled and OTC 61 will be erased from
the current OTC memory and added as a history OTC.
If NC pressure, evaporator temperature and vehicle
speed again indicate a low charge, the PCM will store
a current OTC 61 and disable the AJC compressor
clutch. Only after a relatively high number of failures
occur will the NC be disabled and become inoperative
until the code is cleared, from both current and history
OTC memory.
The A/C status circuit allows the PCM to
determine if the clutch is receiving a complete circuit
via the NC relay. If the status line is intermittently
open or grounded a OTC 61 may set.
DTC61
r--------------------------- --------~
: THIS CHART ASSUMES THAT THE A/C SENSORS, CLUTCH

I CONTROL AND RELAYS ARE FUNCTIONING PROPERLY.
: IF ANY OF THE ABOVE IS NOT "OK," REFER TO THE
I APPROPRIATE CHARTS FOR PROPER DIAGNOSIS.
~-------------- ---------------------~
IGNITION "OFF," ENGINE "OFF," A/C "OFF."

IGNITION "ON," ENGINE IDLING.
TURN A/C "ON."
ROAD TEST VEHICLE.
DOES DTC 61 OR ANY OTHER A/C DTCs SET?
DTC 61 IS INTERMITTENT, REFER

TO SECTION 181 FOR FURTHER
SYSTEM DIAGNOSIS.
(v
ENGINE "OFF."
INSTALL A/C MANIFOLD GAGE SET. (SEE SECTION ,
1B FOR PROPER INSTALLATION INSTRUCTIONS
AND A/C PRESSURE SPECIFICATIONS.)
IGNITION "ON," ENGINE IDLING, A/C"OFF."
IS A/C REFRI.GERANTPRESSURE WITHIN
SPECIFICATION LISTED IN .1 B?
SCAN A/CPRESSURE USING TECH 1.

ARE TECH 1 SC~N TOOL PRESSURES WITHIN
20 LBS OF HIGH SIDE GAGE PRESSURE?
SCAN A/C EVAPORATOR TEMPERATURE

USING TECH 1.
A/C CLUTCH SHOULD ENGAGE WHEN
EVAPORATOR TEMPERATURE IS GREATER
THAN 39 F AND DISENGAGE WHEN
TEMPERATURE IS LESS THAN 36.F.
DOES IT?
REFER TO A/C SECTION 181 AND

PERFORM A/C PERFORMANCE TEST.
CHECK SENSOR CONNECTIONS.

IF OK, REPLACE A/C REFRIGERANT
PRESSURE SENSOR.
LOW A/C REFRIGERANT CHARGE

OR
FAULTY A/C EVAPORATOR TEMPERATURE
SENSOR CONNECTION
OR
FAUL TY A/C EVAPORATOR TEMPERATURE
SENSOR
OR
A/C EVAP TEMPERATURE SENSOR IN IMPROPER
LOCATION.
12-8-92
NS16211

PCM
RIGHT {BANK 1) OXYGEN
SENSOR (025)
, ~ - , - - - ' - - - - - ( ( - - - - - 1 6 6 6 PPL
LEFT 025 GROUND
1 351 BLK/WHT
RIGHT 025 GROUND
ENGINE _.__
GROUND-=-
6-16-93
NS 15889
DTC63
RIGHT (BANK 1) OXYGEN SENSOR (025) CIRCU~T
(OPEN CIRCUIT)

The PCM supplies a voltage of about .55 volt between terminals "B22" and "B23". (If me;:isured with a 10
megohm digital voltmeter, this may read as low as .35 volt.) The Oxygen Sensor (028) varies the voltage within
a range of about 1 volt. If the right (Bank 1) exhaust is rich, the 028 will display close to 1000 miBivolts and
when the exhaust is lean the 028 will display close to 100 millivolts.
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open 028
circuit or cold 028 causes "Open Loop" operation.
OTC 63 Will Set When: Vehicle is operating in "Closed Loop," engine coolant temper~ture greater than 85C
(185F), CKT 1666 voltage steady between 350 millivolts and 550 millivolts, throttle angle greater than 3% with
all conditions met and held for 30 seconds.
illuminated.
OTC 63 Will Clear When: A current OTC 63 will clear when t.he 028 voltage falls out of the 350 to 550
millivolt range. A history OTC 63 will clear after 50 consecutive ignition key cycles without a current OTC 63
being stored.
Number(s) below
1. If the conditions for a OTC 63 exist, the system will
not go "Closed Loop."
2. This will determine if the sensor is a fault or the
wiring or PCM is the cause of the OTC 63.
3. In doing this test use only a high impedance digital
volt ohtnmeter. This test checks the continuity of
CKT 1666 and CKT 351 because if CKT 351 is
open, the PCM, voltage on CKT 1666 will be
greater than .6 volt (600 mV).
Diagnostic Aids:
Normal Tech 1 scan voltage

varies between 100 m V 999 m V (.1 and 1.0 volt) while
in "Closed Loop." OTC 63 sets if voltage remains
between 350 millivolts and 550 millivolts, but the
system will go "Open Loop" in about 15 seconds. Refer
to "lntermittents" in "Symptoms," Section "6E3-B".
DTC63
(OPEN CIRCUIT)
G) ENGINE A,T NORMAL OPERA TING TEMPERATURE (ABOVE 80C/176F).

DOES SCAN TOOL INDICATE "CLOSED LOOP"?
DISCONNECT 025 CONNECTOR.

JUMP~R HARNESS CKT 1666 (PCM SIDE) TO GROUI\ID.
SCAN TOOL SHOULD DISPLAY OXYGEN SENSOR VOLTAGE
BELOW .2 VOLT(200mV)WITH ENGINE RUNNING.
DOES IT?'

DlC(s) WERE SYORED, REFER TO "DIAGNOSTIC
REMOVE JUMPER.
.IGNITION "ON," ENGINE "OFF."
CHECK VOLTAGE OF CKT 1666 (PCM SIDE)AT
025 HARNESS CONNECTOR USING A DVM .
FAUL TY 025 CONNECTION

OR
SENSOR.
.3-.6VOLT
(300 - 600 mV)
FAULTY PCM.
GREATER THAN
.6 VOLT (600 mV)
OPENCKT351
OR
FAUL TY CONNECTION
OR
F~ULTYPCM~
LESS THAN .3
VOLT (300 m V)
OPEN CKT 1666
OR
FAUL TY PCM CONNECTION
OR
FAULTY PCM.
6-16-93
NS 15928

PCM
RIGHT (BANK 1) OXYGEN
SENSOR (025)
l~.._._l----((--1666PPL
LEFT 025 GROUND
1 351
ENGINE
GROUND
-*-=-
BLK/WHT
RIGHT 025 GROUND
6-16-93
NS 15889
DTC64
RIGHT (BANK 1) OXYGEN SENSOR (02S) CIRCUIT

The Powertrain Control Module (PCM) supplies a voltage of about .45 volt between terminals "B22" and
When the 02S reaches operating temperature, it varies this voltage f~om about 100 millivolts (exhaust is
circuit, or cold sensor, causes "Open Loop" operation.
OTC 64 Will Set When: Vehicle is operating in "Closed Loop" and CKT 1666 is below 280 millivolts for
greater than 60 seconds.
illuminated.
OTC 64 Will Clear When: A current DTC 64 will clear wh.~n the 02S voltage rises above the calibrated lean
exhaust threshold. A history DTC 64 will clear after 50 consecutive ignition key cycles without a current DTC 64
being stored.
Number(s) below
1. The engine must be operating in "Closed Loop" to
store DTC 64.
Diagnostic Aids:
Using the Tech 1 scan tool,

observe the long term fuel trim at different RPM and
air flow conditions. The Tech 1 scan tool also displays
the fuel trim cells, so the long term fuel trim values
can be checked in each of the cells to determine when
the DTC 64 may have been set. If the conditions for
DTC 64 exist, the long term fuel trim values will be
around 150.
Check the following possible causes:
Oxygen sensor wire - Sensor pigtail may be
mispositioned and contacting the exhaust
manifold. Check for ground in wire between
connector and sensor.
Lean iniector(s). Perform "Injector/Coil
Balance Test," CHART C-2A.
Fuel contamination - Water, even in small

amounts, near the in-tank fuel pump inlet can
be de.livered to the injectors. The water causes.
a lean exhaust and can set a DTC 64.
Fuel pressure - System will be lean if fuel
pressure is too low. It may be necessary to
monitor fuel pressure while driving the vehicle
at various road speeds and/or loads to confirm.
Refer to "Fuel System Diagnosis," CHART
A-7.
Exhaust leaks - If there is an exhaust leak, the

engine can cause outside air to be pulled into
the exhaust and past the sensor. Vacuum or
crankcase leaks can cause a lean condition.
If DTC 64 is intermittent, refer to "Symptoms,"
Section "6E3-B".
A cracked or otherwise damaged 02S may set
an intermittent OTC 64.
DTC64
RUN WARM ENGINE {75C/167F TO 95C/203F) AT 1200 RPM.

DOES TECH 1 INDICATE RIGHT 025 {BANK 1) VOLTAGE FIXED BELOW .28 VOLT{280 mV)?
DISCONNECT RIGHT 025 {BANK 1) ELECTRICAL CONNECTOR.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY RIGHT 025
{BANK 1) VOLTAGE BETWEEN .28 VOLT AND .7 VOLT
(280 mV AND 700 MV).
DOESIT?

AIDSH ON FACING PAGE.

OR
FAULTY PCM.
6-16-93
NS 15930

PCM
RIGHT (BANK 1) OXYGEN
SENSOR (025)
, ~......
f-~----(~1666PPL
LEFT 025 GROUND
1 351
BLK/WHT
RIGHT 025 GROUND
-*-
ENGINE
GROUND-=-
6-16-93
NS 15889
DTC65
RIGHT (BANK 1) OXYGEN SENSOR (025)
3.4L (VIN S) "F" CARLINE (~Fl)

..
The Powertrain C~mtrol Module (P(?~) su~plies a vol~age of about .45 volt between tenninals "B22" and.
,
When the 028 reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
'
circuit or cold sensor causes "Open.Loop'.' operation.
.
OTC 65 Will Set When: Vehicle is operating in "Closed Loop," CKT 1666 is above 750 millivolts, throttle'
angle is between 6% and 20% condition present for greater than 60 seconds.,

Action Taken (PCM wifl default to): Vehicle will operate in "Open Loop" and MIL will become
illuminated.
OTC 65 Will Clear When: A current OTC 65 will clear when the 028 signal voltage falls below the calibrated
rich exhaust threshold. A history OTC 65 will dear afte-r 50 consecutive ignition key cycleswithout a current
OTC 45 being stored.
Diagnostic Aids: Using the Tech scan tool, ~bserve
MAP sensor - An output that causes the PCM
the long term fuel trim value at different RPM and air
to sense a higher th.an normal manifold
flow conditions. The Tech 1 scan tool als~ displays the
pressure (low vacuum) can cause the system to
fuel trim cells, so the long term fuel trim values can be
go rich. Disconnecting the Manifold Absolute
checked in each of the cells to determine when the
Pressure (MAP) sensor will allow the PCM to
OTC 65 may have been set. If the conditions for OTC
set a fixed value for the MAP sensor.
Substitute a different MAP sensor if the rich
65 exists, the long term fuel trim values will be around
condition is gone, while the sensor is
115 or lower.
Check the following possible causes:
disconnected.
Fuel pressure - System will go rich, if pressure
TP sensor - An intermittent Throttle Position
is too high. The PCM can compensate for some
(TP) sensor output will cause the system to
increase. However, if it gets too high, a OTC
operate richly due to a false indication of the
65 will be set. Refer to "Fuel System
engine accelerating.
Diagnosis," CHART A-7.
028 contamination - Inspect Oxygen Sensor .
(028) for silicone contamination from fuel, or
Leaking fuel injector(s) - Refer to CHART A-7.
An open ground CKT 351 - May result in
use of improper RTV sealant. The sensor may
induced electrical "noise." The PCM interprets
have a white, powdery coating and result in a
this "noise" as reference pulses. The
high but false signal voltage (rich exhaust
additional pulses result in a higher than
indication). The PCM will then reduce the
actual engine speed signal. The PCM then
amount of fuel delivered to the engine causing
delivers too much fuel causing the system to go
a severe surge driveability problem.
rich. The engine tachometer will also show
EGR valve - Exhaust Gas Recirculation (EGR)
higher than actual engine speed, which can
sticking open at idle is usually accompanied by
help in diagnosing this problem.
a rough idle and/or stall condition.
IfOTC 65 is intermittent, refer to "Symptoms,"
Canister purge - Check for fuel saturation. If
Section "6E3-B".
fuel vapor canister is full of fuel, check EV AP
En ine oil contamination - Fuel fouled engine
canister control valve and hoses. Refer to
oil coul cause the 02 to sense a rich air/fuel
"Canister Purge" in "Evaporative Emission
mixture and set a OTC 65.
(EVAP) Control System," Section "6E3-C3".
DTC65
{RICH EXHAUST INDICATED)
ro
RUN WARM ENGINE (75C/167F

95C/203F)AT 1200 RPM:
DOES TECH ONE DISPLAY RIGHT 025 (BANK 1)VOLTAGE FIXED ABOVE .7 VOLT (700 mV)?
DISCONNECT RIGHT 025 (BANK 1) AND

JUMPER HARNESS CKT 1666 TO GROUND.
TECH ONE SHOULD DISPLAY RIGHT 025
(BANK 1) LESS THAN .28 VOLT (280 mV).
DOES IT?
DTC 6515 INTERMITTENT.

IF NO ADDITIONAi- QTCs WERE STORED,
REFER TO "DIAGNOSTIC AIDS ON
FACING PAGE.
CKT 1666 SHORTED TO

VOLTAGE
OR
FAULTY PCM.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
7-2-93
NS 15932

TOIATAND
MAP SENSOR
A/C PRESSURE
SENSOR
452BLK----.;.._,--_ _ _ __.:..__ _ _ ____.
SENSOR GROUNDS
----------t-------il
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416 GRY - - , . . . - - - - ~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
452 BLK
-------+----....,
732 DK BLU
-------+-------------4
416 GRY
.__----;.,.TO TP AND
MAP SENSOR
A/C
11P FUSE #3
_ _ _ _ _ _s_E..
LE~er sw1TCH
TO ~ 2 4 1 B R N
...-
IGNITION
25 AMP
PCM
762 DK GRN/WllT
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
FUSE #12 *
SWITC~139PNK~
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
10-WAY FWD LAMP jiARNESS

. CONN ECTOR (BLACK)
,..--,
I
1-----------,--,.---,~
0
co~c"1:i~
r--i!-1--1
k::taJ-:t. .-.
59DKGRN _
--450 BLK
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
... _ ..,_ _
----1
...
-
7-2-93
NS 15598
DTC66
A/C REFRIGERANT PRESSURE SENSOR CIRCUIT
(LOW PRESSURE)

The NC refrigerant pressure sensor responds to changes in NC refrigerant system high side pressure. This,
input indicates how much load the NC compressor is putting on the engine and is one of the factors used by the
PCM to determine IAC valve position for idle speed control, and engine cooling fan operation. The circuit consists'
of a 5 volt reference and a ground, both provided by the PCM, and a signal line to the PCM. The signal is a
voltage which is proportional to the pressure. The sensor's range of operation is Oto 450 psi. At O psi, the signal
will be about .1 volt, varying up to about 4.9 volts at 450 psi or above. OTC 66 sets if the voltage is less than .1
volt (approximately less than Opsi) for 5 seconds or more. The NC compressor is disabled by the PCM if DTC 66
is present or if pressure is above or below calibrated values described in "Air Conditioning Compressor Clutch
Control," Section "6E3-C10".
OTC 66 Will Set When: The signal voltage sensed at terminal "A5" is below .1 volt for 5 seconds when NC is
selected "ON" and the engine is running.
mph with a current D'I'C 66.
OTC 66 Will Clear When: A current DTC 66 will clear when the refrigerant pressure sensor voltage rises
above the calibrated low pressure threshold. A history DTC 66 will clear after 50 consecutive ignition key cycles
without a current DTC 66 being stored.
3. This step checks to see if the low signal voltage
was due to an open in the sensor circuit or the 5
1. This step checks the voltage signal being received
volt reference circuit since the previous step
eliminated the pressure sensor.
by the PCM from the A/C refrigerant pressure
Diagnostic Aids: DTC 66 sets when signal voltage
sensor.
2. Checks to see if low voltage signal is from the
falls outside the normal possible range of the sensor
sensor or the circuit. J umpering the sensor signal
and is not due to a refrigerant system problem. If the
CKT 380 to 5 volts checks the circuit, connections,
problem is intermittent, check for opens or shorts in
harness or poor connections.
and PCM.
DTC66
(LOW PRESSURE)
G)
G)
G)
IGNITION "OFF" ENGINE "OFF"

IGNITION "ON" ENGINE NOT RUNNING.
SCAN A/C REFRIGERANT PRESSURE SENSOR VOLTAGE
IS VOLTAGE LESS THAN.1V?
DISCONNECT A/C REFRIGERANT PRESSURE SENSOR CONNECTOR.

JUMPER TERMINALS "B" AND "C".
DOES TECH 1 DISPLAY GREATER THAN 4.6 VOL TS?
DTC 66 INTERMITTENT REFER TO

REMOVE JUMPER.
CONNECT VOLTMETER FROM TERMINAL" A" TO "B".
IS VOLTAGE ABOUTS VOLTS?
FAULTY A/C REFRIGERANT PRESSURE SENSOR

CONNECTION
OR
FAUL TY A/C REFRIGERANT PRESSURE SENSOR.
WITH TEST LIGHT TO B +, PROBE PRESSURE

SENSOR CONNECTORJERMINAL "A;'.
IS LIGHT "ON"?
FAULTY CKT 380 PCM CONNECTION

OR
OPENCKT380
OR
FAULTY PCM.
OPEN A/C REFRIGERANT PRESSURE

SENSOR GROUND CKT 452.
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-16-93
NS 15624
6E3-A-102 3.4L. (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

TOIATAND
MAP SENSOR
452BLK------------~------1
A/C PRESSURE
SENSOR
SENSOR GROUNDS
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
38() RE.D/BLK
416GRY - - - - - -
A/C
EVAPORATOR
TEMPERATURE
SENSOR
PCM
452BLK--------J-----J
732DKBLU--------+-----------1
416GRv----------------------1
L-..---'-TO TP AND
A/C
MAP SENSOR
1/P FUSE #3
_______
sE...
~E.SJSWITCH
762 DK GRN/WHT
TO ~ 2 4 1 B R N
....- t
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
IGNITION
25 AMP
FUSE #12 *
SWITCH_
- - - ~ .....__
----,
--~139PNK
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
,---,
1------------~
I
459 DK GRN/WHT
59 DK GRN _ _ _ _ _....,
--<1.---
co~E:t~OR . o ~ B
.
59 DK GRN _ _ _ _.._-_-_
..._
~ H - t - - - 4 5 0 BLK
A/CCOMPRESSOR
CLUTCH RELAY
A/C STATUS
_.
-----=..._~
7-2-93
NS 15598
DTC67
A/C REFRIGERANT PRESSURE SENSOR (CIRCUIT ERROR)
3.4L (VIN S) F" CARLINE (SFI)
11
The PCM can determine ifthe A/C compressorclutch is engaged or not engaged through the A/C clutch status
line. If the PCM has grounded the coil of the A/C clutch control relay, current can flow through the relay contacts
to the A/C compressor clutch and the PCM on the A/C status circuit.
When voltage is present at the PCM A/C clutch status terminal A/C status "ON" will be displayed on the
Tech 1. As the PCM detects that the A/C compressor clutch has cycied "OFF" (through the A/C control switch
etc.), the PCM will record A/C system pressure from the A/C refrigerant pressure sensor. If the A/C refrigerant
pressure does not increase more than 9 psi when the A/C clutch rs turned back 1'0N ," a DTC 67 will set. This
c.ondition can o.ccur if the A/C refrigerant pressure sensor is fixed at one value, or if the A/C refrigerant pressure
sensor ground 1s open.
OTC 67 Will Set When: The PCM does not detect an A/C refrigerant pressure change of more than 9 psi when
the A/C clutch has been cycled.
Action Taken (PCM will default to): The MIL will not become illuminated. The A/C compresso.r will
become disabled, the cooling fan will not be enabled unless A/C had been requested first and the vehicle speed is
above 35 ~ph with a current DTC 67.
OTC 67 Will Clear When: A current DTC 67 will clear when the A/C pressure signal shows an increase of
more than 9 psi since the last time the A/C clutch has been cycled. A history DTC 67 will clear after 50
consecutive ignition key cycles without a current DTC 67 being stored.
4. If the A/~ compressor clutch is disconnected or if
CKT 59 is open between the splice and the clutch,
1. Checks to see if the PCM detects an A/C
the A/C .compressor clutch will not ef!.gage, but the
refrigerant Qressure change of more than 9 psi
PCM will detect voltage on the A/C status line
when the A/C clutch has been cycled.
which will indicate the clutch is "ON." If the A/C
controls are cycled from "OFF" to "ON" at this,
2. If the rela_y pqwer feed CKT 139 is intermittent
the A/C clutch status terminal mai not detect
point, a DTC 67 will set since the clutch did not
voltage when A/C is commanded "ON. '
engage and therefore no pressure change was
3. If tne A/C clutch status line becomes
detected.
intermittentlx open or shorted while the
5. The remaining tests check the A/C refrigerant
compressor is 'ON." the PCM will be wrong_li
pressure sensor circuit for proper operation.
detecting the A/C dutch going "ON" and "OFF.'
.
.
.
When tfie PCM falsely detects the clutch cycling
D1agnost1c Aids: A DTC 67 will store in PCM
from "ON" to "OFF" and the clutch is remaining
memory but will not turn "ON" the Malfunction
"ON," a DTC 67 will set since no pressure change
Indicator Lamp (MIL) "Service Engine Soon."
was detected.
DTC67
(CIRCUIT ERROR)
3.4L (VIN S)
G)
F" CARLINE (SFI)
IF DTC 66 OR 70 IS PRESENT USE THAT CHART FIRST.

CLEAR DTC(s).
START ENGINE.
TURN A/C "ON."
DID A/C COMPRESSOR CLUTCH ENGAGE?
11
IGNITION "OFF."
DISCONNECT A/C
COMPRESSOR CLUTCH
CONNECTOR.
CONNECT A TEST LIGHT
BETWEEN TERMINALS
"A" AND"B".
IGNITION "ON," A/C
"ON."
IS TEST LIGHT "ON"?
PROBE A/CCOMPRESSOR
CLUTCH TERMINAL "A"
WITH TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
. OPEN OR SHORTED A/C

COMPRESSOR CLUTCH
CIRCUIT FROM CLUTCH
TO SPLICE.
OPEN CKT 139

OR59
OR
FAULTY RELAY
CONNECTION.
USING TECH 1, OBSERVE A/C REFRIGERANT PRESSURE WHILE .

CYCLING THE A/C COMPRESSOR CLUTCH FROM "OFF" TO "ON."
DID A/C REFRIGERANT PRESSURE INCREASE MORE THAN 1O psi
WHEN A/C CONTROLS WERE TURNED "ON"?
IGNITION "OFF."
DISCONNECT A/C REFRIGERANT
PRESSURE SENSOR ELECTRICAL
CONNECTOR.
JUMPER HARNESS CONNECTOR
TERMINALS "B" AND "C".
IGNITION "ON."
DOES TECH 1 INDICATE REFRIGERANT
PRESSURE SENSOR VOLTAGE
GREATER THAN 4.8 VOL TS?
FAULTY A/C
COMPRESSOR
CLUTCH
CONNECTION
OR
OPENA/C
COMPRESSOR
CLUtCH COIL.
USING DVM MEASURE

VOLTAGE FROM
PRESSURE SENSOR
CONNECTOR TERMINAL
"B" TO GROUND.
DOES DVM DISPLAY
ABOUT 5 VOLTS?
OPENA/C
COMPRESSOR
CLUTCH GROUND
CIRCUIT.
FAULTY PCM
CONNECTION
OR
OPEN OR
GROUNDED5
VOLT
REFERENCE
CIRCUIT
OR
FAULTY PCM.
FAULTY PCM
CONNECTION
OR
OPEN OR
GROUNDED
A/C
REFRIGERANT
PRESSURE
SENSOR
SIGNAL WIRE
OR
FAULTY PCM.
G)
DTC671S
J~TERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
WITH TEST LIGHT TO 12

VOL TS, PROBE A/C
REFRIGERANT PRESSURE
SENSOR CONNECTOR
TERMINAL "A".
IS TEST LIGHT "ON"?
OPEN A/C
REFRIGERANT
PRESSURE
SENSOR
GROUND
CIRCUIT.
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACIN~ PAGE AND CONFIRM DTC DOES NOT RESET,
FAULTY
SENSOR
CONNECTION
OR
FAULTY
SENSOR.
6-16-93
NS 15625

TOIATAND
MAP SENSOR
A/C PRESSURE
SENSOR
452BLK-,--,----------------~
SENSOR GROUNDS
380 RED/8LK - - - - - - - - - + - - - - - - - I
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
416 GRY - - - - - - - ,
A/C
EVAPORATOR
TEMPERATURE
SENSOR
PCM
452BLK-------+----~
732DKBLU------+------------I
1/P FUSE #3
416GRv---------<-----t11--------~
A/C
~--i~TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 DKGRN/WHT
25 AMP
FUSE #12 *
IGNITION
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
SWITCH_
-~-.._
----.
- - - - - - ~139PNK
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
A/C
COMPRESSOR
CLUTCH

CONNECTOR (BLACK)
,---.,
-------------.-1
I
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
o ~ A1-59DKGRN _ _...____
.... ___,
,,_._
8
__._---450
BLK - - - - . . . . . .
...._
7-2-93
NS 15598
DTC68
A/C COMPRESSOR RELAY
(SHORTED CIRCUIT)

When the PCM detects that NC has been requested, the PCM will activate the NC clutch relay. When the
relay is activated, voltage should be present at both the NC compressor clutch and the NC status terminal' at the
PCM.
If the PCM detects voltage on the NC status terminal when the NC relay has not been commanded "ON" by
the PCM, a DTC 68 will set.
A short to voltage at any point on CKT 59, a grounded relay control circuit or stuck NC relay contacts can set
a OTC 68.
A DTC 68 fault will be stored in PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL)
"Service Engine Soon."
DTC 68 Will Set When: The PCM detects voltage on CKT 59 for more than 10 seconds after the PCM has
disengaged the NC relay.
mph with as current DTC 68.
DTC 68 Will Clear When: A current DTC 68 will clear when the PCM no longer detects voltage on CKT 59
when the NC relay has not been commanded "ON" by the PCM. A history DTC 68 will clear after 50 consecutive
ignition key cycles without.a C?rrent OTC 68 being stored.
3. If DTC 68 reappears at this step, the PCM is
internally shorted to voltage.
1. This step is to determine if voltage is detected on
the NC status line after the PCM has disengaged
Diagnostic Aids: Check for intermittent shorts to
the NC relay.
NC clutch circuit or sticking NC relay.
2. This will isolate the ignition feed portion of the
circuit from the clutch circuit.
(SHORTED CIRCUIT)
3.4L (VIN S}
11
F" CARLINE (SFI)
IGNITION "OFF."
A/C "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH.
IGNITION oN."
PROBE CKT 59 WITH TEST LIGHT TO GROUND.
IS TEST LIGHT "ON"?
DISCONNECT A/C COMPRESSOR CLUTCH

CONTROL RELAY.
IS TEST LIGHT "ON"?
G)
FAULTY A/C COMPRESSOR

CLUTCH CONTROL RELAY
OR
CKT 459 SHORTED TO
GROUND.
..
IGNITION "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH CONTROL RELAY.
IGNITION "ON."
CLEAR DTC(s).
START ENGINE AND RUN FOR 30 SECONDS.
DOES OTC 68 REAPPEAR?
6-15-93
NS 15626

TOIATAND
MAP SENSOR
. 452BLK
A/C PRESSUR.E
SENSOR
-------------------1
380RED/BLK----------4--------1
416 GRY - - - - - ~
PCM
SENSOR GROUNDS
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
452 BLK - - - - - - - - r - - - . . . . . 1
A/C
EVAPORATOR
TEMPERATURE
SENSOR
732DKBLU------+-----------1
416GRv-----------<--------......1
A/C
._____,~TO TP AND
SELECT SWITCH
MAP SENSOR
1/P FUSE #3
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - 762 DKGRN/WHT

25 AMP
FUSE #12 *
IGNITION
A/C EVAPORATOR
TEMPERATURE SIGNAL
SV REFERENCE
A/CREQUEST
S W I T C ~ 1 3 9 P N K _ __,
20AMP
.------1e11-_..----.....1
A/C

CONNECTOR (BLACK)
r--~
COMPRESSOR
CLUTCH
CONTROL
RELAY*
11-----------..11
59 DK GRN
O~
459 DK GRN/WHT
------H
A/C CQMPR~SS()R
CLUTCH RELAY
A/CST~TUS
A r59DKGRN -L--____,'"'
coM:.:'issOR
CLUTCH
~ H - - - - - 4 5 0 BLK
--"--'s--_i~
7.-2-.93
NS15598
DTC69
A/C COMPRESSOR RELAY
(OPEN CIRCUIT)

When the PCM detects that A/Chas been requested, the PCM will activate the A/C clutch relay. Whep the
relay has been activated, voltage should be present at both the A/C compressor clutch and the A/C clutch status
line terminal of the PCM.
If the PCM activates the A/C clutch relay but does not detect voltage present at the A/C status terminal for
,
more than 10 seconds, a OTC 69 will set.
An open or short to ground at any point in CKT 59 will cause DTC 69 to set.
A OTC 69 fault will be stored in the PCM memory but will riot turn "ON" the Malfunction Indicator Lamp
(MIL) "Service Engine Soon."
DTC 69 Will Set When: No voltage is detected by the PCM on CKT 59 after 20 seconds, when the PCM has
commanded A/C "ON."
Action Taken (PCM will default to): The MIL will not become illuminated, the A/C compressor will be
disabled, the cooling fan will not be enabled unless A/C had been requested first and the vehicle speed is above 35
mph with a current DTC 69.
DTC 69 Will Clear When: A current DTC 69 will clear when voltage is present on CKT 59, when the PCM
has commanded the A/C "ON."

1. Determines whether the A/C compressor clutch
relay is faulty or poor connections at relay.
2. If the A/C compressor clutch operates properly and

the Tech l shows A/C status "OFF," then an open
exists between the PCM and the splice to the
compressor.
DTC69
(OPEN CIRCUIT)
CLEAR DTC(s).
START ENGINE .
CYCLE A/C SELECT CONTROLS TO "ON" AND "OFF" WITHIN 20 SECONDS.
DOES A/C COMPRESSOR CLUTCH OPERA TE PROPERLY?
IGNITION "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH CONTROL
RELAY.
IGNITION "ON."
PROBE UNDERHOOD ELECTRICAL CENTER* TERMINALS
"81" AND "82" WITH A TEST LIGHT TO GROUND.
LIGHT "ON" BOTH
DOES TECH 1 INDICATE A/CSTATUS "ON"?
[$]
GROUND DIAGNOSTIC "TEST" TERMINAL.

PROBE UNDERHOOD ELECTRICAL CENTER* TERMINAL "BS"
WITH TEST LIGHT TO B + .
LIGHT"ON"
I

OR
OPEN CKT 59 FROM SPLICE TO PCM
OR
FAULTY PCM .
LIGHT "OFF" ONE OR BOTH
JUMPER UNDERHOOD ELECTRICAL CENTER*

TERMINALS "81" TO "84".
DOES A/C COMPRESSOR CLUTCH ENGAGE?
~
FAULTY A/C COMPRESSOR CLUTCH CONTROL RELAY
CONNECTION
OR
FAULTY A/C COMPRESSOR CLUTCH CONTROL RELAY.
DTC69 IS
INTERMITTENT.
OPEN IN CKT 139 THAT DID NOT LIGHT.
LIGHT "OFF"
I
OPEN A/C COMPRESSOR CLUTCH CONTROL RELAY CIRCUIT

OR
OR
FAULTY PCM.
$
OPEN IN CKT 59 FROM RELAY TO SPLICE.
* REFER TO FIGURE" A2" "UNDERHOOD ELECTRICAL CENTER" FOR RELAY AND TERMINAL LOCATIONS.
* REFER TO FIGURE .. Ar uNDERHOOD ELECTRICAL CENTER" FOR RELAY AND TERMINAL LOCATIONS.
6-15-93
NS 15627

TOIATAND
MAP SENSOR
A/C PRESSURE
SENSOR
452BLK-----------w,-------1
SENSOR GROUNDS
----------+--------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416 GRY - - - - - - - - ,
A/C
EVAPORATOR
TEMPERATURE
SENSOR
PCM
-------+----~
732 DK BLU - - - - - - + - - - - - - - - - - - - 1
452 BLK
416GRv---------------------t
'----------<._ TO TP AND
A/C
MAP SENSOR
1/P FUSE #3
------S-~LE/CT SWITCH
762 DK GRN/WHT
TO ~ 2 4 1 B R N
....- 4
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C f<EQUEST
IGNITION
25 AMP
FUSE #12 *
SWITCH~--~ ~
. . . . . . . - - - - - - - - .....,,,..-139 PNK - - - .
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
,...--...,
1------------~
I
459 DK GRN/WHT
A/C
o ~ A1-59DKGRN _ _ ____.
COMPRESSOR
CLUTCH
8 - - - 4 5 0 BLK ----:l._....,
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
7-2-93
NS15598
DTC70
(HIGH PRESSURE)

The A/C refrigerant pressure sensor responds to changes in A/C refrigerant system high side pressure. This
input indicates how much load the A/C compressor is putting on the engine and is one of the factors used by the
PCM to determine IAC valve position for idle speed control. The circuit consists of a 5 volt reference and a
ground, both provided by the PCM, and a signal line to the PCM. The signal is a voltage which is proportional to
the pressure. The sensor's range of operation is O to 450 psi. At O psi, the signal will be about .1 volt, varying up
to about 4.9 volts at 450 psi or above.
OTC 70 Will Set When: The signal voltage sensed at terminal "A5" is above 4.9 volts for 5 seconds when A/C
is selected and the engine is running.
Action Taken (PCM will default to): The MIL will not become illuminated, the A/C compressor will be
disabled, the engine cooling fan will not be enabled unless A/C had been requested first and the vehicle speed is
above 35 mph with a current DTC 70.
OTC 70 Will Clear When: A current DTC 70 will clear when the refrigerant pressure sensor signal falls
below the calibrated high pressure threshold. A history DTC 70 will clear after 50 consecutive ignition key cycles
without a current DTC 70 being stored.
Diagnostic Aids: DTC 70 sets when signal voltage
falls outside the normal possible range of the sensor
and is not due to a refrigerant system problem. If
1. This step checks the voltage signal being received
problem is intermittent, check for opens or shorts in
by the PCM from the A/C refrigerant pressure
harness or poor connections.
sensor.
2. Checks to see if the high voltage signal is from a
shorted sensor or a short to voltage in the circuit.
Normally, disconnecting the sensor would make a
normal circuit go to near zero volts.
DTC70
(HIGH PRESSURE)
G)
IGNITION "OFF: ENGINE "OFF."

INSTALLTECH 1 SCAN TOOL.
IGNITION "ON" ENGINE NOT RUNNING.
IS A/C REFRIGERANT PRESSURE SENSOR VOLTAGE GREATER THAN 1.SV?
DISCONNECT A/C REFRIGERANT PRESSURE

SENSOR HARNESS CONNECTOR.
DOES TECH 1 DISPLAY LESS THAN 1 VOLT?
A/C REFRIGERANT PRESSURE SENSOR

SIGNAL CIRCUIT SHORTED TO VOLTAGE
OR
FAULTY PCM.
.. AFTER REPAIRS," REFER TO
OTC 70 IS INTERMITTENT. REFER TO

FAULTY A/C REFRIGERANT PRESSURE SENSOR CONNECTION

OR
OPEN CKT452
OR
FAULTY SENSOR.
ore CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-15-93
NS 15628
6E3-A-110 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND E.MISSIONS

TOIATAND
MAP SENSOR
, IC4~
A)C PRESSURE
.
SENSOR
~
. .
- ~
452BLK
. . 380 R E D / B L K - - - - - - - - - + - - - - - - - - 1
.
416GRY-------.
A/C
EVAPORATOR
TEMPERATURE
SENSOR
452 BLK
SENSOR GROUNDS
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
-------+----"
732DKBLU------+-----------t
416GRv--------<9---41....-------~
A/C
..._--;~TO TP AND
SELECT SWITCH
MAP SENSOR
1/P FUSE #3
TO
PCM
~ 241 BRN - - - - - - ~ - - - - - - 7 6 2 DK GRN/WHT
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
FUSE #12 *
IGNITION
25 AMP
SWITCH~-- ..... -- - - ~ ~
- - - - ~139PNK---,
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
A/C
COMPRESSOR
CLUTCH

CONNECTOR (BLACK)
o~
r----,
11------------.-1
I
59 DK GRN
459 DK GRN/WHT
-----+1
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
AB 1-59DKGRN _ _..._--...,...;-'---'
- - - 4 5 0 BLK
----.....t_~
7-2-93
NS 15598
DTC71
A/C EVAPORATOR TEMPERATURE SENSOR CIRCUIT
3.4L (VIN S)
11
11
F CARLINE (SFI)
Integral to the NC system is the NC evaporator temperature sensor. This sensor is mounted to the
evaporator which is located within the 1/P. The PCM receives a voltage signal inversely proportional to the
temperature at the evaporator coils. As the evaporator temperature increases or decreases, the resistance of the
sensor changes and varies the voltage signal to the PCM. This voltage is converted to a temperature valve by the
PCM and can then be displayed in degrees by the Tech 1. A DTC 71 fault will be stored in the PCM when
evaporator temperature is less than -7C but will not illuminate the Malfunction Indicator Lamp (MIL) "Service
Engine Soon."
DTC 71 Will Set When: NC evaporator temperature indicates less than-7C (19F) for 5 seconds.
Action Taken (PCM will default to): The MIL will not become illuminated, the NC compressor will
become disabled, the cooling fan will not be enabled unless NC had been requested first and the vehicle speed is
above 35 mph with a current DTC 71.
OTC 71 Will Clear When: A current DTC 71 will clear when the signal voltage falls within the calibrated
threshold of the NC evaporator temperature sensor. A history DTC 71 will clear after 50 consecutive ignition
key cycles without a current DTC 71 being stored.
1. This test is a verification that the DTC is not
intermittent.
Diagnostic Aids: If a problem is intermittent,

check for opens or shorts in the harness, or poor
connections. A sensor which has backed out of the
evaporator coil bracket will also set a false OTC.
DTC71
G)
DOES TECH 1 DISPLAY A/C EVAPORATOR

TEMPERATURE -7C (19F) OR LESS?
DISCONNECT A/C EVAPORATOR TEMPERATURE

SENSOR CONN ECTOR.
JUMPER TERMINALS "B" TO "C".
DOES TEMPERATURE ON TECH 1 INDICATE 32C?
ADDITIONAL DTCs WERE STORED,
FACING PAGE.
TEST LIGHT CONNECTED

TO B + PROBE HARNESS
CONNECTOR CAVITY C.
LIGHT"ON"
CKT7320PEN
OR
SHORTED TO VOLTAGE
OR
FAULTY PCM CONNECTOR
OR
FAULTY PCM.
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACING PAGE ANO CONFIRM DTC DOES NOT RESET.
6-15-93
NS 16234

VEHICLE
SPEED
SENSOR
(VSS)
PCM
~ ~==================:.::
r:1
111
LOCATED ON TRANSMISSION
VSS SIGNAL (LOW)
VSS SIGNAL (HIGH)
...,.11;,---.;.a:l.!J.,;:------ 817 DK GRN/WHT
TO
SPEEDOMETER
L,; -
;.J
10-WAY INLINE
1/PCONNECTOr~ 434 ORN/BLK
#1
(NATURAL)
-:-
12V
' "
PARK NEUTRAL POSITION
(PNP) SWITCH (CLOSED IN
PARK OR NEUTRAL)
6-16-93
NS 15611
DTC72
VEHICLE SPEED SENSOR (VSS) CIRCUIT SIGNAL ERROR
11
Vehicle speed information is provided to the Powertrain Control Module (PCM) by the Vehicle Speed Sensor
(VSS), which is a Permanent Magnet (PM) generator mounted in the transmission. The PM generator produces a
pulsing voltage whenever vehicle speed is over about 3 mph. The AC voltage level and the number of pulses
increases with vehicle speed. The PCM then converts the pulsing voltage to mph, which is used for calculations.
The vehicle speed can be displayed with a Tech 1 scan tool.
The PCM supplies a signal, on CKT 817, to operate the speedometer and the odometer. The VSS signal is also
sent to the cruise control module.
OTC 72 Will Set When: Not in PIN, transmission output speed changes greater than 1000 RPM, or in PIN,
transmission output speed change greater than 2048 RPM. No DTC 28, and engine speed greater than 200 RPM.
All conditions met for 2 seconds.
Action Taken (PCM will default to): A delayed (soft) landing to third gear and maximum line pressure.
DTC 72 will be stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
OTC 72 Will Clear When: The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" then
"ON."

1. This test checks the function of the VSS circuit.
2. An intermittent connection at the VSS or PCM
may cause a DTC 72 to set. Inspect the harness
and all related connections. Check for damaged or
pushed out terminals.
3. This test checks to make sure the wire harness is
routed away from the exhaust manifold.
4. This test checks for an incorrect PROM or a poor
connection.
Diagnostic Aids:
DTC 24 will set when no vehicle speed is

detected at start off.
DTC 72 will set when vehicle speed has been
detected and is lost.
DTC72
SIGNAL ERROR
3.4L (VIN S) ''F" CARLINE (SFI}
.G)
IGNITION "OFF."
RAISE DRIVE WHEELS.
START ENGINE.
WITH ENGINE IDLING IN GEAR, TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE O.
DOESIT?
IGNITION "OFF."
DISCONNECT VSS HARNESS CONNECTOR AT TRANSMISSION.
CONNECT SIGNAL GENERA TOR TESTER J 33431 aB TO VSS HARNESS
CONNECTOR.
IGNITION "ON," TESTER "ON" AND SET TO GENERAfEA VSS SIGNAL.
THE TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOESln
OTC IS INTERMITTENT. IF NO
ADDITIONAL OTC(s) WERE STORED,
FACING PAGE.
CHECK CALIBRATION 1.0. FOR MOST

CURRENT AND/OR INCORRECT SOFTWARE.
REFER TO SECTION C1.
CKT 400 OR401 OPEN,

SHORTED TO GROUND,
SHORTED TOGETHER,
FAULTY PCM CONNECTIONS
OR
FAULTY PCM.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE ANO CONFIRM OTC DOES NOT RESET.
7-.1-93
PS 17923

TOIATAND
MAP SENSOR
PCM
SENSOR GROUNDS
,
, ~ ~. 452BLK
A/C PRESSURE
SENSOR
. , C
.380 RED/BLK - - - - - - - - - - - - - - - - - 1
_ ,'
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
416GRY-------,
452BLK-------t-------'
732 DK BLU
1/P FUSE #3
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
------+-----------1
416GRv--------.-------~------~
A/C
- ~ - T O TP AND
SELECT SWITCH
MAP SENSOR
A/CREQUEST
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 DK GRN/WHT
25AMP
FUSE #12 *
IGNITION
SWITCH_ _ ____ ________......_ ~
_ _ _ _ . . . . ~139PNK---,
20AMP
~-----181 _________......
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
10-WAY FWDlAMP HARNESS

CONNECTOR (BLACK)
r--,
------------.-11
I
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/C STATUS
59 DK GRN - - - - - - - - - - '
A/C
COMPRESSOR
CLUTCH
450 BLK
----J_-.
7-2,93
NS15598
DTC73

Integral to the A/C system is the A/C evaporator temperature sensor. This sensor is mounted to the
evaporator which is located within the I/P. The PCM receives a voltage signal inversely proportional to the
temperature at the evaporator coils. As the evaporator temperature increases or decreases, the resistance of the
sensor changes and varies the voltage signal to the PCM. This voltage is converted to a temperature value by the
PCM and can then be displayed in degrees by the Tech 1. A DTC 73 fault will be stored in the PCM when
temperature sensor circuit is greater than 31 C but will not illuminate the Malfunction Indicator Lamp (MIL)
"Service Engine Soon."
DTC 73 Will Set When: A/C evaporator temperature indicates greater than 31C for 5 seconds.
Action Taken (PCM will default to): The MIL will not become illuminated, one A/C compressor will be
disabled, the cooling fan will not be enabled unless A/C had been requested first and the vehicle speed is above 35
mph with a current OTC 73.
DTC 73 Will Clear When: A current DTC 73 will clear when the signal voltage falls within the calibrated
threshold of the A/C evaporator temperature sensor. A history DTC 73 will clear after 50 consecutive ignition
key cycles without a current DTC 73 being stored.
1. This test is a verification that the DTC is not
intermittent.
Diagnostic Aids: If a problem is intermittent,

check for opens or shorts in the harness, or poor
connections.
DRIVEABILITY AND EMISSIONS 3.4t (~32) (VIN S) (SFI) 6E3-A-t15
DTC73
DOES TECH 1 DISPLAY A/C EVAPORATOR

TEMPERATURE OF 32~C (90F) OR GREATER?
DISCONNECT A/C EVAPORATOR

TEMPERATURE SENSOR. TECH 1 SHOULD
DISPLAY TEMPERATURE BELOW -7C (19F). ,
DOES IT?
REPLACE SENSOR.

OR
TO SENSOR GROUND
OR
PCM IS FAUL TY.
6-15-93
NS 16237
TO COOLING 7UNDERHOOD
FAN CONTROL
ELECTRICAL CENTER
TO EVAPCANISTER
PURGE
DIGITAL EGR
SOLENOID VALVE
ASSEMBLY
RELAY
SOLENOID]
VALVE 1----
541 BRN
11---698BRN
1--1---
FUSE#6
10AMP
F
.,.... ... "
10 WAY INLINE FWD. LAMP HARN. CONN. (BLK)
EJ
699 RED
PCM
:,,,IGNITION
698
BRN
699 RED
697 LT BLU - - - - - - - - - - - - 697LT BLU
EGR #2 CONTROL
EGR #1
CONTROL
__.__
NTROL-=_._
6-16-93
NS 15638
DTC75
DIGITAL EGR #1 SOLENOID ERROR
EXHAUST GAS RECIRCULATION (EGR) CIRCUIT

Exhaust Gas Recirculation (EGR) is administered through a digitally controlled 3 solenoid valve unit. Each
of the 3 valves is controlled individually and can be open or clo.sed in any combination. During a long closed
throttle deceleration, the PCM will cycle each valve open and measure a change in MAP. This test indicates if
the valve is nonoperational electrically, or if an EGR passage is obstructed. If the PCM does not detect a change
in MAP associated with solenoid #1 being commanded "ON," a DTC 75 will be set.
OTC 75 Will Set When: The engine speed is between 1400 and 2000 RPM, MAP is between 20 and 30 kPa, TP
sensor angle is at 0%, all values must be held fairly constant for the test to run. The test must fail 3 consecutive
times for a DTC 75 to be set.
Action Taken (PCM will default to): The MIL will become illuminated.
OTC 75 Will Clear When: The current DTC 75 will clear after each ignition key cycle, and will only reset
when the test is run and fails again. A history DTC 75 will clear after 50 consecutive ignition key cycles without
1. This test determines if there is power to the EGR
valve.
2. This test will determine if there is an open circuit
in the EGR wiring or if the EGR valve is at fault.
3. This test will determine if there is a short to
ground in CKT 697 going to the EGR valve or if
the PCM is at fault.

by a poor connection, chaffed wire insulation, or a wire
broken inside the insulation.
Intake plenum should be checked for possible
plugged passages.
DTC75
IGNITION "OFF," ENGINE "OFF."

INST All TECH 1.
IS OTC 75 STORED?
DISCONNECT EGR VALVE ELECTRICAL CONNECTOR.

KEY "ON," ENGINE "OFF."
PROBE TERMINAL "D" OF EGR HARNESS CONNECTOR.
OTC 75 INTERMITTENT. SEE

WITH TEST LIGHT CONNECTED TO B +,

PROBE TERMINAL" A" OF EGR HARNESS
CONNECTOR.
USING A TECH 1 SCAN TOOL, SELECT EGR

"OUTPUT TEST," ENERGIZE "EGR 1" SOLENOID.
WITH TEST LIGHT STILL CONNECTED TO B +,
PROBE TERMINAL" A" OF EGR CONNECTOR.
TEST LIGHT SHOULD TURN "ON" WHEN
ENERGIZED.
DISCONNECT (BLACK) PCM CONNECTOR "B".

PROBE TERMINAL" A" OF EGR HARNESS CONNECTOR.
LIGHT"ON"
FAULTY EGRCONNECTION
OR
DIGITAL EGRVALVE.
OPEN IN CKT 697

OR
PCM CONNECTOR
OR
FAULTY PCM.
* THESE STEPS MUST BE DONE VERY QUICKLY AS THE PCM WILL COMPENSATE FUEL DELIVERY.
7-13-93
NS 15641
TO EVAPCAllllSTER
PURGE
SOLENOID]
VALVE -
DIGITALEGR
SOLENOID VALVE
ASSEMBLY
1---
541 BRN
698 BRN
FAN CONTROL
ELECTRICAL CENTER
RELAY
r.:,
L!.J
PCM
FUSE #6
10 AMP
e""\J
_. IGNITION
698
BRN
o---
699 RED
1---
697 LT BLU - - - - - - - - - - - - - 6 9 7 LT BLU
812
699 RED
_::.__
__.__
EGR #2 CONTROL
_::.__
EGR #1
CONTROL
NTROL-:-
6-16-93
NS15638
DTC76

of the 3 valves is controlled individually and can be open or closed in any combination. During a long closed
throttle deceleration, the PCM will cycle each yalve open and measure a change in MAP. This test indicates if
in MAP associated with solenoid #2 being commanded "ON," a DTC 76 will be set.
times for a DTC 76 to be set.
OTC 76 Will Clear When: The current DTC 76 will clear after each ignition key cycle, and will only reset

1. This test determines if there is power to the. EGR
valve.

plugged passages.
DTC76
IGNITION 0FF; ENGINE 0 0FF.

INSTALL TECH 1.
IGNITION 0N," ENGINE "OFF."
IS OTC 76 STORED?

KEY "ON, 0 ENGINE "OFF.
PROBE TERMINAL "D" OF EGR HARt.1,ESS CONNECTOR.
OTC 76 INTERMITTENT. SEE


PROBE TERMINAL
OF EGR HARNESS
CONNECTOR.

"OUTPUTTEST, ENERGIZE "EGR2 SOLENOID.
TEST LIGHT SHOULD TURN "ON WHEN
ENERGIZED.
0
DISCONNECT PCM CONNECTOR ~B" (BLACK).

PROBE TERMINAL "B OF EGR HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 698.
LIGHT"ON"
FAULTY EGRCONNECTION .
OR
DIGITAL EGR VALVE.
OPEN IN CKT 698

OR
PCM CONNECTOR
OR
FAULTY PCM.
* THESE STEPS MUST BE DONE VERY QUICKLY AS THE PCM WILL COMPENSATE FUEL DELIVERY.
7-13-93
NS 15642
FAN CONTROL
ELECTRICAL CENTER
TO EVAP CANISTER
PURGE
DIGITALEGR
SOLENOID VALVE
ASSEMBLY
SOLENOID]
VALVE 1----541 BRN
11---698BRN
11--11---
RELAY
r.:,
L!J
PCM
FUSE #6
10AMP
fl"V
-.IGNITION
698
EGR #2 CONTROL
BRN
699 RED - - - - - - - - - - - - - - 6 9 9 RED

697 LT BLU - - - - - - - - - - - - 6 9 7 LT BLU
EGR #1
CONTROL
:L
::L
NTROL-=_._
6-16-93
NS 15638
DTC77
(ELECTRICAL DIAGNOS.IS)

of the 3 valves is controlled individually and can be open or closed in any combination. During a long 1::losed
throttle deceleration, the PCM will cycle each valve open and measure a chan'ge in MAP. This test indicates if
in MAP associated with solenoid #1 being commanded "ON," a OTC 77 will be set.
times for a OTC 77 to be set.
OTC 77 Will Clear When: The current OTC 77 will clear after each ignition key cycle, and will only reset
a current.OTC 77 being stored.
1. This test determines if there is power to the EGR
valve.
Diagnostic Aids: Ari intermittent may be caused

plugged passages.
DRIVEABILITY AND EMISSIONS 3.4L (k32) (VIN S) (SFI) 6E3-A-121
DTC77
EXHAUST GAS .RECIRCULATION (EGR) CIRCUIT
3.4L (VIN S) "F'' CARLINE (SFI)
'1'
~
IGNITION oFF," ENGINE "OFF."

INSTALL TECH 1.
IGNITION oN," ENGINE "OFF."
IS DTC 77 STORED?

KEY "ON, ENGINE "OFF."
WITH TEST LIGHT CONNECTED TO GROUND,.
PROBE TERMINAL "D" OF EGR HARNESS CONNECtOR.
DTC 77 INTERMITTENT. SEE


PROBE TERMINAL "C" OF EGR HARNESS
CONNECTOR.

"OUTPUTTEST," ENERGIZE "EGR 3u SOLENOID.
PROBE TERMINAL "C" OF EGR CONN ECTOR.
TEST LIGHT SHOULD TURN "ON" WHEN
ENERGIZED.
DISCONNECT PCM CONNECTOR "B" (BLACK).

PROBE TERMINAL "C" OF EGR HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKl'.699.
LIGHT "ON"
FAULTY EGRCONNECTION
OR
DIGITAL EGR VALVE.
OPEN IN CKT 699

OR
PCM CONNECTOR
OR
FAULTY PCM.
"AFTER REPAIRS, u REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
7-13-93
NS 15643
6E3-A-122 3.4L {L32) '{VIN'S) {SFI) DRIVEABILITY AND EMISSIONS
PCM
TRANSMISSION RANGE
B+
.,..._...................................-
1224PNK
- - - - - - - - - - - 1225 DK BLU
1226 RED
I
I
TRANSMISSION
:......_ CONNECTOR
I
.,.,.................................... 1227 BLK/YEL
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
.....___,,,"'""....__5y
..._____ TFT SIGNAL,
_ .............,............,__,....._
470 BLK
MAP
SENSOR
6-16-93
, PS 18513
DTC79
TRANSMISSION FLUID OVERTEMP
The Transmission Fluid Temperature (TFT) sensor is a thermistor within the TR pressure switch assembly,
that controls the signal voltage to the PCM. The PCM supplies a 5 volt reference signal to the sensor on CKT
1227. When the transmission fluid is cold, ,the sensor resistance is high and the PCM will sense high signal
w~~.
As the transmission fluid temperature warms to normal transmission operating temperatqre 100C (212F),
OTC 79 Will Set When: Signal voltage indicates a transmission fluid temperature greater than 146C
(295F) and has not cooled to less than 137C (280F) for 30 minutes, and no DTC 58 or 59 set. If TFT becomes
greater than 151C (306F), a DTC 58 will set.
Action Taken {PCM Will default to): DTC 79 will be stored in the PCM memory but will not turn "ON" the
Malfunction Indicator Lamp (MIL).
OTC 79 Will Clea.r Wh.en: The fault condition(s) no longer exist.

1. This test checks for skewed or shorted circuit.
2. This test simulates a DTC 59.

scan tool TFT displays should rise steadily to
about 100C then stabilize.
the possibility of a "skewed" sensor. A ''.skewed"
enabled complaints.
Check transmission fluid. Refer to "Fluid
Checking Procedure."
DTC79

BEEN PERFORMED?
DOES SCAN TOOL DISPLAYTRANSMISSfON FLUID

TEMPERATURE OF GREATER THAN 146C (295F)?
IGNITION "OFF."
TEMPERATURE OF -40C (-40F).
TFT SENSOR IS INDICATING HIGH TEMPERATURE.

REFER TO "INTERNAL WIRING HARNESS CHECK"
SECTION 7A14A (4L60E) OR 7A17A (4L80E) OF
OTC IS INTERMITTENT.

FAULTY CONTROL MODULE OR
CONNECTIONS.
5-11-93
PS 17931
TORQUE
corJVERTER
ASSEMBLY
PCM
TCCCONTROL
~
TCCCONTROL
FEED BACK
5
8
B......................
COOLER
LINE (FROM PUMP)
422 TAN/BLK
# 11
IGNITION
IGNITION
..__ _ _ _ _ 239 PNK - - - - - - - SWITCH
10A
PS 18511
2NDCL
DTC80
TRANSMISSION COMPONENT SLIPPING
11
The PCM energizes the Torque Converter Clutch (TCC) solenoid by grounding CKT 422. The TCC solenoid
allows converter release fluid to exhaust past the #9 check ball, applying the TCC. The TCC solenoid will
de-energize when the PCM no longer provides a ground. When the TCC solenoid is de-energized, this will block
exhaust fluid, and release the TCC. The PCM moniters the difference in engine speed and the calculated
transmission input shaft speed. With the TCC applied, the scan tool should display TCC slip speed of
approximately -50 RPM to + 50 RPM.
OTC 80 Will Set When: No OTC 28, TCC slip speed is greater than 100 RPM, TCC indicates "ON," gear
indicates 2, 3, or 4, trans range switch indicates "03" or "D4", TP between 0% and 35%, TFT between 60C and
100C. All conditions must be met for 10 seconds.
Action Taken {PCM will default to):

Inhibit TCC operation.
Set line pressure to max (harsh shifts).
Inhibit 4th gear ifin hot mode.
"ON."

actual selected range.
2. This test checks the torque converter for slippage
while in a commanded locked-up state.
Diagnostic Aids:
Check for poor connections at pass-thru

connector.
A faulty trans range pressure switch assembly
may set OTC 80.
DTC80
NOTICE: PERFORM FLUID CHECKING PROCEDURE

BEFORE PROCEEDING WITH DIAGNOSIS CHART.
INSTALL SCAN TOOL.

APPLY BRAKE PEDAL AND SELECT EACH
TRANSMISSION RANGE 01, 02, 03, 04, N, R, P.
DOES EACH SELECTED TRANS RANGE MATCH
TRANS RANGE SW ON SCAN TOOL?
DRIVE VEHICLE IN 4th GEAR AND TCC ENGAGED.

USE SNAPSHOT MODE TO RECORD DATA PARAMETERS.
IS TCC SLIP SPEED EVER GREATER THAN 200 RPM FOR
2 SECONDS WHILE TCC IS ENGAGED?
THE CONDITION MAY BE INTERMITTENT.

REFER TO TORQUE CONVERTER CLUTCH
(TCC) DIAGNOSIS IN SECTION 7 A 14A (4L60E),
7A17A (4L80E) OF THE APPROPRIATE
SERVICE MANUAL.
MECHANICAL COMPONENT FAILURE.

REFER TO "SYMPTOM DIAGNOSIS
CHARTS" SECTION 7A14A (4L60E),
7A17A (4L80E) FOR PROBABLE
MECHANICAL FAILURES.
5-29-93
PS 17429
6E3-A:.126 3.4L {L32) {VIN S) {SFI) DRIVEABILITYAND EMISSIONS
FUSE #11 *
' 10 AMP
PCM
10-WAY FWD LAMP

HARNESS CONNECTOR
,
{BLACK)
IGNITION..,'---~--- 239 PNK
G - - - - - - - T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK ~
GND
::~=m I
SIGNAL
IGNITION
CONTROL
MODULE
(ICM)
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
MINIMUM
- - - - - - - - 424 TAN/BLK
-----1
- - - - - - - - - 423 WHT
-----11
121 WHT
IGNITION CONTROL
BYPASS
IGNITION CONTROL
TACH SIGNAL
D
E
647 LT BLU/BlK
3XREF HIGH
453 RED/BU(
3XREF LOW
PRIMARY
WINDING
6-16-93
NS 15618
DTC82
IGNITION CONTROL 3X SIGNAL ERROR
3.4L {VIN S) "F" CARLINE {SFI)
If the Tech 1 scan.tool did not indicate a cranking RPM and there is no spark present at the plugs, the problem
, lies in the electronic). ignition control system or the power and ground supplies to the Ignition Control Module
(ICM).
The magnetic crank sensor is used to determine engine crankshaft position much the same way as the pickup coil did in distributor type systems. The sensor is mounted in the block near a seven slot wheel on the cran~
shaft. The rotation of the wheel creates a magnetic field in the sensor which induces a voltage signal. The
electronic ignition control module then processes this signal and creates the reference pulses needed by the PCM
and the signal triggers the correct coil at the correct time.
OTC 82 Will Set When: If no 3X reference pulses are detected by the PCM during cranking, a DTC 82 will be
set.
Action Taken {PCM will default to): The engine will not start, a DTC 82 will be stored and the MIL will
remain illuminated.
OTC 82 Will Clear When: A current DTC 82 is cleared immediately after key "OFF," or when the engine is
running. A history DTC 82 will clear after 50 consecutive ignition key cycles without a current DTC 82 being
stored.
OTC Chart Test Description: Number(sl below
Diagnostic Aids: An open or shorted 3X signal will
cause a "Cranks But Won't Run" condition. An
1. This test will determine if the 12 volt supply and a
intermittent connection however may set a DTC 82
good ground is available at the electronic ignition
and then disappear when a connection is made. A
history DTC 82 may indicate poor terminal
control module.
2. Checks for continuity of the crankshaft position
connections, a marginally faulty sensor or a marginal
ICM.
sensor and connections.
3. Voltage will vary in this test depending on
cranking speed of engine.
DTC82
3.4L {VIN S)
11
F" CARLINE {SFI)
r------------------,
: NO IGN CONTROL 3XSIG RPM :
I AND NO SPARK.
1
L-
G)
----------------~
DISCONNECT IGNITION CONTROL MODULE 2 PIN

CONNECTOR.
IGNITION "ON."
CONNECT TEST LIGHT BETWEEN HARNESS TERMINALS.
CONNECT TEST LIGHT FROM

HARNESS TERMINAL "B" TO
GROUND.
DISCONNECT 3X CRANKSHAFT POSITION SENSOR 3-WAY CONNECTOR

FROM IGNITION CONTROL MODULE.
WITH OHMMETER IN 2K OHMS POSITION, PROBE HARNESS TERMINALS
"A" & "B" (SHOULD READ BETWEEN 900-1200 OHMS).
LIGHT "ON"
REPAIR OPEN
GROUND CKT 450.
REPAIR OPEN
IGNITION FEED
CKT 239.
SET VOLTMETER ON 2 VOLT

AC POSITION.
CRANK ENGINE AND
OBSERVE VOLTAGE
READING. READING SHOULD
BE GREATER THAN .1 VOLT
(100 mV).
ISIT?
REPLACE IGNITION
CONTROL MODULE.
GREATER THAN
12000HMS
CRANKSHAFT
POSITION
SENSOR LEADS
SHORTED
TOGETHER OR
FAULTY 3X
CRANKSHAFT
POSITION
SENSOR.
OPEN
CRANKSHAFT
POSITION
SENSOR CIRCUIT,
FAULTY
CONNECTION OR
FAULTY 3X
CRANKSHAFT
POSITION
SENSOR.
FAULTY CONNECTION
OR
FAULTY 3X CRANKSHAFT
POSITION SENSOR.
11-20-92
NS 15630
BLANK
OTC 51, 85, 87

li1 PROM ERROR
85 PROM ERROR
87 ELECTRICALL V ERASABLE PROGRAMMABLE READ
ONLV MEMORV(EEPROM) ERROR
DTC(s) 51, 85, 87 WILL BE STORED WHEN AN INVALID PROGRAM IS DETECTED BY THE PCM. CHECK THAT ALL CONNECTORS
ARE FULLY INSERTED IN THE SOCKET. IF OK, REPROGRAM THE PCM. REFER TO SECTION "6E3-C1" (PCM AND SENSORS). IF
PCM WILL NOT REPROGRAM, REPLACE PCM.
NOTICE: REPLACEMENT PCM's MUST BE REPROGRAMMED,. IT IS ALSO NECESSARY TO TRANSFER THE ESC
MODULE WHEN REPLACING THE PCM. TO PREVENT POSSIBLE ELECTROSTATIC DISCHARGE DAMAGE TO THE PCM, DO
NOT TOUCH THE COMPONENT LEADS.
3-9-93
NS 15100
SFI-U PCM
A/C REFRIGE RANT
PRESSURES ENSOR
SIGNAL
TO A/C REFRIGERANT
PRESSURE SENSOR
...,._ 380 RED/BLK
HARNESS CONNECTOR "C"
TO FUEL PUMP PRIME

CONNECTOR, FUEL
PUMP RELAY AND INTANK FUEL PUMP - - - 120GRY
FUEL PU MP
FEEDBAC K
SIGNAL
10
;.
11
A/D
MUX
KNOCK
SENSOR
SIGNAL
TO KNOCK
SENSOR - - 496 DK BLU
TO ENGINE COOLANT
TEMPERATURE
SENSOR HARNESS
CONNECTOR "B" - - - - - 410 YEL
ENGINE COOLAN T
TEMPERATURE
SENSOR SIGNAL
15
16
INTERNAL VIEW OF SFI-U PCM
6-15-93
NS 15631
DTC86
A/D ERROR
The ND multiplexer chip is an internal part of the PCM. The above exploded view SFI-U PCM shows sensor
inputs to the ND multiplexer that can affect driveability and diagnostics.
OTC 86 Will Set When: Any of the above circuits is shorted to system voltage for 15 seconds.
OTC 86 Will Clear When: A current DTC 86 will clear when 12 volts is no longer sensed on the above
circuits. A history DTC 86 will clear after 50 consecutive ignition key cycles without a current DTC 86 being
stored.
Diagnostic Aids: If DTC 86 is not present, all
circuits leading to the PCM that are connected to the
ND multiplexer should be checked for an intermittent
short to B + . Move the harnesses of each component
and watch the scan data on the Tech 1. The circuit
that is shorted to B + will show erratic changes in data
on the Tech 1.
DTC86
A/DERROR
FOR OTC 86. CHECK FOR ANY DTCs THAT ARE STORED AND REHR TO THOSE CHARTS. IF NO OTHER DTCs ARE STORED,
CHECK ALL PCM CONNECTORS AND TERMINALS FOR PROPER LOCATION. OTC 86 WILL SET ONLY WHEN THE CIRCUITS
LEADING TO THE A/D MULTIPLEXER, INTERNAL TO THE PCM GETS SHORTED TO B +. IF OTC 86 IS INTERMITTENT, REFER TO
3-9-93
NS 15377
TCC
SOLENOID
TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
PCM
r---.,
TCCCONTROL
.---,-----1-----+-t T - - - - - - - - - - - - - - 422 TAN/BLK

#11 IGNITION
10A
SWITCH
T03-2
CONTROL
SOLENOID
TO 1-2
SHIFT
SOLENOID
T02-3
SHIFT
SOLENOID
6-28-93
PS18515
DTC90
TRANSMISSION TCC SOLENOID CIRCUIT (TCC ERROR)
11
The TCC solenoid is an electrical device used to control fluid acting on the TCC converter clutch valve, which
then controls TCC apply and release. The PCM monitors T.P. voltage, vehicle speed, and other inputs to
determine when to energize the TCC solenoid. Ignition voltage is supplied directly to the TCC solenoid. The
Powertrain Control Module (PCM) controls the solenoid by providing the ground path through CKT 422.
OTC 90 Will Set When: The PCM corpmands the TCC solenoid "ON" and the voltage stays high (B+) for 2
seconds. The PCM commands the TCC solenoid "OFF" and the voltage drops to zero volts for 2 seconds.
Action Taken (PCM will default to): No TCC will occur, and no fourth gear ifin hot mode. DTC 90 will be
stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
"ON."

1. This test checks for a shorted, internal
transmission harness or TCC solenoid ..
2. This test checks power supply to the TCC solenoid.
Diagnostic Aids: Check all connections at the

transmission pass-thru connector.
Some slight TCC slip is normal.
An open in the ignition feed circuit will cause
multiple DTC(s) to set.
DTC90
TRANSMISSION TCC SOLENOID
CIRCUIT (TCC ERROR
3.4L. (VIN S) F" CARLINE (SFI)
11
INSTALL TECH 1.
RECORD THEN CLEAR DTCs.
ENTER MISC TESTS/TRANSMISSION/TCC SOLENOID.
COMMAND TCC SOLENOID "ON"/"OFF" THREE TIMES WHILE LISTENING AT
BOTTOM OF TRANSMISSION PAN (USE STETHESCOPE IF NECESSARY).
DOES SOLENOID "CLICK" WHEN COMMANDED?
IGNITION "OFF."
DISCONNECT TRANSMISSION WIRING CONNECTOR ASM. (ADDITIONAL DTCs WILL SET.)
INSTALLJ 39775 JUMPER HARNESS/PROBE KIT ON THE EXTERNAL WIRING CONNECTOR.
CONNECT TEST LIGHT FROM CAVITY "E" OF J 39775 TO GROUND.
IS TEST LIGHT "ON"?
INSTALL TEST LIGHT FROM CAVITIES "E" TO "T."

(4L60E) OR ''E'' TO "S" (4L80E) OF J 39775.
COMMAND TCC SOLENOID "ON"/"OFF" THREE TIMES.
IS TEST LIGHT "ON" WHEN COMMANDED "ON" AND
"OFF" WHEN COMMANDED "OFF"?
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
REPAIR OPEN OR SHORT TO GROUND IN THE

IGNITION VOLTAGE FEED CIRCUIT TO THE
TRANSMISSION. IF THE FUSE IS OPEN, CHECK
THE TRANSMISSION INTERNAL WIRING HARNESS
OR SOLENOID FOR SHORT TO GROUND.
CHECK CKT 422 {4L60E) OR CKT 1350 (4L80E) FOR

AN OPEN OR SHORT FROM THE CONTROL MODULE
TO THE TRANSMISSION WIRING CONNECTOR.
IF OKAY, REPLACE CONTROL MODULE.
EXTERNAL TRANSMISSION WIRING

CHECKS OKAY. REFER TO "INTERNAL
WIRING HARNESS CHECK" IN
SECTION 7 A 14A (4L60E) OR 7 A 17 A {4L80E).
4-13-93
PS 17530
6E3-A-134 3.4L {L32). {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
PCM
r----~
--~~~~~.....~~I
. . - - - - - - - - - 1 2 2 9 LT BLU/WHT
PRESSURE CONTROL
SOLENOID LOW
- - - - - - - - - - - 1 2 2 8 RED/BLK
PRESSURE CONTROL
SOLENOID HIGH
PRESSURE CONTROL
SOLENOID (PCS)
06-16-93
PS 18518
DTC93
PRESSURE CONTROL SOLENOID (PCS) CIRCUIT
{CURRENT ERROR)
.3.4L (VIN S) ''F" CARLINE (SFI)

The pressure control solenoid is a PCM controlled device used to regulate transmission line pressure. The
PCM compares TP voltage, engine RPM and other inputs to determine the appropriate line pressure for a given
load. The PCM will regulate the pressure by applying a varying amperage to the pressure control solenoid. The
applied amperage can vary from 0.1 to 1.1 amp. The PCM then monitors the amperage at the return line.
OTC 93 Will Set When: The return amperage varies greater than 0.16 amp from the commanded amperage
for at least one second, and no DTC 75 stored.
Action Taken {PCM will default to): Full line pressure will be applied causing harsh shifts. DTC 73 will
be stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
"ON."

1. This test checks the ability of the PCM to
command the pressure control solenoid.
2. This test checks for voltage at PCM.
Diagnostic Aids: Check for poor connections at

PCM and at transmission connector.
DRIVEABILITYAND .EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-135
DTC93
(CURRENT ERROR)
INSTALL TECH 1.
ENGINE OPERATING, TRANSMISSION IN PARK.
ENTER MISC TESTS/TRANSMISSION/PCS CONTROL.
USING TECH 1, APPLY 1.0 AMPS THRU 0.1 AMPS WHILE OBSERVING
DESIRED PCS AND ACTUAL PCS.
IS ACTUAL PCS READING ALWAYS WITHIN 0.16 AMPS OF DESIRED PCS?
IGNITION "OFF."
INSTALLJ 39775 JUMPER HARNESS/PROBE KIT ON THE
TRANSMISSION EXTERNAL WIRING HARNESS CONNECTOR.
JUMPER J 39775 CAVITIES "M" AND "R".
USING J 39200 DVM ON 10 AMP SCALE. CONNECT (IN
SERIES) TO CAVITIES "C" AND "D."
USING TECH 1, APPLY 1.0 AMPS THRU 0.1 AMPS WHILE
OBSERVING DESIRED PCS AND J 39200 DVM READING.
IS DESIRED P,CS ALWAYS WITHIN 0.16 AMPS OF J 39200
DVM READING?
PROBLEM IS INTERMITTENT REFER TO nDIAGNOSTIC AIDS;
IGNITION "OFF." "

CK TRANS WIRING CONNECTOR TERMINAL TENSION ON
THE PCS CIRCUITS. IF OK, REFER TO SECTION 7A14A
(4L60E) OR 7A17A (4L80E)" INTERNAL WIRING HARNESS
CHECK " FOR INTERNAL PCS CIRCUIT DIAGNOSIS.
VERIFY CKTs 1228 AND 1229 ARE NOT OPEN OR

SHORTED. ALSO VERIFY TERMINAL TENSl()N ON THESE
CIRCUITS AT THE PCM CONNECTOR. IF OK, REPLACE PCM.
4-26-93
PS 16751
TO OTHER CIRCUITS
PCM
#1S(U/H)
TO ..., i : f . - - - - - - - " - " - - - - - - - - 5 3 9 PNK--...---539 PNK
IGNITION
10 AMP
539 PNK
PCM IGNITION FEED

PCM IGNITION FEED
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER.

3-26-93
PS17226
DTC96
TRANSMISSION SYSTEM VOLTAGE LOW
CKT 539 is the ignition feed for the PCM.
OTC 96 Will Set When: The ignition is "ON" and PCM terminals "B30" and "03" voltage is less than the
graduated scale of: -40C (-40F) = 7.3 volts, 90C (194F) = 10.3 volts, or 150C (304F) = 11.7 volts, with engine
speed greater than 1000 RPM for 4 seconds.
Action Taken (PCM will default to): During the time the failure is present, the pressure control solenoid is
turned "OFF" (maximum line pressure), there is a soft landing to third gear, and TCC operation is inhibited.
(The setting of additional diagnostic trouble codes may result.) DTC 96 will be stored in the PCM memory but
will not turn "ON" the Malfunction Indicator Lamp (MIL).

1. This test checks for normal battery voltage
between 9-15 volts.
2. This test checks if the low voltage display is due to
the generator, B + voltage supply CKT(s), or PCM.
If the voltage is less than 9 volts, the PCM is OK.
Diagnostic Aids: If diagnostic trouble code sets

when an accessory is operated, check for poor
connections or excessive current draw. Refer to
SECTION 8A of appropriate service manual for circuit
details. Also, check for poor connections at starter
solenoid or fusible link.
DTC96
3.4L (VIN S)
G)
11
F" CARLINE (SFI)
ENGINE OPERATING GREATER THAN 800 RPM.

NOTE BATTERY VOLTAGE ON SCAN TOOL.
IS SYSTEM VOLTAGE LESS THAN 9 VOLTS?
CHECK BATTERY VOLTAGE AT BATTERY.

IS BATTERY VOLTAGE GREATER THAN 9 VOLTS?

"DIAGNOSTIC AIDS."
IGNITION "OFF."
IGNITION "ON."
WITH J 39200, PROBE B + VOLTAGE INPUT TERMINALS.
IS VOLTAGE INPUT LESS THAN 9 VOLTS?
REFER TO SECTION 603 FOR

CHARGING SYSTEM DIAGNOSIS.
FAUL TY CONTROL MODULE CONNECTOR

OR
FAUL TY CONTROL MODULE.
5-7-93
PS 17066
DTCs 98, 99
INVALID PCM PROGRAM
OTC 98 OR 99 Will BE STORED WHEN AN INVALID PROGRAM IS DETECTED BY THE PCM.

REFER TO SECTION 6E3-C1 (PCM AND SENSORS) FOR REPROGRAMMING PROCEDURES. IF OTC 98
OR 99 CONTINUES TO BE DISPLAYED USING A TECH 1, REPLACE PCM.
rn
Important
THE KNOCK SENSOR (KS) MODULE MUST BE TRANSFERRED TO THE REPLACEMENT PCM.
REFER TO SECTION "6E3-C1" FOR COMPONENT REPLACEMENT.
6-17-93
PS 17174
DRIVEABILITYAND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-B-1
SECTION B
SYMPTOMS
\
CONTENTS
Important Preliminary Checks

Before Using This Section
Symptom
Visual/Physical Check
lntermittents (1 of 2)
Hard Start
Surges and/or Chuggles
Lack of Power, Sluggish, or Spongy
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses (1 of 2)
Rough, Unstable, or Incorrect Idle, Stalling (1 of 2)
Poor Fuel Economy
Excessive Exhaust Emissions or Odors
Dieseling, Run-On
Backfire
... .. .
. . .. .
. . . . . ..
. ... .
...... ..
PCM Connector" A" Symptom Chart (1 of 2)

PCM Connector "B" Symptom Chart (1 of 2)
PCM Connector "C" Symptom Chart (1 of 2)
Restricted Exhaust System Check (Chart B-1)
.....
... ....
.. .
. . . .. . . . .
.'.
.....
.... .. . ..
. . .. .
Page 8-2
Page B-2
Page B-2
Page B-2
Page B-3
Page B-5
Page B-6
Page,B-7
Page B-8
Page B-9
Page B-10
Page B-12
Page B-14
Page B-15
Page B-16
Page B-17
Page B-18
Page B-20
Page B-22
Page B-24
6E3-B-2 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
IIMPORTANTPRELIMINARYCHECKS I
BEFORE USING THIS SECTION
Before using this section you should have performed the "On-Board Diagnostic (OBD) System
Check" and determined that:
1. The PCM and MIL (Service Engine Soon) are operating correctly.
2. There are no diagnostic trouble codes stored, or there is a diagnostic trouble code but no MIL
(Service Engine Soon).
SYMPTOM
Verify the customer complaint and locate the correct symptom in the table of contents. Check
the items indicated under that symptom.
VISUAUPHYSICAL CH ECK
Several of the symptom procedures call for a careful visual/physical check. The importance of
this step cannot be stressed too strongly - it can lead to correcting a problem without further checks
and can save valuable time. This check should include:
PCM grounds and sensors for being clean, tight and in their proper location.
Vacuum hoses for splits, kinks, and proper conhections, as shown on "Vehicle Emission
Control Information" label. Check thoroughly for any type ofleak or restriction.
Air leaks at throttle body mounting area and intake manifold sealing surfaces.
Ignition wires for cracking, hardness, proper routing and carbon tracking.
Wiring for proper connections, pinches and cuts.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6~3-8-3
INTERMITTENTS
-
..
..
..,."-'lllll1,1v11.
(Page 1 of 2)
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J..l.1.0.:J
VJ.
----.,
,..,,._,...,
"""'&
ttr\1\.Tn
.a..1.
..,
..
_l_
1\KTT
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-,-.,..-
(Service Engine Soon) or store a DTC.
DO NOT use the diagnostic trouble code charts in "Engine Components/Wiring

Diagrams/Diagnostic Charts," Section ''6E3-A" for intermittent problems. The fault must be present
to locate the problem. If a fault is intermittent, use of diagnostic trouble code charts may result in
Most intermittent problems are caused by faulty electrical connections or wiring. Perform
careful visual/physical check as described at start of"Symptoms," Section "6E3-B". Check for:
Poor mating of the connector halves or terminal not fully seated in the connector body
(backed out).
- Improperly formed or damaged terminal. All connector terminals in the problem circuit
should be carefully reformed or replaced to ensure proper contact tension.
Poor terminal to wire connection. This requires removing the terminal from the connector
body to check. Refer to "Introduction" in SECTION 6E, "Wiring Harness Service."
If a visual/physical check does not find the cause of the problem, the vehicle can be driven with a
voltmeter connected to a suspected circuit. A Tech 1 scan tool can also be used to help detect
intermittent conditions. An abnormal voltage or Tech 1 scan tool reading, when the problem
occurs, indicates the problem may be in that circuit.
Loss of diagnostic trouble code memory . To check, disconnect .TP sensor and idle engine until
MIL (Service Engine Soon) comes "ON." DTC 22 should be stored and kept in memory when
ignition is turned "OFF." Ifnot, the PCM connections or the PCM is faulty.
An intermittent MIL (Service Engine Soon) with no stored diagnostic trouble code may be caused
by:
Ignition coil shorted to ground and arcing at spark plug wires or plugs.
MIL (Service Engine Soon) wire to PCM shorted to ground (CKT 419).
Diagnostic enable terminal wire to PCM shorted to ground (CKT 448).
PCM grounds, refer to PCM wiring diagrams.
Excessive current draw from faulty systems such as damaged cooling fan motor, etc.
.,
"
6E3-B-4 3.4L (l32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
INTERMITTNTS
(Page 2of 2)
Definition:
Problem may or may not turn "ON" the MIL

(Service Engine Soon) or store a DTC.
Check for an electrical system interference caused by a defective relay, PCM driven solenoid, or
switch. They can cause a sharp electrical surge. Normally, the problem will occur when the
faulty component is operated.
Check for improper installation of electrical options such as lights, 2-way radios, etc.
Ignition control wires should be routed away from spark plug wires, Ignition Cont.rol (IC) system
wires, Ignition Control (IC) system assembly and generator. Wires from PCM to Ignition
Control (IC) system should have a good connection.
Check for open diode across NC compressor clutch, and for other open diodes (refer to wiring
diagrams).
If problem has not been found, refer to "PCM Connector Symptom" charts at the end of
Check for improperly formed or damaged terminal on CKT 423. Refer to "DTC 41", Section
"6E3-A".
DRIVEABlllTY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-B-5
HARD START
Definition:
'
Engine cranks OK, but does not start for a

long time. Does eventually run, or may start
but immediately dies.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms," Section "6E3-B".
Make sure the driver is using the correct starting procedure .
. ADDITIONAL CHECKS
CHECK:
CHEC.K:
IAC operation - use CHART C-2B.

Basic engine problem. Refer to SECTION 6A.
CHECK: Service bulletins for updates.
SE.NSORS
1 scan tool, compare engine

coolant temperature with ambient temperature on cold engine.
If engine coolant temperature readings ar~ 5 degrees greater than or less than
ambient air temperature. on a cold engine, check resistance in engine coolant
temperature sensor circuit or sensor itself. Compare ECT sensor resistance value to
the "Diagnostic Aid" chart ori DTC 15 chart.
CHECK: MAP sensor. Check for flooding.
CHECK: TP sensor for binding or a high TP sensor voltage with the throttle closed (should read
between .29 volt and .98 volt.)
CHECK: Engine Coolfl,nt Tewpe.ratur.e ,(ECT) sensor using a Tech
IGNITION SYSTEM
CHECK: For proper ignition voltage output with spark tester J 26792 (ST 125).
CHECK: Spark plugs. Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
burned electrodes, or heavy deposits. Repair or replace as necessary.

CHECK: Bare or shorted wires.
CHECK: Crankshaft position sensor, resistance and connect.ons.
FUEL SYSTEM
CHECK: Fuel pump relay operation - pump should turn ''ON" for 2 seconds when ignition is
turned "ON." Use OTC 54.

CHECK: Fuel pressure, use CHART A-7.
CHECK: Contaminated fuel.
CHECK: Both injector fuses (visual inspect).
NOTICE: A faulty in-tank fuel pump check valve will allow the fuel in the lines to drain back to
the tank after engine is stopped. To check for this condition, perform fuel system diagnosis
CHART A-7.
SURGES AND/OR CHUGGLES

Definition:
Engine power variation under steady

throttle or cruise feels like the vehicle
speeds up and slows down with no change in
the accelerator pedal.
PRELIMINARY CHECKS
Perform the careful visual checks as described at start of"Symptoms," Section "6E3-B".
Be sure driver understands transmission torque converter clutch and A/C compressor operation
as explained in the owner's manual.
ADDITIONAL CHECKS
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
PCM grounds for being clean, tight and in their proper location.
Vacuum lines for kinks or leaks.
Generator output voltage. Repair.ifless than 9 volts or more than 16 volts.
Speedometer reading with the speed on a Tech 1 scan tool are equal.
Service bulletins for updates.
SENSORS
CHECK: Oxygen Sensor(s) 028. The Oxygen Sensor(s) 028 should respond quickly to different
throttle position. If they do not, check the Oxygen Sensor(s) 028 for silicon or other
contaminations from fuel or improper use of RTV sealant. The sensor(s) may have a
white, powdery coating and result in a high but false signal voltage (rich exhaust
indication). The PCM will then reduce the amount of fuel delivered to the engine,
causing a severe driveability problem. Also, watch for green (glycol) contamination or
cracking.
IGNITION SYSTEM
CHECK: For proper ignition voltage output using spark tester J 26792 (ST 125) or equivalent.
burned electrodes, or heavy deposits. Repair or replace as necessary. Also, check spark
plug wires.
FUEL SYSTEM
NOTICE: To determine if the condition is caused by a rich or lean system, the vehicle should be
driven at the speed of the complaint. Monitoring long term and short term fuel trim will help
identify a problem.
Lean - Long term fuel trim above 150. Refer to "Diagnostic Aids" on facing page of DTC 44/64.
Rich - Long term fuel trim below 110. Refer to "Diagnostic Aids" on facing page of DTC 45/65.
CHECK: Fuel pressure while condition exists. Use CHART A-7.
CHECK: In-line fuel filter. Replace if dirty or plugged.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-B-7

'
LACK OF POWER, SLUGGISH OR SPONGY

Definition:
Engine delivers less than expected power.

Little or no increase in speed when accelerator
pedal is pushed down part way.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms," Section "6E3-B" .
Compare customer's vehicle to similar unit. Make sure the customer has an actual problem .
Remove air filter and check for dirt, or other contamination. Replace as necessary .
ADDITIONAL CHECKS
CHECK: PCM grounds for being clean, tight and in their proper locations. Refer to PCM wiring
diagrams.
CHECK: EGR operation for being open or partly open all the time. Refer to CHART C-7.
CHECK: Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
CHECK: Exhaust system for possible restriction.
Inspect exhaust system for damaged or collapsed pipes.

Inspect muffler for heat distress or possible internal failure.
CHECK: Torque Converter Clutch (TCC) for proper operation. Refer to SECTION 7 A.
-
ENGINE MECHANICAL
CHECK: Engine valve timing and compression.
CHECK: Engine for correct or worn camshaft. Refer to SECTION 6A.
IGNITION SYSTEM
CHECK: Knock Sensor (KS) system for excessive spark retard activity. Refer to CHART C-5. Use
Tech 1 scan tool.

CHECK: Secondary voltage using a shop oscilloscope or a spark tester J 26792 (ST 125).
FUEL SYSTEM
CHECK: Restricted fuel filter.
DETONATION/SPARK KNOCK
Definition:
A mild to severe ping, usually worse under

acceleration. The engine makes sharp metallic
knocks that change with throttle opening.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of "Symptoms," Section "6E3-B".
Park/Neutral Position (PNP) switch. Be sure Tech 1 scan indicates drive with gear selector in
drive or overdrive. Use CHART C-lA.
NOTICE: If Tech 1 scan tool readings are normal (refer to facing page of "On-Board Diagnostic
System Check") and there are no engine mechanical faults, fill fuel tank with a premium
gasoline that has a minimum octane reading of92 and revaluate vehicle performance.
CH ECK: EGR system for not opening. Use CHART C-7.
CHECK: TCC operation, TCC applying too soon. Use CHART C-8.
ADDITIONAL CHECKS
IGNITION SYSTEM
CHECK: Spark plugs for proper heat range. Refer to "Owner's Manual," check should read "OB".
CHECK: Knock Sensor (KS) system for no retard, use CHART C-5.
ENGINE MECHANICAL
CHECK: For excessive oil in the combustion chamber.
Valve oil seals for leaking.

CHECK: Combustion chambers for excessive carbon buildup.
Remove carbon with top engine

cleaner and follow instructions on can.
CHECK: Combustion chamber pressure by performing a compression test. Refer to SECTION 6A.
CHECK: For incorrect basic engine parts such as cam, heads, pistons, etc.
COOLING SYSTEM
Check for obvious overheating problems:

- Low engine coolant.
- Loose water pump belt.
- Restricted air flow to radiator, or restricted water flow through radiator.
- Inoperative electric cooling fan circuit, use CHART C-12.
- Correct coolant solution should be a 50/50 mix of GM #1052753 anti-freeze coolant (or
equivalent) and water.
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify problem.
Lean - Long term fuel trim above 150. Refer to "Diagnostic Aids" on facing page of DTC 44/64.
Rich - Long term fuel trim below llO. Refer to "Diagnostic Aids" on facing page of DTC 45/65.
HESITATION, SAG, STUMBLE

Definition:
Momentary lack of response as the accelerator is

pushed down. Can occur at all vehicle speeds.
Usually most severe when first trying to make the
vehicle move, as from a stop sign. May cause
engine to stall if severe enough.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms," Section "6E3-B" .
SENSORS
t
CHECK: TP sensor - Check TP sensor for binding or sticking. Voltage should increase at a steady
CHECK: MAP sensor- use CHART C-lD.
rate as throttle is moved toward Wide Open Throttle (WOT).
IGNITION SYSTEM
CHECK:
CHECK:
Spark plugs for being fouled or for faulty spark plug wire routing.
Ignition Control (IC) system ground, CKT 450.
FUEL SYSTEM
t
t
t
t
CHECK:
CHECK:
CHECK:
CHECK:
Fuel pressure, use CHART A-7.

Contaminated fuel.
EV AP canister purge system for proper operation. Use CHART C-3.
Fuel injectors. Perform injector/coil balance test, use CHART C-2A.
ADDITIONAL CHECKS
t
t
CHECK:
CHECK:
CHECK:
CHECK:

EGR operation, use CHART C-7.
Engine thermostat functioning correctly and proper heat range.
Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
"
CUTS OUT, MISSES

(Page 1 of 2)
Definition:
Steady pulsation or jerking that follows engine

speed, usually more pronounced as engine load
increases, not normally felt above 1500 RPM or 48
km/h (30 mph). The exhaust has a steady spitting
sound at idle or low speed.
PRELIMINARY CHECKS
ADDITIONAL CHECKS
CHECK: For Electromagnetic Interference (EMI). A mistake can be caused by Electromagnetic
Interference (EMI) on the 3X reference low circuit. EMI can usually be detected by
monitoring engine RPM with a Tech 1 scan tool. A sudden increase in RPM with little
change in actual engine RPM change indicates EMI is present. If the problem exists,
check routing of spark plug wires and ignition control ground circuit.
CHECK: Intake and exhaust manifold passage for casting flash.
IGNITION SYSTEM
Check for cylinder miss:

1. Start engine allowing engine to stabilize then disconnect IAC motor. Remove one spark plug
wire at a time using insulated pliers.
CAUTION: Do Not perform this test for more than 2 minutes, as this test may
cause damage to the catalytic converter.
If there is an RPM drop on all cylinders (equal to within 50 RPM), go to "Rough, Unstable, or
Incorrect Idle, Stalling" symptom. Reconnect IAC valve.
3. If there is no RPM drop on one or more cylinders or excessive variation in RPM drop, check
for spark on the suspected cylinder(s) using a shop oscilloscope or with J 26792 (ST 125)
spark tester or equivalent. If no spark, refer to SECTION 60 for intermittent operation or
miss. If there is a spark, remove spark plug(s) in these cylinders and check for:
Insulator cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
CHECK: Spark plug wires by connecting ohmmeter to ends of each wire in question. If meter
reads over 30,000 ohms, replace wire(s).
2.
CUTS OUT, MISSES

(Page 2 of 2)
Definition:

ENGINE MECHANICAL
CHECK: Compression. Perform compression check on questionable cylinder(s) found above. If
compression is low, repair as necessary. Refer to SECTION 6A.

CHECK: Base engine. Remove rocker covers. Check for bent pushrods, worn rocker arms, broken
valve springs, worn camshaft lobes and valve timing. Repair as necessary. Refer to
SECTION6A.
FUEL SYSTEM
CHECK: Fuelsystem-Pluggedfuelfilter,lowpressure. UseCHARTA-7.
CHECK: Injector drivers. Disconnect all injector harness connectors. Connect J 34730-2C injector
test light between the harness terminal of each injector connector and note light while
cranking. If tester light fails to blink at any connector, it is a faulty injector drive circuit
harness, connector or terminal.
CHECK: Perform the injector/coil balance test. Refer to CHART C-2A.
ROUGH, UNSTABLE, OR INCORRECT IDLE,

STALLING
(Page 1 of 2)
Definition:
Engine runs unevenly at idle. If severe, the engine or

vehicle may shake. Engine idle speed may vary in RPM.
- Either condition may be severe enough to stall engine.
PRELIMINARY CHECKS
CHECK: For vacuum leaks.

CHECK: PCM grounds for being clean, tight and proper routing. Refer to PCM wiring diagrams.
ADDITIONAL CHECKS
CHECK: MAP sensor. Refer to CHART C-10.
CHECK: Throttle linkage for sticking or binding.
CHECK: PNP switch circuit. Refer. to CHART C-lA, or use Tech 1 scan tool and be sure tool
indicates vehicle is in drive with gear selector in drive or overdrive.

CHECK: IAC operation, use CHART C-2C.
CHECK: EGR valve. There should be no EGR at idle. Refer to CHART C-7.
CHECK: NC signal to PCM, Tech 1 scan tool should indicate NC is being requested whenever
CHECK:
CHECK:
CHECK:
CHECK:
NC is selected. If problem exists with NC "ON," check NC system operation, CHART

C-10 or applicable OTC.
Crankcase ventilation valve for proper operation by placing finger over inlet hole in
valve end several times. Valve should snap back. If not, replace valve. Refer to
"Crankcase Ventilation," Section "6E3-Cl3".
For broken motor mounts.
Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
IGNITION SYSTEM
CHECK: Ignition system; wires, plugs, etc.
CHECK: For open ignition control CKT 423. Refer to "OTC 41", Section "6E3-A".
ENGINE MECHANICAL
CHECK: Perform a cylinder compression check. Refer to SECTION 6.
CHECK: For correct camshaft or weak valve springs.
DRIVEABIUTYAND EMISSIONS 3.4L (L32)(VIN S) (Sfl) 6E3-B-13

STALLING
(Page 2 of 2)
Definition: Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engirie idle speed may vary in RPM.
Eithe.r condition may be severe enough to stall engine.
FUEL S.YSTEM
NOTICE: Moriitoring long term fuel trim will help identify the cause of the problem. ff the
system is running lean (long term fuel trim greater than 150); refer to 1'Diagnostic Aids'' on facing
page of OTC 44/64. If the system is running rich (long term fuel trim less than 110), refer to
"Diagnostic Aids" on facing page of OTC 45/65.
CHECK:
CHECK:
CHECK:
CHECK:
'
Injector/coil balance. Refer to CHART C~2A.

For fuel in pressure regulator hose. If fuel is present, replace regulator assembly.
Evaporative Emission (EVAP) Control System, use CHART C-3.
The Oxygen Sensor(s) (02S) should respond quickly to different throttle positions. If they
do not, check the Oxygen Sensor(s)(02S) for silicon contamination from fuel or improper
use of RTV sealant. The sensor wm have a white~ powdery coating and will result in a.
high but false signal voltage (rich, exhaust'indication). The PCM will then reduce the
l:lr~o4-nt of fuel delivered to the engine, causing a severe. driveability problem.
c
,,
'
'
'
.'
'
6E3-B-14 3.4L (L32) (VIN. S) (SFI) ORIVEABIUTYAND EMISSIONS
, POOR FUEL ECONOMY

Definition:
Fuel economy, as measured by an actual road

test, is noticeably lower.-than expected. Also,
economy is noticeably lower than it was on
this vehicle.at one time, as previously .shown
by a,n actqal road test.
PRELIMINARY CHECKS
Perform the careful visual checks as described at start of "Symptoms," Section "6E3-B".
Visually (physically) check: Vacuum hoses for .splits, kinks, and proper ~onnections as shown on
"Vehicle Emission Control Information" label.
Check owner's driving habits.
Is NC "ON" full time (defroster mode "ON"}?
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acce.leration too much, too often?
Check air cleaner filter for dirty or.being plugged.
Fuel leaks..
ADDITIONAL CHECKS
CHECK: TCC operation. 'use CHART C-8. A Tech 1.scan tool should indicate an RPM drop, when
the TCC is commanded "ON."

CHECK: For exhaust system restriction.
CHECK: For proper calibration of speedometer.
CHECK: Air intake system and crankcase for air leaks.
IGNITION SYSTEM
CHECK: Spark plugs.
Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
CHECK: For open ignition control CKT 423. Refer to "OTC 41," Section "6E3-A".
COOLING SYSTEM
CHECK: Engine coolant level.
CHECK: Engine thermostat for faulty part (always open) or for wrong heat range.
SECTION 68.
ENGINE MECHANICAL
CHECK: Compression. Refer to SECTION 6A.
Refer to
DRIVEABILITY AND:EMISSIONS 3.4L. (l32) cv,N S) (SFI) 6E3".'Bi-15
EXCESSIVE EXHAUST EMISSIONS OR ODORS

Definition:
,l)
Vehicle fails an enii <::<::ion tP.st VPhirlP h~<::

excessive "rotten egg" smell. Excessive odors do
not.necessarily indicate excessive emissions.
PRELIMINARY CHECKS
Perform "On-Board Diagnostic (OBD) System Check."
NOTICE: If emission test shows excessive CO and HC check items which cause vehicle to run
RICH (long term fuel trim less than 110), refer to "Diagnostic Aids" on facing page of OTC 45/65.
NOTICE:. If emission test shows excessive NOx, check items which cause vehicle to run lean or
too hot such as inoperative cooling fan, or.inoperative EGR valve.
.... "
ADDITIONAL CHECKS

CHECK: EGR valve for; not opening. Use CHART C-7.
CHECK: For lead contamirtation for catalytic converter (look for the removal of fuel filler neck''
restrictor).
CHECK: Carbon buildup. Remove carbon with top engine cleaner. Follow instructions on can.
CHECK: Crankcase ventilation valve for being plugged or stuck or fuel in the crankcase.
IGNITION SYSTEM
t
CHECK: Spark plugs, plug wires, and ignition components. Refer to SECTION 60.
COOLING SYSTEM
NOTICE: If the Tech 1 scan tool indicates a very high engine coolant temperature and the
system is running lean:
CHECK: Engine thermostat for faulty part (always open) or for wrong heat range. Refer to
SECTION 68.
CHECK: Cooling fan operation, use CHART C-12.
FUEL SYSTEM
NOTICE: If the system is running RICH (long term fuel trim near 110), refer to "Diagnostic
Aids" on facing page of OTC 45/65.
If the system is running LEAN (long term fuel trim near 150) refer to "Diagnostic Aids" on
facing page of DTC 44/64.
CHECK:For properly installed fuel cap .

CHECl<:Fuel pressure. Use CHART A-7 .
CHECK: Injector/coil balance test. Use CHART C-2A .
CHECK: Evaporative emission canister for fuel loading . Use CHART C-3.
)'
61:3~8-16 3~4l (L32) (VIN S) (SFI) DRIVEABILITY:AtJD EMl~SiC>NS
DIE'SELING, RUN-ON
Definition: Engine continues to run after key is turned
"OFF," but runs very roughly. If engine runs
smoothly, check ignition switch and
adjustment.
PRELIMINARY CHECKS
Perform tlie careful visual/physical checks as described at start of"Symptoms,"Se<!yon "6E3-B".
FUEL SYSTEM
CHECK: Injectors for leaking. Refer to "Fuel System Diagnosis," CHART
,,,
"
'
,',
.,
A- 7.
j
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-B-17
BACKFIRE
uermmon:
r ue1 1gnnes ms1ae mtake manifold or in

exhaust system, making loud popping
noise.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of "Symptoms," Section "6E3-B" .
ADDITIONAL CHECKS
CHECK: EGR gasket for faulty or loose fit.
CHECK: EGR operation for being op~n.all the time. Refer to "Exhaust Gas Recirculation (EGR),"
CHARTC-7.
CHECK: Intake and exhaust manifold for casting flash.
IGNITION SYSTEM
CHECK: Proper ignition coil output voltage with spark tester J 26792 (ST 125) or equivalent.

CHECK: Spark plug wires for crossfire, also inspect Electronic Ignition (EI) system assembly,
spark plug wires, and proper routing of plug wires.
NOTICE: If an intermittent condition exists in the ignition system, refer to "Ignition Control
.
(IC) System," Section "6E3-C4" or SECTION 6D.
'
ENGINE MECHANICAL
CHECK: Compression - Look for sticking or leaking valves.
CHECK: Valve timing, refer to SECTION 6A.
CHECK: Intake and exhaust manifold passages for casting flash.
FUEL SYSTEM
CHECK: Perform fuel system diagnosis check, see CHART A-7.
CHECK: Fuel injectors. Perform injector/coil balance test, refer to CHART C-2A.
6E3-B-18 3.4L (L32) (VIN S) (SFI) DRIVEABIUTY AND EMISSIONS
PCM CONNECTOR .. A .. SYMPTOMS CHART

CLEAR 32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED
POSSIBLE SYMPTOMS FROM

FAULTY CIRCUIT
A1
SENSOR GROUND FOR IAT, MAP,

A/CREFRIGERANT PRESSURE
AND A/C EVAPORATOR
TEMPERATURE SENSORS
452
BLK
IAT,MAP,A/CREF.
PRESS SENSORS
HARN CONN "A"
ANDA/C
EVAPORATOR
TEMP. SENSOR "C"
23 (1)
33 (1)
71 (1)
22 (1)
ENGINE STARTS AND STALLS NO POWER,

ENGINE WILL NOT RUN.
A2
A/CREQUEST
762
DKGRN/WHT
HEATER AND A/C

CONTROL
ASSEMBLY
NONE
A/C INOPERATIVE. REFER TO SECTION C10.
A3
A/C EVAPORATOR
TEMPERATURE SENSOR SIGNAL
732
DKBLU
A/C EVAPORATOR
TEMP. SENSOR "B"
73 (3)
71 (4)
A/C INOPERATIVE REFER TO TO SECTION

C10.
AS
A/C REFRIGERANT PRESSURE

SENSOR SIGNAL
380
RED/BLK
A/C REF. PRESS

SENSOR HARN
CONN "C"
66 (2)
70(4)
NO A/C, REFER TO SECTION C10.

A/CCLUTCH TOGGLES "OFF"/"ON,"
HIGH AND UNSTABLE IDLE.
A6
FUEL PUMP SIGNAL
120
GRY
FUEL PUMP RELAY

"A2 AND FUEL
PUMP PRIME
CONNECTOR
54 (2)
HARD TO START, LONG CRANK TIME.

REFER TO CHART A7.
FUEL PUMP ENABLE
465
DKGRN/WHT FUEL PUMP RELAY

"C2"
54(2)
A4
A7
AS
HARD TO START, LONG CRANK TIME.

REFER TO CHART A7.
A9
A10
A 11 1-2 SHIFT SOLENOID
1222
LTGRN
TRANSMISSION
CONNECTOR "A"
NONE
2nd AND 3rd GEAR ONLY - OR - 1st AND 4th

GEAR ONLY. REFER TO SECTION CS.
A 12 2-3 SHIFT SOLENOID
1223
YEL/BLK
TRANSMISSION
CONNECTOR "B"
NONE
3rd AND 4th GEAR ONLY - OR-1t AND 2nd

GEAR ONLY. REFER TO SECTION CS.
A 15 TCC CONTROL CIRCUIT
422
TAN/BLK
TRANSMISSION
CONNECTOR "T"
90
NO TCC, POOR FUEL ECONOMY, CHUGGLE

OR TRANS BUMP. REFER TO SECTION CS.
A 16 3-2 CONTROL SOLENOID
687
WHT
TRANSMISSION
CONNECTOR "S"
NONE
HARSH 3-2 SHIFT - OR - 3-2 SHIFT FLARE.

REFER TO SECTION CS.
A 17 SENSOR GROUND FOR TP AND
470
BLK
ECTSENSOR "A"
TP SENSOR "B"
15 (1)
21 (1)
22m
ENGINE STARTS AND STALLS, NO POWER,

583
LT BLU/BLK
TCCBRAKE
SWITCH "B"
37
NO TCC, POOR FUEL ECONOMY. REFER TO

SECTION CS.
A13
A14
ECTSENSORS
A 18 TCC BRAKE SWITCH SIGNAL
REFER TO ELECTRICAL DIAGNOSIS (SECTION SA).

OPEN CIRCUIT.
GROUNDED CIRCUIT.
OPEN OR GROUNDED CIRCUIT.
(4) SHORTED TO VOLTAGE.
(1)
(2)
(3)
6-21-93
NS 15632
PCM Connector "A" Symptom Chart (1 of 2)
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-8-19

1
ECM CONNECTOR A' SYMPTOMS CHART

CLEAR 32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAUL TY CIRCUIT
LTBLU
TCC SOLENOID-"B"
NONE
NO 4TH GEAR. POOR FUEL ECONOMY,

CHUGGLE OR SHUTTER CONDITION. REFER
TO SECTION CS
A20
A21
A22 4th GEAR SWITCH-(AtT)
446
----------------------- ---
A22 CLUTCH ANTICIPATE SWITCH(MIT)
48
-------GRY
------- --------------------------------------CLUTCH
NONE
IDLE FLARE WITH CLUTCH PEDAL
ANTICIPATE
CRUISE RELEASE
SWITCH-"B"
DEPRESSED
A23
A24
A25
A26
A27
A28
A29 MAP SENSOR SIGNAL
432
LTGRN
MAP SENSOR
HARN CONN "B"
33 (4)
34(3)
44(2)
UNSTABLE IDLE, ROUGH, HESITATION,

HIGH IDLE, HUNTING IDLE, LEAN EXHAUST,
POOR PERFORMANCE, STALLS, MISS,
SURGE.
A30 TP SENSOR SIGNAL
417
DKBLU
TP SENSOR HARN
CONN "C"
21 (4)
22 (3)
HIGH IDLE, SURGE, LACK OF

PERFORMANCE
A31 ENGINE COOLANT TEMP.

SENSOR SIGNAL
410
YEL
ECT SENSOR HARN

CONN "B"
14(2)
15 (1 4)
HARP TO START, LACK OF PERFORMANCE,

POOR FUEL ECONOMY.
A32
*
(1)
(2)
(3)
(4)
REFER TO ELECTRICAL DIAGNOSIS (SECTION BA)

OPEN CIRCUIT
GROUNDED CIRCUIT
OPEN/GROUNDED CIRCUIT
SHORTED TO VOLTAGE
11-12-92
NS 15633
6E3-B-20 3.4L (L32) (VIN S) ,(SFI) DRIVEABILITY AND EMISSIONS
PCM CONNECTOR ''B" SYMPTOMS CHART

BLACK 32 PIN CONNECTOR
PIN FUNCTION
CKT
#
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAUL TY CIRCUIT
81
82
COOLING FAN RELAY CONTROL
335
DKGRN
ENGINE COOLING
FAN CONTROL
RElAY-"D2"
NONE
INOPERATIVE FAN. FAN RUNS All THE

TIME. REFER TO SECTION C12 .
83

PUMP RELAY CONTROL
436
BRN
SECONDARY AIR
INJECTION PUMP
RELAY CONN "E2"
NONE
INOPERATIVE AIR BYPASS SOLENOID. HC

AND CO EMISSION LEVELS Will BE TOO
HIGH. REFER TO SECTION C6.
84
EVAP CANISTER PURGE
428
DKGRN/WHT
EVAPCANISTER
PURGE SOLENOID
CONN A"
NONE
FUEL LOSS OR FUEL VAPOR ODOR. POOR

IDLE, STALLING, POOR DRIVEABILITY.
A/C COMPRESSOR CLUTCH
459
DKGRN/WHT
A/C RELAY HARN

CONN 85"
68 (2)
NO A/C CLUTCH ENGAGEMENT (1) AIC ON

All THE TIME (2). REFER TO SECTION C10.
419
BRN/WHT
10-WAY IN-LINE
1/PCONN. "8"
NONE
NO Mil (1) Mil ON All THE TIME (2).

REFER TO "ON-BOARD DIAGNOSTIC
SYSTEM CHECK."*
811 EGR #1 CONTROL
697
LTBLU
DIGITAL EGR HARN

CONN "A"
75(3)
ROUGH IDLE, SPARK KNOCK, STALLS

AFTER COLD START, SURGE DURING
CRUISE. REFER TO SECTION C6.
812 EGR #2 CONTROL
698
BRN
DIGITAL EGR HARN

CONN "B"
76(3)
813 EGR #3 CONTROL
699
RED
DIGITAL EGR HARN

CONN "C"
77 (3)

814 BATTERY+ (KEEP ALIVE
340
ORN
1/PFUSE #4
NONE
340
ORN
1/PFUSE #4
NONE
451
BLK/WHT
ENGINE GROUND
LOCATED AT LFT
FRT OF ENGINE
NONE
NO SYMPTOMS, IF BOTH POWER

GROUNDS ARE OPEN, ON START. REFER
TO "ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
818 2NDGEARSTARTINDICATOR
LAMP OUTPUT
1443
DKBLU
NONE
NO SECOND GEAR INDICATOR LAMP
819 SERIALDATA
800
TAN
SECOND GEAR
START SWITCH
CONNECTOR "A"
DATA LINK
CONNECTOR "M"
NONE
NO DLC DATA. REFER TO "ON-BOARD

DIAGNOSTIC SYSTEM CHECK." *
..
BS
86
RELAY CONTROL
MALFUNCTION INDICATOR
87
LAMP (Mil) "SERVICE ENGINE

SOON"
88
89
810
MEMORY)
815 BATTERY+ (KEEP ALIVE

MEMORY)
816 PCM GROUND
CRANKS BUT Will NOT START IF BOTH

BATTERY FEEDS ARE OPEN. REFER TO
"ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
CRANKS BUT Will NOT START IF BOTH
BATTERY FEEDS ARE OPEN. REFER TO
"ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
817
(1)
(2)
(3)
*
OPEN CIRCUIT
GROUNDED CIRCUIT
OPEN OR GROUNDED CIRCUIT
REFER TO SECTION SA
619-93
NS 15634
PCM CONNECTOR "B" SYMPTOMS CHART

RI ACK 22 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAUL TY CIRCUIT
820 LEFT (BANK 2) 025 GROUND
351
BLK/WHT
LEFT02S
13,44,45
ROUGH OR INCORRECT IDLE, LEAN

EXHAUST. POOR PERFORMANCE.
821 LEFT (BANK 2) 025 SIGNAL
1665
PPlJWHT
LEFT02S
13,44,45
ROUGH OR INCORRECT IDLE, LEAN

EXHAUST POOR PERFORMANCE.
822 RIGHT (BANK 1 )025 SIGNAL
1666
PPL
RIGHT02S
63 (1)
64(3)
65(4)
ROUGH OR INCORRECT IDLE, LEAN OR

RICH EXHAUST, HESITATION, SURGE,
POOR PERFORMANCE, POOR FUEL
ECONOMY.
823 RIGHT (BANK 1) 025 GROUND
351
BLK/WHT
RIGHT02S
63 (1)
64(3)
65(4)
ROUGH OR INCORRECT IDLE, LEAN OR

RICH EXHAUST, HESITATION, SURGE,
POOR PERFORMANCE, POOR FUEL
ECONOMY.
824 IAC COIL "B" HIGH
1749
LTGRN/WHT
IAC HARN CONN
35(3)
HIGH OR LOW IDLE, STALLS. REFER TO

CHARTC-28.
"a~
825 IAC COIL "B" LOW
444
LTGRN/BLK
IAC HARN CONN

"A"
35 (3)

CHART C-28.
826 IAC COIL "A" LOW
1748
LT BLU/BLK
IAC HARN CONN
35 (3)
HIGH OR lOW IDLE, STALLS. REFER TO

CHARTC-28.
"("
827 IACCOIL "A" HIGH
1747
LTBLU/WHT
IAC HARN CONN

"D"
35 (3)

CHARTC-28.
828 BUFFERED SPEED OUTPUT

(4000 PULSES/MILE)
817
DKGRN/WHT
INST. Cl.LISTER
NONE
829 VSS INPUT LOW
401
PPL
VSS HARN CONN

"A''
24, 72
INOPERATIVE SPEEDOMETER,
INOPERATIVE CRUISE CONTROL *
INOPERATIVE CRUISE CONTROL, TRANS
SHIFT FROM DRIVE TO NEUTRAL.*
830 VSSINPUT HIGH
400
YEL
VSS HARN CONN

"B ..
24,72
INOPERATIVE CRUISE CONTROL, TRANS
SHIFT FROM DRIVE TO NEUTRAL. *
831 5 VOLT REF MAP, TP, A/C

REFRIGERANT PRESSURE AND
EVAPORATOR TEMPERATURE
SENSORS
416
GRY
TP SENSOR HARN
CONN "A",MAP
HARN CONN "C"
A/C PRESS SENSOR
HARN CONN "B"
Alt EVAPORATOR
TEMPERATURE
SENSOR CONN "A"
22 (3)
34(3)
66
67
70
71
73
ENGINE STARTS AND STALLS, NO POWER,

A/CINOP.
832 PCM GROUND
451
BLK/WHT
ENGINE GROUND
LOCATED AT LEFT
FRONT OF ENGINE
NONE
CRANKS BUT WILL NOT START IF BOTH

POWER GROUNDS ARE OPEN. CHECK
GROUNDS AT ENGINE BLOCK, IGNITION
CONTROL SYSTEM, PARK/NEUTRAL
POSITION SWITCH. REFER TO "ON-BOARD
DIAGNOSTIC SYSTEM CHECK." *
<
(1)
(2)
(3)
*
OPEN CIRCUIT.
GROUNDED CIRCUIT.
OPEN/GROUNDED CIRCUIT.
REFER TO SECTION SA.
6-17-93
NS 15635
PCM CONNECTOR "C" SYMPTOMS CHART

BLUE 32 PIN CONNECTOR
PIN FUNCTION
COMPONENT
CONNECTOR
CAVITY
CKT
#
WIRE COLOR
551
TAN/WHT
ENGINE GROUND
LOCATED AT
FRONT OF ENGINE
NONE
59
DKGRN
A/C CLUTCH RELAY

"84"
68(4)
FUEL PUMP RELAY

"C1"
87 (1)
C1
PCM GROUND
C2
A/CSTATUS
C3
IGNITION FEED
439
PNK
PRESSURE CONTROL SOLENOID
1228
RED/BLK
DTC(s)
AFFECTED

FAULTY CIRCUIT
CRANKS BUT WILL NOT START IF BOTH
PCM GROUNDS OPEN, CHECK GROUNDS
AI ENGINE BLOCK, IGNITION CONTROL
. SYSTEM, PARK/NEUTRAL POSITION
SWITCH. REFER TO "ON-BOARD
DIAGNOSTIC SYSTEM CHECK."
POOR A/C PERFORMANCE
69 (1)
NO START. REFER TO "OBD SYSTEM
CHECK."
C4
cs
TRANSMISSION
CONNECTOR ''C"
93
'HARSH SHIFTS
1229 LTBLUE/WHT TRANSMISSION

CONNECTOR "D"
93
HARSH SHIFTS
LOW
DIAGNOSTIC ENABLE
448
WHT/BLK
DATA LINK
CONNECTOR "B"
NONE
C10 2ND GEAR START SWITCH
553
LTBLU
2ND GEAR SWITCH
NONE
HIGH
C6
C7
cs
C9
CONNECTOR "A"
SIGNAL
NO SYMPTOMS. REFER TO "OBD SYSTEM

CHECK."
1sr GEAR STARTS WHEN 2ND GEAR STARTS
ARE SELECTED
C11
1746
PNK/BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "C"&
INJECTOR#3
NONE
MISFIRE, RUNS ROUGH, POOR

PERFORMANCE; POOR FUEL ECONOMY.
REFER TO CHART C2A *
1745
LTGRN/BLK
10-WAYINJ/
ENGINE HARNESS
CONN. "B" &
INJECTOR#2
NONE

PERFORMANCE, POOR FUEL ECONOMY.
1744
BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "A" &
INJECTOR#1
NONE
MISFIRE. RUNS ROUGH, POOR

846
YEL/BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "F" &
INJECTOR#&
NONE

845
BLK/WHT
NONE

C17 PCM GROUND
551
TAN/WHT
10-WAY INJ/
ENGINE HARNESS
CONN. ''E'' &
INJECTOR#S
ENGINE GROUND
LOCATED AT
FRONT OF ENGINE
NONE
NO SYMPTOMS. IF BOTH ECM GROUNDS

ARE OPEN, NO START, REFER TO "OBD
SYSTEM CHECK."
C18 REFERENCE LOW CAMSHAFT

POSITION SENSOR &
632
PNK/BLK
36(3)
SLIGHT ENGINE MISS, POOR

PERFORMANCE, POOR FUEL ECONOMY
CAMSHAFT
POSITION SENSOR
HARNESS CONN
"C" CRANKSHAFT
POSITION SENSOR
HARN CONN "C"
17 (3)
C19
(1)
(2)
(3)
(4)
OPEN CIRCUIT
GROUNDED CIRCUIT
SHORTED TO VOLTAGE
6-19-93
NS 15644
PCM CONNECTOR "C" SYMPTOMS CHART

BLUE 32 PIN CONNECTOR
CKT
#
WIRE COLOR
C20 KNOCK SENSOR SIGNAL
496
DK/BLU
C21 24X REFERENCE SIGNAL
1800
PIN FUNCTION
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAUL TY CIRCUIT
KNOCK SENSOR
43 (3)
LACK OF PERFORMANCE, SPARK KNOCK.

REFER TO SECTION CS.
LTBLU/WHT
HIGH RESOLUTION
24X CRANKSHAFT
POSITION SENSOR
"B"
36 (3)
LONG CRANK TIME, INCORRECT IDLE, LACK

OF POWER, HESITATION OR SAG.
229
DKBLU
PASS-KEYII
DECODER MODULE
CONNECTOR" A3"
46
633
BRN/WHT
CAMSHAFT
POSITION SENSOR
17 (3)
SLIGHT ENGINE MISS, POOR

PERFORMANCE POOR FUEL ECONOMY.
C22
C23 PASS-KEY II SIGNAL
{FUEL ENABLE)
CRANKS, BUT WON'T START.
C24
C25 CAMSHAFT POSITION SENSOR
SIGNAL
"8"
C26
C27 IGNITION CONTROL {IC)
423
WHT
IGNITION
CONTROL MODULE
HARN CONN "B"
42 (2)
SURGE, HESITATION, RUNS ROUGH,

STALLS, LACK OF PERFORMANCE.
(28 IGNITION CONTROL BYPASS
424
TAN/BLK
IGNITION
CONTROL MODULE
HARN CONN "A"
42 (2)
SURGE, HESITATION, RUNS ROUGH,

STALLS, LACK OF PERFORMANCE.
C29 IAT SENSOR SIGNAL
472
TAN
IATHARNESS
CONN "B"
23 (1)
HARD TO START, POOR PERFORMANCE.
25 (2)
C30 3X REFERENCE HIGH
647
LT BLU/BLK
IGNITION
CONTROL MODULE
HARN CONN "E"
82 (3)
CRANKS BUT WILL NOT START. REFER TO

"ON-BOARD DIAGNOSTICS SYSTEM
CHECK."
C31 3X REFERENCE LOW
453
RED/BLK
IGNITION
CONTROL MODULE
HARN CONN "F"
NONE
NO SYMPTOMS, REFER TO SECTION C4.
844
LT BLU/BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "D"
INJECTOR#4
NONE

REFER TO CHART C-2A.
*
(1)
(2)
(3)
(4)
REFER TO ELECTRICAL DIAGNOSIS {SECTION SA).

OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
6-17-93
NS 15645
6E3-B-24 3.4L (L32) (VIN S) (SFI) DRIVEABlLITY AND EM1,SSfONS
CHART 8-1
RESTRICTED EXHAUST SYSTEM CHECK
3.4L {VIN S) F" CARLINE {SFI)
11
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. Either of
the following procedures may be used for diagnosis, depending upon engine or tool used:
OR CHECK AT OXYGEN SENSOR (025):
CHECK AT AIR PIPE:
Remove the rubber hose at the exhaust

manifold AIR pipe check valve. Remove
check valve.
Connect exhaust backpressure kit (with air
adapter) J 35314-A.
Insert the adapter into the exhaust manifold
AIR pipe.
1.
2.
3.
1.
2.
Carefully remove oxygen sensor.

Install exhaust backpressure gage J 3/5314-A
in place of oxygen sensor (refer to
il 1ustration).
After completing test described below, coat
threads of oxygen sensor with anti-seize
compound PIN 5613695 or equivalent prior to
re-ins tall a tion.
3.
9'.
_l--,
_--
))
\.... -a
i~
EXHAUST BACK PRESSURE KIT WITH AIR ADAPTER

2
AIR PIPE {EXHAUST PORT)
CHECK VALVE
BACK PRESSURE GAGE

75 3363-6E
OXYGEN SENSOR (025)
EXHAUST MANIFOLD
75 3338-6E
DIAGNOSIS:
1.
2.
3.
4.
5.
With the engine idling at normal operating temperature, observe the exhaust system backpressure
reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi).
Increase engine speed to 2000 RPM and observe gage. Reading should not exceed 20. 7 kPa (3 psi).
If the backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffier failure.
If there are no obvious reasons for the excessive backpressure, the catalytic converter is suspected to be
restricted and should be replaced using current recommended procedures.
4-30-92
7S3340-6E
DRIVEABllll'Y AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-B-25
BLANK,
6E3-C-1 3.4L (L32) (VIN S) {SFI) DRIVEABILITY AND EMISSIONS
SECTION C
COMPONENT SYSTEMS
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread-locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
Section
"C" provides information on the following:

General description of components and systems.
On-vehicle service.
Part names.
Diagnostic charts. These include a functional check of the system as well as diagnosis of any problem
found in the functional check.
,
For locations of components, wiring diagrams, and PCM connector end view, refer to the front on the '' A''
Section of the engine being diagnosed.
Following are the sub-section identification and the system covered:
Powertrain Control Module (PCM) and Sensors Page C1-1
C1
C2
Fuel Metering System Page C2-1
C3
Page C3-1
C4
Electronic Ignition (El) System Page C4-1
CS
Page CS-1
C6
Secondary Air Injection (AIR) System Page C6-1
C7
Exhaust Gas Recirculation (EGR) System , Page C7-1
CB
Page C8-1
C10 A/CCompressorClutchControl PageC10-1
C12 Cooling Fan Control PageC12-1
C13 Crankcase Ventilation System Page C13-1
C14 Air Intake System PageC14-1
DIAGNOSTIC CHARTS
The diagnostic charts for each system are found after the on-vehicle service and parts information at the back of
each section. Following are the charts found in this section.
Manifold Absolute Pressure (MAP) Output Check
Page C1-14
ChartC-10
Injector/Coil Balance Test Procedure (1 of 3) Page C2-16
ChartC-2A
Idle Air Control (IAC) Circuit Page C2-22
ChartC-28
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Check Page C3-6
Chart C-3
Misfire Page C4-8
Chart C-4F
Knock Sensor (KS) System Check Page CS-4
Chart C-5
Secondary Air Injection (AIR) System Check Page C6-6
ChartC-6
Exhaust Gas Recirculation (EGR) Flow Check Page C7-4
ChartC-7
Transmission Range (TR) Pressure Switch Assembly Circuit Check Page C8-10
ChartC-8A
2nd Gear Start Switch Indicator Lamp Control Circuit Check
Page C8-12
ChartC-88
2nd Gear Start Switch Signal Circuit Check Page C8-14
ChartC-8C
Transmission 1-2 Shift Solenoid Circuit Check Page C8-16
ChartC-80
Transmission 2-3 Shift Solenoid Circuit Check Page C8-18
ChartC-8E
Transmission 3-2 Control Solenoid Circuit Check
Page C8-20
ChartC-8F
Transmission TCC Solenoid Circuit Check Page C8-22
ChartC-8G
A/C Compressor Clutch Control Circuit Diagnosis (1 of 2)
Page C10-4
Chart C-10
Cooling Fan Control Circuit Diagnosis (1 of 2) Page C12-2
Chart C-12
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-C1-1
SECTION C1
POWERTRAIN CONTROL MODULE (PCM) AND SENSORS

CONTENTS
General Description
PCM Function .
Memory
EEPROM
RAM
Short Term Fuel Trim
Long Term Fuel Trim
Speed Density System
Speed
Density .
Information Sensors
Sensor
Intake Air Temperature (IAT) Sensor
Sensor
Oxygen Sensor (025)
Throttle Position (TP) Sensor
Knock Sensor (KS)
A/C "Request" Signal
Park/Neutral Position (PNP) Switch
3X Crankshaft Position Sensor ........ .
Camshaft Position Sensor
24X Crankshaft Position Sensor
Diagnosis
PCM Inputs
... ..... .... . ... . ... ..
C1-1
C1-1
Cl-1
C1-2
C1-2
C1-2
C1-2
C1-2
C1-3
C1-3
C1-3
C1-3
C1-3
C1-4
C1-4
C1-4
C1-5
C1-5
C1-5
C1-6
C1-6
Cl-6
C1-7
C1-7
C1-7
C1-8
GENERAL DESCRIPTION
POWERTRAIN CONTROL MODULE {PCM)
NOTICE: To prevent possible Electrostatic
Discharge damage to the PCM, Do Not touch the
connector pins or soldered components on the.
circuit board.
The Powertrain Control Module (PCM) (Figure
Cl-1}, is located under hood between the right shock
tower and the bulkhead. It is the control center of the
fuel injection system and constantly ~onitors. the
information from various sensors and controls the
systems that affect vehicle performance. The PCM
also performs the diagnostic function of the system. It
can recognize operational problems, alert the driver
through the Malfunction Indicator Lamp (MIL)
"Service Engine Soon," and store a Diagnostic Trouble
Code (DTC) which identifies the problem areas to aid
the technician in making repairs. A scan tool must be
used to retrieve DTCs from the PCM memory. DTCs
can no longer be retrieved by grounding terminals "A"

Sensor
Intake Air Temperature (IAT)
Sensor
Sensor ,
Oxygen Sensor (025)
vss .. -: .................. .
Crankshaft Position Sensor
On-Vehicle Service
PCM and Components Replacement
PC:1\11
If PCM is Being Replaced
EEPROM Programming
Functional Check
Sensor
Oxygen Sensor (025)
,.Sensor
vss . . . . . . . . . . . . . . . .. . . . . . . .
C1-8
C1-8
C1-8
C1-8
C1-8
C1-9
C1-9
C1-9
C1-9
C1-9
Cl-9
Cl-10
Cl-10
Cl-10
Cl-10
Cl-10
C1-1 O
Cl-11
Cl-11
C1-12
Cl-12
(1-12
to "B" at the DLC. This also eliminates the PCM

function of flashing Code 12. Refer to "Introduction,"
SECTION 6E for more information on using the
diagnostic function of the PCM.
The PCM used on the 3.4L engine is referred to as
SFI-66. For service, this PCM consists of only two
parts: a dual processor controller and Knock Sensor
(KS) module.
PCM FUNCTION
The PCM contains a power supply which regulates
the 12 volt vehicle supply input to 5 and 12 volts, and
these voltages are used for various internal and
external functions.
.
The PCM supplies a buffered 5 or 12 volts to power
various sensors or switches. This is done through
resistances in the PCM which are so high in value that
a test light will notlight when connected to the circuit.
In some cases, even an analog shop voltmeter will not
give an accurate reading because its resistance is too
low. Therefore, the use of a 10 megohm input
impedance digital voltmeter or a Tech 1 scan tool is
necessary to assure accurate voltage readings.
6E3-C1-2 3.4L (L32) (VIN S) (SFI) DRIVEABIUTY AND EMISSIONS
PCM
PCM HARNESS CONNECTOR (B)
PCM HARNESS CONNECTOR (C)
PCM HARNESS CONNECTOR (A)
PCM ENGINE HARNESS CONNECTORS
SECONDARY PUSH LOCK RETAINERS

PCM HARNESS CONNECTORS
NS 15050
Figure C1-1 Powertrain Control Module (PCM)
The Input/Output (1/0) devices in the PCM include

analog to digital converters, signal buffers, counters
and special drivers. The PCM controls output circuits
such as the fuel injectors, IAC, cooling fan relay, etc.
by controlling the ground circuit through transistors
or a device called a "quad-driver" in the PCM.
Memory
There are two types of memory storage within the
PCM: EEPROM an.d RAM.
EEPROM
Electrically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered to the circuit boards within the
PCM. The EEPROM contains the overall control
algorithms. The EEPROM can be reprogrammed by
using the Tech 1 scari tool or other Techline
terminal/equipment.
RAM
Random Access Memory (RAM) is the
microprocessor "scratch pad." The processor can write
into or read from this memory as needed. This
memory is volatile and needs a constant supply of
voltage to be retained. If the voltage is lost, the
memory is lost and the PCM logs a OTC indicating this
loss.

Short term fuel trim is an PCM volatile memory
register that will contain a number between Oand 255.
The neutral value for the short term fuel trim is 128;
any deviation from this value indicates the short term
fuel trim is changing the injector pulse width. The
amount of pulse width change depends on how far the
short term fuel trim value is from 128. The short term
fuel trim changes the pulse width by varying the
"Closed Loop" factor of the base pulse width equation.
As the.PCM monitors the Oxygen Sensor (02S) inputs,
it is constantly varying the short term fuel trim value.
The value is updated very quickly, therefore, the short
term fuel trim only corrects for short term fuel trim
trends. The c,:orrection of long term fuel trim trends is
the function of the long term fuel trim.
Long Term Fuel Trim

The long term fuel trim is a matrix of cells
arranged by RPM and MAP. Each cell of the long term
fuel trim is a register like the short term fuel trim. As
the engine operating conditions change, the PCM will
switch froni cell to cell to determine what "long term
fuel trim" factor to use in the base pulse width
equation.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C1-3

While in any given cell, the PCM also monitors the
short term fuel trim. If the short term fuel trim is far
enough from 128, the PCM will change the long term
fuel trim value. Onee the long term fuel trim \lalue is
changed it should force the short term fuel trim back
toward 128.
If the mixture is still not correct (as judged by the
028), the short term fuel trim will continue to have a
large deviation from the ideal 128. In this case, the
long term fuel trim value will continue to change until
the short term fuel trim becomes balanced.
Both the short term fuel trim and long term fuel
trim are limited by calibrated values. If the mixture is
off enough so that long term fuel trim reaches the limit
of its control and still cannot correct the condition, the
short term fuel trim would also go to its limit of control
in the same direction. If the mixture is still not
corrected by both short term fuel trim and long term
fuel trim at their extreme values, a DTC 44, 45, 64 or
65 will likely result. Under the conditions of power
enrichment, the PCM sets the short term fuel trim to
128 and freezes it there until power enrichment is no
longer in effect. This is done so the "Closed Loop"
factor and the long term fuel trim will not try to
correct for the commanded richness of power
enrichment.
SPEED DENSITY SYSTEM

The Sequential Fuel Injection (SFI) system is a
speed and air density system. The system is based on
"speed density" fuel management which calculates air
volume through the intake.
Three specific data sensors provide the PCM with
the basic information for the fuel management portion
of its operation. That is, three specific signals to the
PCM establish the engine speed and air density to
determine the optimum fuel delivered by the injectors.
Speed
The engine speed signal from the 3X crankshaft
position sensor is conditioned by the elec'tronic
Ignition Control Module (ICM) system module. This
signal is input to the PCM on the crank reference high,
CKT 647. The PCM uses this information to
determine the speed" or RPM factor for fuel and
ignition management.
Density
Th:ree sensors contribute to the density factor, the
Intake Air Temperature (IAT), the Manifold Absolute
Pressure (MAP) and the Engine Coolant Temperature
(ECT) sensors.
The IAT sensor is a 2-wire sensor that measures

the temperature of the air entering the intake
manifold. The IAT sensor is a thermistor that changes
its resistance as an in vet se function of temperature.
When the temperature is low, the r~sistance is high,
and when the temperature is high, the resistance is
low.
The engine coolant temperature sensor is also a
2-wire sensor that measures temperature. It is
mounted in the engine coolant stream and operates the
same way as the IAT sensor.
The IAT and ECT sensors work together to assure
that proper temperature information gets to the PCM.
The Manifold Absolute Pressure (MAP) sensor is a
3-wire sensor that monitors the changes in intake
manifold pressure which results from changes in
engine loading. These pres.~ure changes are supplied
to the PCM in the form of analog electrical signals.
As intake manifold pressure increases, the air
density in the intake manifold also increases and
additional fuel is required. The MAP sensor sends this
pressure information to the PCM and the PCM
incr~ases the amount of fuel injected by increasing the
injector pulse width. Conversely, as manifold pressure
decreases, the amount of fuel is decreased.
These four inputs MAP, IAT, ECT sensors, and
RPM are the major determinants of the air/fuel
mixture delivered by the fuel injection system.
The remaining sensors and switch~s provide
electrical inputs to the PCM which are used for
modification of the air/fuel mixture, as well as for
other PCM control functions, such as Idle Air Control
(IAC).
INFORMATION SENSORS
Engine Coolant Temperature (ECT) Sensor
Figure C1-2
The engine coolant temperature sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
Low coolant temperature produces a high resistance
(100,000 ohms at -40C/-40F) while high temperature
causes low resistance (70 ohms at 130C/266F).
The PCM supplies a 5 volt signal to the engine
coolant temperature sensor through a resistor in the
PCM and. measures the voltage. The voltage will be
high when the engine is cold, and low when the engine
is hot. By measuring the voltage, the PCM calculates
the engine coolant temperature. Engine coolant
temperature affects most systems the PCM controls.
A failure in the coolant sensor circuit should set
either a OTC 14 or OTC 15. Remember, these OTC(s)
indicate a failure in the coolant temperature circuit so
proper use of the chart will lead to either repairing a
wiring problem or replacing the sensor to properly
repair a problem.
6E3,.(1-4 3.4L (L32) (VIN S} (SFI} DRJVEABILITY ANO EMISSIONS
HARNESS CONNECTOR
2
LOCKING TAB
SENSOR
SS 1640-6E
Figure C1-2 Engine Coolant Temperature Sensor
MAP SENSOR
4S0552-6E
Figure C13 MAP Sensor

The Intake Air Temperature (IAT) sensor is a
thermistor (a resistor which changes value based on
the temperature of air entering the engirte and is
mounted in the air cleaner). Low temperature
produces a high resistance (approximately 100,000
ohms at -40C/-40F) while high temperature causes
low resistance (approximately 70 ohms at
130C/266F). The PCM supplies a 5 volt signal to the
sensor through a resistor in the PCM and measures
the voltage. The voltage will be high when the intake
air is cold and low when the air is hot. By measuring
the voltage the PCM calculates the intake air
temperature.
The IAT sensor is used to control spark timing and
delays EGR when the intake air is cold.
A failure in the IAT sensor circuit should set either
a DTC 23 or DTC 25. Once a diagnostic trouble code is
set, the PCM will use an artificial default value for
IAT and some vehicle performance will return.
Manifold Absolute Pressure (MAP) Sensor

Figure C1-3
The Manifold Absolute Pressure (MAP) sensor
measures the changes in the intake manifold pressure
which result from engine load and speed changes, and
converts this to a voltage output.
A closed throttle on engine coastdown would
produce a relatively low MAP output, while a wideopen throttle would produce a high output. Manifold
Absolute Pressure (MAP) is the OPPOSITE of what
you would measure on a vacuum gage. When manifold
pressure is high, vacuum is low. The MAP sensor is
also used to measure barometric pressure under
certain conditions, which allows the PCM to
automatically adjust for different altitudes.
The PCM sends a 5 volt reference signal to the
MAP sensor. As the manifold pressure changes, the
electrical resistance of the sensor also changes. By
monitoring the sensor output voltage, the PCM
calculates the manifold pressure. A higher pressure
EXHAUST OXYGEN SENSOR (02S)

4-2-92
* 4S00786E
Figure C1-4 Exhaust Oxygen Sensor (02S)
(high voltage) requires more fuel; while a lower

pressure (low voltage) requires less fuel.
A failure in the MAP sensor circuit should set a
DTC 33 or DTC 34. CHART C-lD can also be used to
checkthis MAP sensor.
Oxygen Sensor (025)

The Oxygen Sensors (028) are essentially small
variable batteries; they have the ability to produce a
low voltage signal that feeds information on engine
exhaust,oxygen content from each bank of cylinders.
Two oxygen sensors are used in the 3.4L (VIN S). One
sensor is placed in each exhaust manifold to measure
the state of the gases produced by each bank of
cylinders. This allows for more precise fuel control
which lowers emissions and increases efficiency to the
PCM (Figure Cl-5).
The 028 is constructed from a zirconia/platinum
electrolytic element. Zirconia is an electrolyte that
conducts electricity under certain chemical conditions.
The insulator is made of a ceramic material. The
element is an insulator when cold.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI). 6E3-C1-5
OXYGEN SENSOR ELEMENT

21%
21%
OXYGEN
OXYGEN
EXHAUST
GAS WITH
0%
OXYGEN
........
....
..
....
....
....
....
......
..
......
........
..
not cause things to happen. It is a type of gage: Lean

mixture = high oxygen content in the exhaust = low
voltage output; rich mixture = low oxygen content in
the exhaust= high voltage output .
An open Oxygen Sensor (028) circuit should set a
DTC 13 or 63. A constant low voltage in the Oxygen
Sensor (028) circuit should set a DTC 44 or 64 .
0.6V
MORE CONDUCTION
The Oxygen Sensor (028) provides the feedback

information for the "Closed Loop" operating mode of
the fuel delivery system. The oxygen sensor indicates
EXHAUST
GASWITH
2%
OXYGEN

Figure C1-7
LESS CONDUCTION
9S 6325-6E
Figure C15 Oxygen Sensor {02S) Element
At exhaust temperatures around 316C (600F), the

element becomes a semiconductor. A platinum coating
on the outer surface of the element stimulates further
combustion of the exhaust gases right at the surface
and this helps keep the element up to the desired
temperature. The oxygen sensor has an inte.rnal
cay~ty which is filled with atmospheric (reference) air.
The atmosphere has approximately 21% oxygen in it.
In the electrical circuit this internal cavity is the
positive ( +) terminal. The outer surface of the
element is exposed to the exhaust gas stream. It is the
negative(-) or ground terminal. Due to the electrolytic
properties of the element, the oxygen concentration
differences between the reference air and exhaust
gases produce smaUvoltages.
A rich exhaust (excessive fuel) has almost no
oxygen. When there is a large difference in the
amount of oxygen touching the inside and outside
s~rfaces, there is more conduction, and the sensor puts
out a voltage signal greater than 0.6 volt.
When lean (excessive oxygen) there is about two
percent oxygen in the exhaust. This is a smaller
difference in oxygen from the outside surfaces which
results in less conduction and a voltage signal less
than 0.3 volt. The voltages are monitored and used by
the PCM to "fine tune" the air fuel ratio to achieve the
ideal mixture desired.
The PCM puts out a reference signal of 0.45 volt
(refer to Figure Cl-6). The reference signal serves two
purposes. The first is to run the engine when it is in
"Open Loop" mode of operation. When the air/fuel
ratio is correct the PCM "senses" 0.45 volt. When the
engine is operating with a rich air/fuel ratio there is a
reduction of free oxygen in the exhaust stream and the
028 voltage rises above the reference voltage. When
the engine is run lean, the voltage drops below the
reference voltage due to excess oxygen in the exhaust
stream.
The Throttle Position (TP) sensor is a

potentiometer connected to the throttle shaft on the
throttle body. The TP sensor electrical circuit consists
of a 5 volt supply line and a ground line, both provided
by the PCM. By monitoring the voltage on this signal
line the PCM calculates throttle position. As the
throttle valve angle is changed (accelerator pedal
moved), the output of the TP sensor also changes. At a
closed throttle position, the output of the TP sensor is
low (approximately .29 to .98 volt). As the throttle
valve opens, the output increases so that, at wide-open
throttle, the output voltage should be approximately.5
volts.
The PCM can determine fuel delivery based on
throttle valve angle (driver demand). A broken or
loose TP sensor can cause intermittent bursts of fuel
from the injector, and an unstable idle, because the
PCM senses the throttle is movi~g. A problem in any
of the TP sensor circuits should set either a DTC 21 or
22. Once a diagnostic trouble code is set, the PCM will
use an artificial default value for the TP sensor and
some vehicle performance will retu;n. A high idl; will
result when either DTC 21 or DTC 22 is set.
Refer to '!On-Vehicle Service" for replacement of
the TP sensor.

The Vehicle Speed Sensor (VSS) sends a pulsing
voltage signal to the PCM which the PCM converts to
miles per hour. This sensor mainly controls the
operation of the TCC system. There are several
different types of vehicle speed sensor~. Refer to
"Torque Converter Clutch (TCC) System," Section
"6E3-C8", DTC 24 or SECTION SA for more
information.
Knock Sensor (KS)

Refer to "Knock Sensor (KS) System," Section
"6E3-C5" for description of KS system.
6E3-C1-6 3.4L (L32) (VIN S) (SFI), DRIVEABILITY AND EMISSIONS
A/C "Request" Signal

This signal tells the PCM that the NC selector
switch is turned "ON." The PCM uses this to adjust
the idle speed before turning "ON" the NC compressor
clutch.
If this signal is not available to the PCM, the NC
compressor will be inoperative. Refer to "A/C
Compressor Clutch Control," Section "6E3-C10" for
repair procedures.
The Park/Neutral Position (PNP) switch indicates

to the PCM when the transmission is in park or
neutral or drive. This information is used for the EGR
and the IAC valve operation.
[I] Important
Vehicle should not be driven with transmission

position switch disconnected, as idle quality will be
affected and a possible false DTC 24 (VSS).
Refer to "On-Vehicle Service" in SECTION 7A for

more information on the PNP switch which is part of
the transmission position switch assembly, mounted
on the transmission shift lever.
SENSOR THROTTLE POSITION (TP)

2
SCREW ASSEMBLY - TP SENSOR ATTACHING

9P1074-6E
Figure C1-7-Throttle Position (TP) Sensor
Refer to CHART C-lA for PNP switch check.
3X CRANKSHAFT POSITION SENSOR

The crankshaft position sensor provides a signal
through the electronic ignition control module which
the PCM uses as reference to calculate RPM and
crankshaft position. Refer to "Electronic Ignition (El)
System," Section "6E3-C4" for further information.
RICH
0.60v
RICH
0.60v
PCM02S
REFERENCE
SIGNAL
0.45v
PCM02S
REFERENCE
SIGNAL
0.4Sv
LEAN
0.30v
LEAN
0.30v
NORMAL OPERATION
RICH TOO LONG DTC 45 OR 65
RICH
0.60v
RICH
0.60v
PCM02S
REFERENCE
SIGNAL
0.4Sv
PCM02S
REFERENCE
SIGNAL
0.4Sv
LEAN
0.30v
LEAN
0.30v
LEAN TOO LONG OTC 44 OR 64
Park/Neutral Position (PNP) Switch (Part of

Transmission Position Switch)
Figure C1-8
BETWEEN 0.3-0.6v TOO LONG - OTC 13 OR 63

6-19-93
9S6344-6E
Figure C16 - Normal 025 Voltage and Abnormal Trends
TRANSMISSION POSITION SWITCH

HARNESS CONNECTOR
MS 11588
Figure C1-8- Transmission Position Switch
CAMSHAFT POSITION SENSOR

The camshaft position sensor is a "Hall-effect"
switch, located on the front top of the engine. It is
supplied ignition voltage and has its own ground. The
camshaft position sensor sends a signal to the PCM
when the #1 cylinder is on the intake stroke. This
signal is used by the PCM to synchronize Sequential
Fuel Injection (SFI) mode of operation with the intake
valve opening. If the camshaft position sensor signal
is notxeceived by the PCM, the PCM will still operate
in SFI mode based on the reference signal, however,
SFI mode timing may not be as ~ccurate because the
PCM does not know the exact time the intake valve is
opening. A slightly rough idle would result. A loss of
this signal or extra cam signals, above 500 RPM, to the
PCM will set a DTC 17.
KNOCK SENSOR
2
BOLT/SCREW
NS 15845
Figure C1-9 - Low Resolution 3X Crankshaft Po.sition

Sensor

The 24X crankshaft sensor is used to improve idle
spark control at engine speeds up to approximately
2000 RPM. Refer to "Electronic Ignition (EI) System,"
Section "6E3-C4" for further information.
CAMSHAFT POSITION SENSOR ASSEMBLY
DIAGNOSIS
To read Diagnostic Trouble Code(s) [DTC(s)], use a
Tech 1 scan tool. To clear the DTC(s) from memory:
[gnition "OFF."
Disconnect 1/P Fuse #4 for 30 seconds or use
the Tech 1 scan tool to clear DTC(s) function.
Since the PCM can have a failure which may affect
only one circuit, following the diagnostic procedures in
this section will determine which circuit has a problem
and where it is.
BOLT (1) TORQUE 10 Nm (8 lb. ft)
ENGINE BLOCK ASSEMBLY
NS 15091
Figure C1-10 -.Camshaft Position Sensor
If a diagnostic chart indicates that the PCM

connections or PCM is the cause of a problem and the
PCM is replaced, the Knock Sensor (KS) module must
be transferred to the new PCM ahd the new PCM must
then be programmed. If this. does not correct the
problem, one of the following may be the reason:
There is a problem with the PCM terminal
connections. - The diagnostic chart will say
PCM connections or PCM. The terminals may
have to be removed from the connector in order
to check them properly.
6E3-C1-8 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
The problem is intermittent. - This means that

the problem is not present at the time the
system is being checked. In this case, refer to
the "Symptoms," Section "6E3-B" portion of
the manual and make a careful physical
inspection of all portions of the system
involved.
Shorted solenoid. relay coil, or harness. Solenoids and relays are turned "ON" and
"OFF" by the PCM using internal electronic
switches called "drivers." Each driver is part
of a group of four called "quad-drivers."
Failure of one driver can damage any other
driver in the set.
A shorted solenoid, relay coil, or computer
harness will not damage the PCM but will cause
the component to be inoperative.
J 34636 or BT-8405 testers or equivalent
provide a fast, accurate means of checking for a
shorted coil or a short to battery voltage.
PCM INPUTS
All of the sensors and input switches can be
diagnosed by the use of a Tech 1 scan tool. The
following is a short description of how the sensors and
switches can be diagnosed by the use of a Tech 1 scan
tool. The Tech 1 scan tool can also be used to compare
the values for a normal running engine with the
engine you're diagnosing.

A Tech 1 scan tool displays engine temperature in
degrees centigrade. After the engine is started, the
temperature should rise steadily to about 90C (194F)
then stabilize when the thermostat opens. If the
engine has not been run for several hours (overnight)
the engine coolant and intake air temperatures should
be within 5 of each other. A fault in the ECT sensor
circuit should set a DTC 14 or DTC 15. The Diagnostic
Trouble Code (DTC) charts also contain a "Diagnostic
Aid" chart to check for sensor resistance values
relative to temperature.

A Tech 1 scan tool displays temperature of the air
entering the engine and should read close to ambient
air temperature when the engine is cold, and rise as
underhood temperature increases. If the engine has
not been run for several hours (overnight) the IAT
temperature and engine coolant temperature should
read close to each other. A failure in the IAT sensor
circuit should set a DTC 23 or 25. The DTC charts also
contain a chart to check for sensor resistance values

A Tech 1 scan tool displays manifold pressure in
volts. Low pressure (high vacuum) reads a low voltage
while a high pressure (low vacuum) reads a high
voltage. A failure in the MAP sensor circuit should set
a DTC 33 or 34 and using the chart will find the cause
of the problem. A DTC 33 may be set if a rough or
unstable idle exists. CHART C-lD can also be used to
check MAP sensor.
Oxygen Sensor (025)

The Tech 1 scan tool has several positions that will
indicate the state of the exhaust gases, Oxygen Sensor
(028) right (Bank 1) and 028 left (Bank 2) voltages,
sliort term fuel trim Bank 1 and 2 and long term fuel
trim Bank 1 and 2. Refer to Tech 1 scan tool position
information in "Introduction" in SECTION 6E.
A problem in the Oxygen Sensor (028) circuits, or
fuel system, should set a DTC 13 or 63 (open circuit),
DTC 44, 64 (lean indication), DTC 45, 65 (rich
indication). Refer to applicable chart if any of these
DTC(s) were stored in memory.

A Tech 1 scan tool displays throttle position in
volts. Voltage should increase at a steady rate as
throttle is moved toward WOT.
FRONT ENGINE COVER
24x CRANKSHAFT POSITION

SENSOR ASSEMBLY
BOLT (2) TORQUE 10 Nm (8 lb. ft.)
NS 15606
Figure C1-11 - High Resolution 24X Crankshaft Position Sensor

The PCM has the ability to auto-zero the TP sensor
voltage if it is between .29 volt (290 m V) and .98 volt
(980 m V). This means that any voltage between .29
and .98 volt will be determined by the PCM to be 0%
throttle. Tech 1 scan tools have the ability to read the
throttle angle and should display 0% when the throttle
is closed. A failure in the TP sensor or circuit should
set a DTC 21 or 22.
vss

The Tech 1 scan tool will display camshaft position
sensor data as "IGN Control Cam Signal." As the
sensor pulses the scan data will switch from O to 1. All
camshaft position sensor data should be checked at
idle. An error in the camshaft position sensor circuit
should set a DTC 17 and using the chart will find the
cause of the error.
A Tech 1 scan tool reading should closely match

with speedometer reading with drive wheels turning.
A failure in the VSS circuit should set a DTC 24.
Crankshaft Position Sensor

The Tech 1 scan tool displays crankshaft position
sensor data as "ENGINE SPEED (RPM)." A failure in
this circuit should set a DTC 82.
The Tech 1 scan tool will display 24X crankshaft

position sensor data as "IGN Control 24X Signal."
Data will be displayed in RPM. An error in the 24X
sensor circuit should set a DTC 36.
ON-VEHICLE SERVICE
POWERTRAIN CONTROL MODULE (PCM)
Service of the PCM should normally consist of
either replacement of the PCM or reprogramming of
the EEPROM.
-----.. ==--~
NS 15648
Figure C1-12- PCM Mounting
rn
Important
When replacing the production PCM with a service
PCM (controller), it is important to transfer the
broadcast code and production PCM number to the
service PCM label. Please do not record on PCM
cover. This will allow positive identification of
PCM parts throughout the service life of the
vehicle.
rn
Important
. . .
To prevent internal PCM damage, the 1gmt10n
must be "OFF" when disconnecting or
reconnecting power to PCM (for example, battery
cable, PCM pigtail, PCM fuse,jumper cables, etc.).
PCM AND COMPONENTS REPLACEMENT
Data Link Connector (DLC), formerly ALDL,

must be secure.
2. Refer to up-to-date Techline terminal/equipment
user's instructions.
3. If PCM fails to program, do the following:
Check all PCM connections.
Check Techline terminal/equipment for latest
software version.
Try again to program the PCM. If it fails
again, replace the PCM. Replacement PCM
must be programmed.
4. If vehicle is equipped with an aftermarket antitheft system, it may require a reset procedure.
Refer to appropriate service manual/section.
Functional Check
PCM
OR
NOTICE: To prevent possible Electrostatic

Discharge damage to the PCM, Do Not touch the
connector pins or soldered components on the
circuit board.

1.
2.
3.
4.
5.
6.
Negative battery cable.

PCM mounting hardware.
Connectors from PCM.
PCM from engine compartment.
PCM access cover.
Knock Sensor (KS) module.
rn
Important
The Knock Sensor (KS) module must be
transferred to the replacement PCM.
The replacement PCM is supplied without a
EEPROM program, the replacement PCM
must be programmed before the vehicle will
run.
IF PCM IS BEING REPLACED

New PCM from its packaging and check the
service number to make sure it is the same as the
defective PCM.
2. Access cover.
1.
EEPROM PROGRAMMING
1.
Use Techline terminal/equipment to perform the

"On-Board Diagnostic (OBD) System Check,"
Setup:
Battery is charged.
Ignition is "ON."
Battery/cig. lighter connection secure.
Refer to "On-Board Diagnostic (OBD) System

Check," in "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A" in
this service manual.
I++! Install or Connect

1. Knock Sensor (KS) module.
2. Access cover on PCM.
3. Connectors to PCM.
4. PCM located under hood.
5. Negative battery cable.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
Figure C1-13
NOTICE: Care must be taken when handling
sensor. Damage to sensor will affect proper
operation of the fuel injection system.
I++! Remove or Disconnect

1.
2.
3.
4.
Relieve coolant pressure.

Electrical connector.
Carefully back out engine coolant temperature
sensor.

l. Coat threads (only) with sealer P/N 9985253 or
equivalent torque to 13 Nm (10 lb. ft.).
2. Sensor in engine. Locking tab on sensor assembly
must be located within area shown in Figure
Cl-13.
3. Electrical connector.
5. Refill lost coolant.
EXHAUST OXYGEN SENSOR (025)
4-2-92
* 45 0078-6E
Figure C1-14 - Oxygen Sensor (02S)
other contaminants. Also, avoid using cleaning

solvents of any type. Do not drop or roughly
handle the Oxygen Sensor (02S).
LOWER INTAKE MANIFOLD
The IAT sensor is located in the rear air intake

duct.
The oxygen sensors may be difficult to remove

when engine coolant temperature is below 48C
(120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
3. Carefully back out Oxygen Sensor (02S) using tool
J 29533A/BT-8127.
NS 13751
FigureC1-13 - Engine Coolant Temperature Sensor
INTAKE AIR TEMPERATURE (IAT) SENSOR
1. Electrical connecter.
2. Clamp.
3. Sensors.

1.
2.
3.
Sensor.
Clamps.
OXYGEN SENSOR (025)
FigureC1-14
NOTICE:
The Oxygen Sensors (02S) use a

permanently attached pigtail and connector. This
pigtail should not be removed from the oxygen
sensor. Damage or removal of the pigtail or
connector could affect proper operation of the
oxygen sensor.
[I] Important
Take care when handling the Oxygen Sensor

(02S). The in-line electrical connector and
louvered end must be kept free of grease, dirt or
[I] Important
A special anti-seize compm.md is. used on the

Oxygen Sensor (02S) threads. The compound
consists of a liquid graphite and glass beads.
The graphite will burn away, but the glass
beads will remain making the sensor easier to
remove.
New or service sensors will already have the

compound applied to the threads. If a sensor is
removed from an engine and if for any reason it is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat threads of Oxygen Sensor (02S) with anti~
seize compound PIN 5613695, or equivalent if
necessary.
2. Sensor, and torque to 41 Nm (30 lb. ft.).
6EJ-C1-12 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
MAP SENSOR CONNECTOR
MAPSENSOR
EGR CONNECTOR
OXYGEN SENSOR(02S) PIGTAIL
NS15649
Figure C1-15- MAP Sensor Service
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR
Figure C1-15

2. MAP sensor electrical connector.
3. MAP sensor bolts/screws (2).
4. Inlet vacuum hose.
5. MAP sensor. Refer to Figure Cl-15.
E3 Install or Connect
1.
MAP sensor to intake plenum. Refer to Figure

Cl-15.
3. Inlet vacuum hose.
THROTTLE POSITION (TP) SENSOR

1. TP sensor electrical connector.
2. Remove TP sensor attaching screws and retainers.
3. Sensor.

With throttle valve in the normal closed idle
position, install throttle position sensor on throttle
body assembly (refer to Figure Cl-16).
2. Two TP sensor screws. Tighten to 2.0 Nm (18.0
lb. in.).
3. TP sensor electrical connector.
1.
vss
Refer to SECTION 7 for transmission mounted
vss.
SCREW ASSEMBLY TP SENSOR A TT ACHING
9P 1074-AS
Figure C1-16-Throttle Position (TP) Sensor Service
PCM
TO A/C EVAPORATOR
TEMPERATURE SENSOR
MANIFOLD
ABSOLUTE
PRESSURE
(MAP)
SENSOR
TOA/C
REFRIGERANT
PRESSURE SENSOR
1 - - - - - - 4 1 1 ' - - - - - 452 BLK
SENSOR GROUND
t---------- 432 LT GRN

1-----~1o:c-----
MANIFOLD
VACUUM
416 GRY
SVOLT
REFERENCE
TOT/P
SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
6-16-93
NS 15613
CHARTC-10
MANIFOLD ABSOLUTE PRESSURE {MAP) OUTPUT CHECK
The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which
result from engine load (intake manifold vacuum) and RPM changes and converts these into a voltage output.
The PCM sends a 5 volt reference voltage to the MAP sensor. As the manifold pressure changes, the output
voltage of the sensor also changes. By monitoring the sensor output voltage, the PCM calculates the manifold
pressure. A lower pressure (low voltage) will be 1-2 volts at idle, while higher pressure (high voltage) output
voltage will be 4-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used under certain conditions,
to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses
the MAP sensor to control fuel delivery and ignition timing.

(j] Important
Be sure to use the same Diagnostic Test
Equipment for all measurements.
NOTICE: Make sure electrical connector

remains securely fastened.
When comparing Tech 1 scan tool readings to a

known good vehicle, it is important to compare
vehicles that use a MAP sensor having the same
color insert or having the same "Hot Stamped"
number.
Applying 34 kPa (10 inch Hg) vacuum to the MAP
sensor should cause the voltage to be 1.5 to 2.1
volts less than the voltage at Step 1. Upon
applying vacuum to the sensor, the change in
voltage should be instantaneous. A slow voltage
change indicates a faulty sensor.
4. Disconnect sensor from bracket and twist sensor

(by hand only) to check for intermittent
connection. Output changes greater than .1 volt
indicates a bad sensor.
1.
2.
3. Check vacuum hose to sensor for leaking or

restriction. Be sure no other vacuum devices are
connected to the MAP sensor vacuum hose.
CHARTC-10
NOTICE: THIS CHART ONLY APPLIES TO MAP SENSORS

HAVING GREEN OR BLACK COLOR KEV INSERT (SEE BELOW).
IF DTC 33 OR 34 IS SET, USE THOSE CHARTS FIRST.

IGNITION "ON," ENGINE "OFF.''
SCAN TOOL SHOULD INDICATE A MAP SENSOR VOLTAGE.
COMPARE THIS READING WITH THE READING OF A KNOWN GOOD VEHICLE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN:!: .4VOLT.
IS IT?
DISCONNECT AND PLUG VACUUM SOURCE TO MAP SENSOR.

CONNECT A HAND VACUUM PUMP TO MAP SENSOR.
START ENGINE.
NOTE MAP SENSOR VOLTAGE.
APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CHANGE.
SUBTRACT SECOND READING FROM THE FIRST. VOLTAGE VALUE
SHOULD BE GREATER THAN 1.5 VOL TS.
ISIT?
NO TROUBLE FOUND. CHECK MAP SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION. BE SURE THIS
SOURCE SUPPLIES VACUUM TO MAP SENSOR ONLY.
REPLACE MAP SENSOR.
CHECK MAP SENSOR CONNECTION.

IF OK, REPLACE MAP SENSOR.
HOT-STAMPED
NUMBER
LS9045-6E
LS 8963-6E
Figure 1 - Co or Key Insert
Figure 2 - Hot Stamped Number
3-10-92
75 3162-6E
6E3-C1-16 3.4L (L32) (VIN S) {SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION C2
FUEL METERING SYSTEM

CONTENTS
General Description
Purpose
Modes of Operation
Starting Mode
Clear Flood Mode
Run Mode
Acceleration Mode
Fuel Cutoff Mode
Deceleration Mode
Catalytic Converter Protection
Mode
Battery Voltage Correction Mode
Fuel Metering System Components
Fuel Supply Components
Fuel Pump Electrical Circuit
Fuel Rail Assembly
Fuel Injector
Fuel Pressure Regulator Assembly
Throttle Body Assembly
Idle Air Control (IAC) Valve
Assembly
C2-1
C2-1
C2-1
C2-1
C2-1
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-3
C2-3
C2-3
C2-4
C2-4
GENERAL DESCRIPTION
PURPOSE
The function of the fuel metering system is to
deliver the correct amount of fuel to the engine under
all operating conditions.
Fuel is delivered to the engine by individual fuel
injectors mounted in the intake manifold near each
cylinder.
The main control sensor is the Oxygen Sensor
(028), located in the exhaust manifold. The 028 tells
the Powertrain Control Module (PCM) how much
oxygen is in the exhaust gas, and the PCM changes the
air/fuel ratio to the engine by controlling the fuel
injectors. The best mixture to minimize exhaust
emissions is 14.7:1, which allows the three-way
catalytic converter to operate most efficiently.
Because of the constant measuring and adjusting of
the air/fuel ratio, the fuel injection system is called a
"Closed Loop" system.
MODES OF OPERATION
The PCM monitors information from several
sensors to determine how much fuel to give the engine.
The fuel is delivered under one of several conditions
called modes. All the modes are controlled by the PCM
and are described below.

Diagnosis
Fuel Pump Relay
On-Vehicle Service
Fuel Pump Relay
Port Fuel Injection Components
Fuel Pressure Relief Procedure
Engine Fuel Pipes
Fuel Rail Assembly
Fuel Pressure Connection
Fuel Injectors
Pressure Regulator Assembly

Throttle Body Replacement
Torque Specifications
Chart C-2A- Injector Coil/Balance Test
Procedure (1 of 3)
Chart C-2B - Idle Air Control (IAC) Circuit
C2-5
C2-5
C2-5
C2-5
C2-6
C2-6
C2-6
C2-6
C2-6
C2-9
C2-10
C2-10
C2-11
C2-11
C2-12
C2-12
C2-14
C2-14
C2-16
C2-22
Starting Mode
When the ignition switch is turned to the "ON"
position (before engaging starter), the PCM energizes
the fuel pump relay for two seconds allowing the fuel
pump to build up pressure. The PCM then checks the
Engine Coolant Temperature (ECT) and Throttle
Position (TP) sensors and determines the proper
air/fuel ratio for starting. This ranges from 1.5:1 at
-36C (-33F) to 14.7:1 at 94C (201F} running
temperature. The PCM controls the amount of fuel
delivered in the starting mode by changing how long
the injectors are energized. This is done by pulsing the
injectors for very short times.
Clear Flood Mode

If the engine floods, it can be cleared by pushing
the accelerator pedal down all the way. The PCM
enables the clear flood mode and temporarily suspends
fuel delivery. The PCM maintains the clear flood
mode as long as the throttle stays wide open, and the
engine speed remains below 600 RPM. If the throttle
position becomes less than 62%, the PCM returns to
the starting mode.

Run Mode
Catalytic Converter Protection Mode
The run mode has two conditions called "Open

Loop" and "Closed Loop."
When the engine is first started and engine speed
is above 400 RPM, the system goes into "Open Loop"
operation. The PCM ignores the signal from the 028
and calculates the air/fuel ratio based on inputs from
the Engine Coolant Temperature (ECT) and Intake
Air Temperature (IAT) sensors.
The system stays in "Open Loop" until the
following conditions are met:
1. The 028 has varying voltage output, showing
that it is hot enough to operate properly. (This
depends on temperature.)
2. The ECT sensor is above a specified
temperature.
3. A specific amount of time has elapsed after
starting the engine.
The specific values for the above conditions vary
with different engines, and are stored in the
Programmable Read Only Memory (PROM) portion of
the PCM. When these values are met, the system goes
into "Closed Loop" operation. In "Closed Loop," the
PCM calculates the air/fuel ratio (injector on-time)
bas;!d on the signal from the 028. This allows the
air/fuel ratio to stay very close to 14. 7: 1.
The PCM constantly monitors engine operation,

and estimates conditions that could result in high
catalytic converter temperatures. If the PCM
determines the converter may overheat, it causes the
system to return to "Open Loop" operation and
enriches the fuel mixture.
Acceleration Mode
When the driver pushes on the accelerator pedal,
air flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, the PCM increases the pulse width to the
injectors to provide extra fuel during acceleration. The
amount of fuel required is based on throttle position,
manifold air pressure, and engine speed.
Fuel Cutoff Mode

To prevent possible engine damage from overspeed, the PCM cuts off fuel from the injectors when
engine speed is above 6000 RPM with the vehicle in
any forward gear position, or in reverse. The PCM also
cuts-off fuel to the injectors at vehicle speeds above 108
mph to prevent tire damage.

When battery voltage is low, the PCM can
compensate for the weak spark by:
Increasing the amount offuel delivered.
Increasing the idle RPM.
Increasing ignition dwell time.

COMPONENTS
The fuel metering system consists of the following
parts:
Fuel supply components (fuel tank, pump,
lines).
Fuel pump electrical circuit.
Fuel rail assembly, including:
Fuel injectors.
Fuel pressure regulator.
Throttle body assembly, including:
Idle Air Control (IAC) valve.
Throttle Position (TP) sensor.
FUEL SUPPLY COMPONENTS

The fuel supply is stored in the fuel tank. An
electric fuel pump, located in the fuel tank with the
gage sending unit, pumps fuel through an in-line fuel
filter to the fuel rail assembly. The pump is designed
to provide fuel at a pressure greater than is 'needed by
the injectors. The pressure regulator, part of the fuel
rail assembly, keeps fuel available to the injectors at a
regulated pressure. Unused fuel is returned to the fuel
tank by a separate line. (For further information see
SECTION 6C for replacement procedures covering the
fuel tank, fuel pump, in-line filter and fuel lines.)
Deceleration Mode
FUEL PUMP ELECTRICAL CIRCUIT
When 'the driver releases the accelerator pedal, air

flow into the engine is reduced. The corresponding
changes in throttle position and manifold air pressure
are relayed to the PCM, which reduces the injector
pulse width to reduce fuel flow. If the deceleration is
very rapid, or for long periods (such as long closed
throttle coast-down), the PCM shuts "OFF" fuel
completely to protect the catalytic converter.

the fuel pump relay for two seconds, causing the fuel
pump to pressurize the fuel system. If the PCM does
not receive ignition reference pulses (engine cranking
or running) within two seconds, it de-energizes the fuel
pump relay, causing the fuel pump to stop. If the fuel
pump relay fails, Diagnostic Trouble Code (DTC) 54 is
set in the PCM.
RETAINER FUEL TUBE

2
INJECTOR ASSEMBLY MFI FUEL
CONNECTION ASSEMBLY FUEL PRESSURE
REGULATOR ASSEMBLY FUEL PRESSURE
NA 1320-AS
Figure C2-1 - Fuel Rail Assembly
FUEL RAIL ASSEMBLY

Figure C2-1
The fuel rail assembly, mounted in the engine
intake manifold, performs several functions. It
positions the injectors in the intake manifold,
distributes fuel evenly to the injectors, and integrates
the fuel pressure regulator into the fuel metering
system. The fuel rail also provides a threaded fitting
for connecting a pressure gage.
Fuel Injector
Figure C2-2
A fuel injector is a solenoH operated device,
controlled by the PCM, that meters pressurized fuel to
a single engine cylinder. The PCM energizes the
injector solenoid, which opens a ball valve, a.Bowing
fuel to flow past the ball valve, and through a recessed
flow director plate. The director plate has six
machined holes that control the fuel flow, generating a
conical spray pattern of finely atomized fuel at the
injector tip. Fuel is directed at the intake valve,
causing it to become further atomized and vaporized
before entering the combustion chamber.
An injector that is stuck partly open would cause
loss of pressure after engine shut down. Consequently,
long cranking times would be noticed on some. engines.
Dieseling also could occur because some fuel could be
SOLENOID ASSEMBLY
HOUSING SPRAY
SPACER & GUIDE ASM
SPRING CORE
HOUSING SOLENOID
CORE SEAT
VALVE BALL
10
SOLENOID
PLATE DIRECTOR
11
FILTER FUEL INLET
BACKUP 0-RING
PA0496-SV
Figure C2-2 - MFI Injector Assembly Cross-Sectional

View
delivered to the engine after the ignition is turned

"OFF.''

Figure C2-3
The fuel pressure regulator is a diaphragmoperated relief valve with fuel pump pressure on one
side, and regulator spring pressure and intake
manifold vacuum on the other. The regulator's
function is to maintain a constant pressure differential
across the fuel injectors at all times. The pressure
regulator compensates for engine load by increasing
fuel pressure as engine vacuum drops.
With the ignition "ON" and engine "OFF" (zero
vacuum), fuel pressure at the pressure test connection
should be 284-325 kPa (41-47 psi). If the pressure is
too low, poor performance could result. If the pressure
is too high, excessive odor and a DTC 45 may result.
CHART A-7 has information on diagnosing fuel
pressure conditions.
6E3-(2 ...4 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
8
3
7
COVER ASSEMBLY
SPRING
RAIL ASSEMBLY - MFI FUEL
DIAPHRAGM
FUEL RETURN
SEAT
LEVER ASSEMBLY - THROTTLE
VALVE
TUBES - COOLANT
CONNECTION -VACUUM
SENSOR - THROTTLE POSITION (TP)
RETAINER- SPRING
VALVE ASSEMBLY - IDLE AIR CONTROL (IAC)
3
BODY ASSEMBLY - THROTTLE
8P0968-AS
Figure C2-3 - Pressure Regulator Assembly
THROTTLE BODY ASSEMBLY

Figure C2-4
The throttle body assembly is attached to the
intake manifold air plenum, and is used to control air
flow into the engine, thereby controlling engine
output. The throttle valve within the throttle body is
opened by the driver through the accelerator controls.
During engine idle, the throttle valve is almost closed,
and air flow control is handled by the Idle Air Control
(IAC) valve, described below. To prevent throttle
valve icing during cool weather operation, engine
coolant is directed through the coolant cavity, on the
bottom of the throttle body.
The throttle body also provides the location for
mounting the TP sensor, for sensing changes in engine
vacuum due to throttle valve position. Vacuum ports
are located at, above, or below the throttle valve to
generate vacuum signals needed by various
components.
Idle Air Control (IAC)Valve Assembly

Figure C2-5
The purpose of the IAC valve assembly is to control
engine idle speed, while preventing stalls due to
changes in engine load.
The IAC valve, mounted in the throttle body,
controls bypass air around the throttle valve. By
moving a conical valve known as a pintle, IN toward
NA 1321-AS
Figure C2-4 - Throttle Body Assembly
the seat (to decrease air flow); or "OUT" away from the
seat (to increase airflow), a controlled amount of air
moves around the throttle plate.
If engine speed is too low, more air is bypassed
around the throttle valve to increase RPM. If engine
speed is too high, less air is bypassed around the
throttle valve to decrease RPM.
The PCM moves the IAC valve in small steps,
called counts. These counts can be displayed on a scan
tool which plugs into the Data Link Connector (DLC).
During idle, the proper position of the IAC valve is
calculated by the PCM, based on battery voltage,
coolant temperature, engine load, and engine RPM. If
the RPM drops below specification and the throttle
valve is closed, the PCM senses a near stall condition
and calculates a new valve position to prevent stalling:
If the IAC valve is disconnected and reconnected
while the engine is running, the resulting idle RPM
may be wrong and resetting of the IAC valve will be
required.
After running the engine, the IAC valve resets
when the ignition is turned "OFF." When servicing
the IAC valve, it should only be disconnected or
connected with the ignition "OFF."
If the PCM is without battery power for any
reason, the programmed position of the IAC valve
pintle is lost, and is replaced with a default value.
Different shaped pintles are used for different IAC
valve applications.

For diagnosis of the fuel pump relay circuit, refer to
the Diagnostic Trouble Code (OTC) 54 chart.
VALVE ASSEMBL V - IDLE AIR CONTROL (IAC}
VALVE - THROTTLE
PINTU - IAC VALVE
ELECTRICAL INPUT SIGNAL
.B
AIRINLET
NA0494-SV
Figure C2-5 - IAC Valve Air Flow Diagram (Typical)
Be sure to use the correct part number, with the

correct pintle shape and diameter, when replacement
is required.
The IAC valve affects only the idle characteristics
of the vehicle. If it is fully retracted, too much air will
be allowed into the manifold and idle speed will be
high. If it is stuck closed, too little air will be allowed
in the manifold, and idle speed will be too low. If it is
stuck part way open, the idle may be rough, and will
not respond to engine load changes. A OTC 35 should
set if a controlled idle cannot be maintained.

The nonadjustable TP sensor is mounted on the
side of the throttle body opposite the throttle lever. It
senses the throttle valve angle and relays that
information to the PCM. Knowledge of throttle angle
is needed by the PCM to generate the required injector
control signals (pulses). For further information, refer
to "Powertrain Control Module (PCM) and Sensors,"
Section "6E3-Cl".
DIAGNOSIS
FUEL PUMP RELAY
The fuel pump relay is mounted behind the driver
side kick panel/dead pedal (driver side left foot rest).
See illustration in "On-Vehicle Service."
Some failures of this system will result in an

"Engine Cranks But Won't Run Symptom." If this
condition exists, see CHART A-3. This chart will
determine if the problem is caused by the ignition
system, PCM, or fuel pump circuit. If it's determined
to be a fuel problem, CHART A-7 will be used. This
includes the injectors, pressure regulator, fuel pump,
and fuel pump relay.
If a problem occurs in the fuel metering system, it
usually results in either a r.ich or lean 028 signal.
This condition is sensed by the 028 and causes the
PCM to change the fuel calculation (injector pulse
width). The change made to the fuel calculation is
indicated by a change in the short and long term fuel
trim values which can be monitored with a scan tool.
A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a
prolonged change is indicated by the long term fuel
trim value. Average fuel trim values will be around
128, but will vary slightly from engine to engine .
rn
Important
When using a scan tool to observe fuel trim values

remember that if the system is in control, 11-0 actio~
is required unless a driveability symptom is
present.
Listed below are examples of lean and rich 028

signals with the system in control and out of control:
A momentary lean 028 signal (system is in
control) will appear on the scan tool as:
Short term fuel trim value above 128
(adding fuel).
Long term fuel trim value around 128.
A prolonged lean 02S signal (system is in
Short term fuel trim value around 128.
Long term fuel trim value above 128
(added fuel).
A prolonged lean 028 signal (system is out of
Short term fuel trim value well above 128
(adding fuel).
Long term fuel trim value well above 128
(added fuel).
If both the short and long term fuel trim values are
fixed well above 128, see OTC 44 for items which can
cause a lean 028 signal.
A momentary rich 028 signal (system is in
Short term fuel trim value less than 128
(reducing fuel).
6E3-C2-6 3.4L (1:.32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

3.
Driver side kick panel/dead pedal (driver side left

foot rest).
4. Fuel pump relay from electrical connector.

1. Fuel pump relay.
2. Driver side kick panel/dead pedal (driver side left
foot rest).
3. Ignition "OFF."
PORT FUEL INJECTION COMPONENTS

CAUTION:
To reduce the risk of fire and
personal injury, relieve the fuel system
pressure before servicing fuel system
components. .
After relieving system pressure, a
small amount of fuel may be released
when servicing fuel lines or
connections. To reduce the chance of
personal injury, cover fuel line fittings
with a shop towel before disconnecting, to catch any fuel that may
leak out. Place the towel in an
approved container when disconnect
is completed.
LEfT DOOR JAM(" A" PILLAR)

2
DEAD PEDAL BRACKET
FUELPUMPRELAY
NS 15279
Figure C26 Fuel Pump Relay
A prolonged rich 028 signal (system is in control)

will appear on the scan tool as:
Long term fuel trim value less than 128
(reduced fuel).
A prolonged rich 028 signal (system is out of
Short term fuel trim value much less than 128
(reducing fuel).
Long term fuel trim value much less than 128
(reduced fuel).
If both the short and long term fuel trim values are
fixed well below 128, see DTC 45 for items which can
cause the system to run rich. If a driveability
symptom exists, refer to the particular symptom in the
"Symptoms," Section "6E3-B" for additional items to
check.
ON-VEHICLE SERVICE
FUEL PUMP RELAY
Figure C2-6
FUEL PRESSURE RELIEF PROCEDURE

Tool Required:
J 34730-1, Fuel Pressure Gage
1.
2.
3.
4.
5.
6.
Ignition "OFF."
Disconnect negative battery cable to avoid possible
fuel discharge if an accidental attempt is made to
start the engine.
Loosen fuel filler cap to relieve tank vapor
pressure.
Connect gage J 34730-1 or equivalent to fuel
pressure valve. Wrap a shop towel around fitting
while connecting gage to avoid spillage.
Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel
connections are now safe for servicing.
Drain any fuel remaining in gage into an approved
container.
Engine Fuel Pipes

Figure C2-7

side kick panel/dead pedal (driver side left foot rest).
Tools Required:
J 37088-A, Fuel Line Release Tool Set
1. Ignition "OFF."
2. Negative batteryeable.
2.
1.
Ignition "OFF."

3.
Relieve fuel system pressure. (Refer to "Fuel

Pressure Relief Procedure.")
4. Quick-connect fittings at engine fuel pipes.
5. Slide rubber ust covers rom qu1c -connec
fittings at engine fuel pipes.
6. Grasp both sides of fitting. Twist female connector
t turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn

when using compressed air, as flying dirt
8. Choose correct tool from J 37088-A or J 39504 tool
set for size of fitting. Insert tool into female
connector, the~ push/pull inward to release
locking tabs.
9. Pull connection apart.
&!] ILii'I Clean and Inspect

NOTICE: If it is necessary to remove rust or burrs
from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring
sealing surface.
Using a clean shop towel, wipe off male pipe
end.
Inspect both ends of fitting for dirt and burrs.
Clean or replace components/assemblies as
required.
Engine fuel pipe retaining bolts.
Accelerator cable from routing clip.
Fuel tube retainer from fuel rail.
Engine fuel pipes.
0-rings from fuel rail and discard.
10.
11.
12.
13.
14.
BOLT
EVAPORATIVE EMISSION CANISTER PURGE
SOLENOID VALVE
.
INTAKE PLENUM
BRACE
FUEL RAIL ASSEMBLY
NS 15929
Figure C2-7 Engine Fuel Pipes

I
1~t---2
t---3
I
l.. +I Install or Connect
Lubricate new 0-rings with clean engine oil and

install in fuel rail.
2. Engine fuel pipes to fuel rai1.
3. Fuel tube retainer and retainer screw.
Finger tighten only.
4. Engine fuel pipe retaining bolts.
1.
l~I Tighten
Fuel tube retainer screw to 5 Nm (45 lb. in.).
5. Quick-connect fittings to engine fuel pipes.
6. Apply a few drops of clean engine oil to the male
pipe end of engine fuel pipe, pressure gage adapter
or fuel line shutoff adapter.
7. Push both sides of fitting together to cause the
retaining tabs/fingers to snap into place.
8. Once installed, pull on both sides of fitting to make
sure connection is secure.
INJECTOR WIRING HARNESS

2
NUT
BOLT
FUEL RAIL
INTAKE PLENUM
STUD
Figure C28 Fuel Rail Removal
NS 15924
RETAINER- FUEL TUBE
INJECTOR ASSEMBLY - MFI FUEL
SCREW - FUEL TUBE RETAINER ATTACHING
BACKUP - 0-RING
0-RING - FUEL INLET TUBE
10
0-RING - LOWER INJECTOR (BROWN)
0-RING - FUEL OUTLET TUBE
11
SEAL - FUEL PRESSURE CONNECTION
RAIL ASSEMBLY - MFI FUEL
12
CONNECTION ASSEMBLY - FUEL PRESSURE
0-RING - UPPER INJECTOR (BLACK)
13
CAP - FUEL PRESSURE CONNECTION
CLIP- FUEL INJECTOR RETAINER
10-27-92
NA 0197-XV
Figure C2-9 - Fuel Rail Assembly

9. Slide dust covers over quick-connect fittings.
10. Accelerator cable into routing clip.
11. Tighten fuel filler cap.
Ill 1
ll'l'I Inspect
Turn ignition switch to the "ON" position for two

seconds, then turn to the "OFF" position for ten
seconds. Again turn to the "ON" position and
check for leaks.
FUEL RAIL ASSEMBLY

Figures C2-8 through C2-10
IDENTIFICATION NUMBER
The names of component parts appear rn the

numbered list on the disassembled view.
An eight digit identification number is stamped on
the side of the fuel rail. Refer to this number if
servicing or part replacement is required.
I I 1111 I I
'--v-'
'-y---'
IE-
SOURCECODE
SHIFT IDENTIFICATION
ASSEMBLY PLANT CODE
NOTICE:
YEAR
Use care in removing the fuel rail assembly, to

prevent damage to the injector electrical connector
terminals and the injector spray tips. When
removed, support the rail to avoid damaging its
components.
Prevent dirt and other contaminants from
entering open lines and passages. Fittings should
be capped, and holes plugged, during servicing.
DAY OF YEAR
NOT ALL PRODUCTION INFORMATION MAY .BE SHOWN
NA 1319-AS
Figure C2-10 - Fuel Rail Assembly Identification
brown 0-ring in the lower position on

the injector. The 0-rings are the same
size but, are made of different materials.
~ Clean
ll'l'I Inspect
Before removal, the fuel rail assembly may be

cleaned with a spray type engine cleaner following
package instructions. Do Not immerse fuel rail in
liquid cleaning solvent.

1.
2.
3.
4.
5.
6.
7.
8.
Ignition "OFF."
Engine fuel pipes. (Refer to "Engine Fuel Pipes.")
Vacuum line harness from fuel rail.
Main electrical harness connector at fuel rail.
Fuel rail attaching bolts.
Fuel rail assembly.
!++I Install or Connect

CAUTION: To reduce the risk of fire and
personal injury that may result from a
fuel leak, always install injector 0-rings in
the proper position. If the upper and
lower 0-rings are different colors (black
and brown), be sure to install the black
0-ring in the upper position and the
1.
2.
The fuel injector lower 0-ring uses a nylon

collar, called the 0-ring backup, to properly
position the 0-ring on the injector. Be sure to
.reinstall the 0-ring backup, or the sealing 0ring may move on the injector when installing
the fuel rail and result in a possible vacuum
leak and driveability complaints will occur.
Fuel rail assembly in intake manifold.

Tilt rail assembly to install injectors.
l~I Tighten
Fuel rail attaching bolts to 25 N m (18 lb. ft.).
Engine fuel pipes to fuel rail.
Engine fuel pipes. (Refer to "Engine Fuel Pipes.")
Main electrical harness connector at fuel rail.
Rotate injector(s) as required to avoid
stretching wire harness.
6. Vacuum line harness connector from fuel rail.
8. Ignition "OFF."
3.
4.
5.
!LI Inspect

check for leaks.
._. ,
n
---~2
FUEL PRESSURE CONNECTION

Figure C2-9
. __ .....LOCK.
..
'
Clean
-:. :~< __ _5 -;ELEASE
Area around fuel pressure connection with GM

X-30A or equivalent.
INJECTOR ASSEMBLY - Mfl FUEL

CLIP - INJECTOR RETAINER
1.
2.
3.
Figure C2-11 MFI Fuel Injector
4.
9P 1063-AS
Ignition "OFF."
Fuel pressure connection and seal.

1. New seal on fuel pressure connection.
2. Fuel pressure connection in fuel rail.
l~I Tighten
3.
4.
5.
Fuel pressure connection to 13 Nm (115 lb.

in.).
Ignition "OFF."
..
!LI Inspect

check for leaks.
INJECTOR ASSEMBLY - FUEL
FUEL INJECTORS
Figures C2-9, C2-11 and C2-12
NOTICE:
Use care in removing injectors to

prevent damage to the electrical connector pins on
the injector, and the nozzle. The fuel injector is
serviced as a complete assembly only. Since it is
an electrical component, Do Not immerse it in
cleaner.

1.
2.
3.
4.
Ignition "OFF."
Pressure Re lief Procedure.")
Fuel rail assembly. (Refer to "Fuel Rail
Assembly.")
PART NUMBER IDENTIFICATION
BUILD DATE CODE
MONTH 1-9 (JAN-SEPT) 0, N, D (OCT, NOV, DEC)
DAY
YEAR
MP 1222-AS
Figure C2-12 - Injector Part Number Location
!+t+! Disassemble
1.
2.
3.
4.
Rotate injector retainer clip to release position.

Fuel injector.
Injector 0-ring seals from both ends of injector,
and discard.
Discard injector retainer clip.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3"'C2-11
[I] Important
When ordering new fuel injectors. be sure to order

the correct injector for the application being
serviced.
!+*+I Assemble
personal injury that m~~ result f!om. a
fuel leak, always install mJector 0-rmgs m
the proper position. If the upper and
lower 0-rings are different colors (black
and brown), be sure to install the black
0-ring in the upper position ~r:td the
brown 0-ring in the lower pos1t1on on
the injector. The 0-ri_ngs are the ~ame
size but, are made of different materials.

Figures C2-13 through C2-15
The throttle body assembly r epah procedm es
cover component replacement with the unit on the
vehicle. However, throttle body replacement requires
that the complete unit be removed from the engine.
An eight digit part identification number is
stamped on the side of the throttle body casting. Refer
to this number if servicing, or part replacement is
required. For identification of parts during repair,
refer to the disassembled view.
NOTICE: The TP sensor and IAC valve should

NOT come in contact with solvent or cleaner, as
they may be damaged.
!LI Inspect
1.
2.
3.
4.
The fuel injector lower 0-ring uses a nylon collar,

called the 0-ring backup, to properly position the
0-ring on the injector. Be sure to reinstall the
0-ring backup, or the sealing 0-ring may move on
the injector when installing the fuel rail and result
in a possible vacuum leak and driveability
complaints will occur.
Lubricate new injector 0-ring seals with clean
engine oil, and install on injector.
New retainer clip onto injector.
Fuel injector into fuel rail injector socket with
electrical connectors facing outward.
Rotate injector retainer clip to lock position.

1. Fuel rail assembly.
2. Tighten fuelfiller cap.
3. Ignition "OFF."
!L'l'I Inspect
l++I, Remove or Disconnect

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

check for leaks.
PRESSURE REGULATOR ASSEMBLY
[I] Important
The pressure regulator and fuel rail are serviced as

a complete assembly only. Do not attempt to
remove the regulator cover from the fuel rail.
Clean
The throttle bore and valve deposits may be

cleaned on-vehicle, using carburetor cleaner and a
parts cleaning brush. Do Not use a cleaner that
contains methyl ethyl ketone, an extremely strong
solvent, and not necessary forthis type of deposit.
The throttle body metal parts may be cleaned
following disassembly, in a cold immersion-type
cleaner such as GM X-55 or equivalent.
Ignition "OFF."
Partially drain radiator, to allow coolant hoses at
throttle body to be removed.
Air inlet duct at throttle body, and crankcase vent
pipe at valve cover grommet.
TP sensor and IAC valve electrical connectors.
Vacuum harness connector from throttle body.
Throttle, T.V. (transmission control), and cruise
control cables.
Coolant hoses from throttle body.
Throttle body attaching bolts.
Throttle body assembly and flange gasket.
Discard gasket.
NOTICE:
Use care in cleaning old gasket

material from machined aluminum surfaces.
Sharp tools may damage sealing surfaces.
~ Clean
Gasket surface on intake manifold.
!++! Install or Connect

1. Throttle body assembly with new flange gasket.
2. Throttle body attaching bolts.
6E3-C2-12 3.4L (L32) (VIN S) (SFI) DRIVEABJLITY AND EMISSIONS

Refer to SECTION 6C, for additional
information on accelerator controls.
5.
6.
7.
Vacuum harness connector.

TP sensor and IAC valve electrical connectors.
Air inlet duct to throttle body, and crankcase vent
pipe to valve cover grommet.
8. Refill radiator.
9. Ignition "OFF."
IL'l'I Inspect
NA 1322-AS
Figure C2-13 - Throttle Body Identification
With the engine "OFF," check to see that the

accelerator pedal is free:
Depress pedal to the floor and release.
Figt1re Cl-15

1.
2.
3.
4.
TP sensor attaching screws.
TP sensor.
'
TP sensor static seal.
NOTICE: 'l'he TP sensor is an electrical

component and must not be soaked in any liquid
cleaner or solvent, as damage may result.

1.
2.
TP sensor static seal.

With throttle valve closed, position TP sensor on
throttle shaft, then align with screw holes.
3. TP sensor attaching screws.
l~I Tighten
STUD
2
GASKET
INTAKE PLENUM
THROTTLE BODY
BOLT
4.
TP sensor attaching screws to 2.0 Nm (18 lb.

in.).
IDLE AIR CONTROL (IAC) VALVE
Figures Cl-15 and Cl-16

NS 15925
Figure C2-14 - Throttle Body Removal
l~I Tighten
3.
4.
Throttle body attaching bolts to 27 Nm (20

lb. ft.).
Coolant hoses to throttle body.
Throttle, T.V., and cruise control cables.
rn
Important
Make sure throttle and cruise control linkage

does not hold throttle open.

1.
2.
3.
IAC valve attaching screws.
IAC valve assembly.
NOTICE: On IAC valves that have been in

service: Do Not push or pull on the IAC valve
pintle. The force required to move the pintle may
damage the threads on the worm drive. Also, Do
Not soak IAC valve in any liquid cleaner or
solvent, as damage may result.
BODY ASSEMBLY -THROTTLE

2
SEAL STATIC
SCREW-TP SENSOR ATTACHING
SCREW- IAC VALVE ATTACHING
0-RING- IAC VALVE
6-25-93
NA0198-XV
6E3-C2-14 3.4L (L32) (VIN S) {SFI) DRIVEABILITY AND EMISSIONS

4.
5.
Reset IAC valve pintle position:
A. Turn ignition "ON" for five seconds.
B. Turn ignition "OFF" for ten seconds.
C. Start engine and check for proper idle
operation.
THROTTLE BODY REPLACEMENT

A
DISTANCE OF PINTLE EXTENSION
DIAMETER OF PINTLE
IACV 0-RING
IACV ATTACHING SCREW ASSEMBLY

75 3422-6E
Figure C2-16 - Idle Air Control (IAC) Valve
Clean IAC valve 0-ring sealing surface, pintle

valve seat and air passage.
Use carburetor cleaner and a parts cleaning
brush to remove carbon deposits. Do Not use a
cleaner that contains methyl ethyl ketone, an
extremely strong solvent, and not necessary
for this type of deposit.
Shiny spots on the pintle or seat are normal,
and do not indicate misalignment or a bent
pintle shaft.
If air passage has heavy deposits, remove
throttle body for complete cleaning.
Inspect IAC valve 0-ring for cuts, cracks or
distortion. Replace if damaged.
rn
llI Clean and Inspect
Important
If installing a new IAC valve, be sure to replace

with an identical part. IAC valve pintle shape and
diameter are designed for the specific application.
l@I Measure (If Installing a New IAC Valve)
Distance between tip of IAC valve pintle and

mounting flange.
If greater than 28 mm, use finger pressure to
slowly retract the pintle. The force required to
retract the pintle of a new valve will not cause
damage to the valve.

1.
2.
3.
Lubricate IAC valve 0-ring with clean engine oil.

IAC valve assembly.
Attaching screws.
l~I Tighten
IAC valve attaching screws to 3.4 Nm (30 lb.

in.).
Throttle body from intake plenum.

"Throttle Body Assembly.")
IL!
(Refer to
Inspect
Replacement throttle body for items to be

transferred from old unit.
l+:+I Disassemble
Throttle body removed from engine, following

component repair procedures.
l+*+I Assemble.
Replacement throttle body with transferred parts,

following component repair procedures.
Replacement throttle body to intake plenum.

(Refer to "Throttle Body Assembly.")
TORQUE SPECIFICATIONS
Fuel Tube Retainer screw
Fuel Rail Attaching
Bolts
Fuel Pressure Connection
Throttle Body Attaching
Bolts
Throttle Position (TP)
Sensor
Idle Air Control Valve
5 Nm (45 lb. in.)
25 N m (18 lb. ft.)

13 Nm (115 lb. in.)
27 N m (20 lb. ft.)
2 N m (18 lb. in.)

3.4 Nm (30 lb. in.)
BLANK
J 39200 DVM
I 1
c:::J i::::i t::J t::J
FUEL INJECTOR
TESTER
+ if\.:-4---"'11'--......~ - -
LOW VEHICLE BATTERY
READY TO TEST
TEST IN PROGRESS
mV
fl'*'
J 39200
DIGIT AL VOLT
METER(DVM)
V-DC(9ml
V-AC
AMPERAGE SUPPLY SELECTOR SWITCH

Coil Test
4amp
c::J CJ CJ
OFF
Balance Test
4amp
2.5 amp
0.5-2.5
amp
0.5 amp
POS
NEG
PUSH TO START TEST
FUEL INJECTOR
TESTER J 39021
VEHICLE BATTERY
CHARTC-2A
(Page 1 of 3)
INJECTOR COIL TEST PROCEDURE

Chart Test Description: Number(s) below refer
to circled number(s) on the diagnostic chart.
1. This is the set-up step for performing the injector
coil test. Also read instructions included with
tools used for test.
2. Engine coolant temperature affects the tool's
ability to detect a faulty injector. If engine
coolant temperature is NOT between 50F and
95F the comparison chart (Page 2 of 3) must be
used.
3. The first second of the voltage reading may be
inaccurate due to initial current surge, therefore,
record the lowest voltage displayed after the first
second of test. The voltage reading should be
within range (see example). The voltage reading
' as the injector
may increase throughout the test
windings warm and the resistance changes. An
erratic voltage reading (one that jumps up and
down) indicates an intermittent connection
within the fuel injector.
4. To check the mechanical (fuel delivery) portion of
the fuel injector, perform an injector balance test.
Resistance
Ohms
Voltage Spec.
at so- 95 F
118-12.6
5.7-6.6
lnj#
2
Reading
Pass/Fail
6.3
5.9
6.2
6.1
p
p
3
4
P
r------------------------,
I
5
4.8
f
I
L------------------------~
6
6.0
P
EXAMPLE
520-93
PS17395
CHARTC-2A
ENGINE "OFF."
RELIEVE FUEL PRESSURE. (REFER TO "FUEL PRESSURE RELIEF" IN THIS
SECTION.)
ACCESS INJECTORS AS REQUIRED (REFER TO "ON-VEHICLE SERVICE" IN
THIS SECTION.)
CONNECT FUEL INJECTOR TESTER J 39021 TO VEHICLE BATTERY.
SET AMPERAGE SUPPLY SELECTOR SWITCH TO THE "COIL TEST" 0.5 AMP
POSITION.
CONNECT LEADS FROM THE J 39200 DIGITAL VOLT METER (DVM) TO THE
FUEL INJECTOR TESTER.
SET DVM TO THE TENTHS SCALE (0.0).
CHECK ENGINE COOLANT TEMPERATURE.
IS IT BETWEEN 50 AND 95 F?
CONNECT TESTER TO AN INJECTOR.

PRESS THE "PUSH TO START TEST" BUTTON AND OBSERVE DVM.
VOLTAGE MAY CLIMB DURING TEST. WATCH FOR ERRATIC
READING (VOLTAGE JUMPS UP AND DOWN).
RECORD LOWEST VOLTAGE DISPLAYED AFTER FIRST SECOND OF
READING.
REPEAT FOR EACH INJECTOR.
DOES ANY INJECTOR VOLTAGE READING FALL OUTSIDE
5.7-6.6VOLTS, ORDO ANY HAVE ERRATIC VOLTAGE READINGS?
PROCEED TO "CHART C-2A

(PAGE 2 OF 3)".
REPLACE FAULTY INJECTORS.
PERFORM "INJECTOR BALANCE TEST (PAGE 3 OF 3)".
3-24-93
PS 17396
J 39200 DVM
11 111111111
FUEL INJECTOR
- TESTER +
SJ i::::::i E:::I &:rJ
G:llr--J--'l'--___.T---
LOW VEHICLE BA TfERY
READY TO TEST
TEST IN PROGRESS
mvfl....,.
J 39200
V-DCs~A
V-AC
AMPER.l\GE SUPPLY SELECTOR SWITCH

Coil Test
ts i::::J i:::lJ
OFF.
DIGIT AL VOLT
METER(DVM)
Balance Test
4amp
4amp
2.5 amp
0.5 amp
0.5-2.5
amp
+
POS
NEG
PUSH TO START TEST
FUEL INJECTOR
TESTERJ 39021
VEHICLE BATTERY
CHARTC-2A
(Page 2 of 3)

11 11
3.4L (VIN S) F CARLINE (SFI)
second of test. The voltage reading may increase
throughout the test as the injector windings
warm and the resistance changes. An erratic
voltage reading (one that jumps up and down)
indicates an intermittent connection within the
fuel injector.
2. From recorded voltages (see example), identify
the highest voltage reading recorded (other than
those above 9.5 volts). Subtract all other voltages
from the highest voltage recorded. The
subtracted value for any injector must not exceed
0.6 volt.
.--~~~~~~~~~~--.--------,
Highest Voltage Reading
: 7.1 Volts :
.i--~~-,-~~~~~~~-;-,-------1
Acceptable Subtracted Value : 0.6 Volt :

Above/Below 50-95F.
:
:
'--~~~~~~~~~~~--------J
lnj.
No.
Voltage
Reading
Subtracted
Value
Pass/Fail
~ 1
9.8
F ;
~-------------------------------J
2
6.6
0.5
P
3
6.9
0.2
P
~ 4
5.8
1.3
F ;
L-------------------------------J
p
7.0
5
0.1
p
0.0
6
EXAMPLE
5-20-93
PS17397
CHARTC-2A
3.4L (VIN S) ''F'' CARLINE (SFI)
r----------------------,
: FROM "CHART C-2A (PAGE 1 OF 3)" :
L-
CD
--------------------~

PRESS "PUSH TO START TEST" BUTTON AND OBSERVE DVM.
RECORD LOWEST VOLTAGE DISPLAYED AFTER THE FIRST
SECOND OF READING.
DOES ANY INJECTOR HAVE AN ERRATIC READING OR A
READING ABOVE 9.5 VOLTS?
DISREGARD INJECTOR(S) WITH VOLTAGE

READING ABOVE 9.5 VOLTS OR ERRATIC
READINGS (JUMPS UP ANO DOWN) FROM
CALCl)LA TIONS. THESE INJECTORS ARE
FAULTY AND MUST BE REPLACED.
FROM RECORDED VOLTAGl:S, IDENTIFY THE HIGHEST VOLTAGE

READING RECORDED {OTHER THAN THOSE ABOVE 9.5 VOLTS).
SUBTRACT All OTHER VOLTAGES FROM THE HIGHEST VOLTAGE
RECORDED.
DOES ANY SUBTRACTED VALUE EXCEED 0.6 VOLTS?
REPLACE ANY INJECTOR:

WHOSE SUBTRACTED VALUE HAS EXCEEDED 0.6 VOLTS.
WHOSE INITIAL READING WAS ABOVE 9.5 VOLTS.
THAT HAD AN ERRATIC READING.
PERFORM "INJECTOR BALANCE

TEST (PAGE 3 OF 3)".
3-24-93
PS 17398
6E3-C2-20 3.4L (L32) (VIN.S) (SFI) DRIVEABILITY AND EMISSIONS
(INITIAL PRESSURE)
..,
,
I
r, ,..... ,
FUEL INJECTOR
TESTER
+t)
LOW VEHICLE BATTERY
TEST IN PROGRESS

Coil Test
I ~I
4amp
2.5 amp
Balance Test
~ ~
0.5 amp
INJECTOR
CON NECTOR
2ND
READY TO TEST
4amp
0.52.5
amp
II
11
NEG
POS
PUSH TO START TEST
READING
(PRESSURE AFTER DROP)
FUEL INJECTOR
TESTERJ 39021
VEHICLE BATTERY
EXAMPLE
CYLINDER
1sT Reading
296 kPa
(43 psi)
296 kPa
(43 psi)
296kPa
(43psi)
. 296 kPa
(43 psi)
296 kPa 296 kPa

{43 psi) (43 psi)
2NDReading
131 kPa
(19 psi)
117 kPa
(17 psi)
124 kPa
(18 psi}
145 kPa
(21 psi)
131 kPa 130 kPa

(19 psi) (19psi}
Amount of Drop
165 kPa
(24 psi)
179 kPa
(26 psi}
172 kPa
(25 psi)
151 kPa
(22 psi)
165 kPa 166 kPa

(24 psi} (24 psi}
OK
FAULTY.RICH
(TOO MUCH
FUEL DROP)
OK
fAUL TY, LEAN

(TOO LITTLE FUEL
DROP)
166 kPa/24 psi ave.

10 kPa/1.5 ~si
156 kPa to 176 Pa
22.5 psi to 25.5 psi
OK
OK
CHARTC-2A
(Page 3 of 3)
INJECTOR BALANCE TEST PROCEDURE

1. Engine cool down period (10 minutes) is
necessary to avoid irregular fuel pressure
readings due to "Hot Soak" fuel boiling.
2. Energize tester one time and record pressure drop
at the lowest point (Disregard any slight pressure
variations).
3. If the pressure drop of all injectors is within 10
kPa (1.5 psi) of the average fuel pressure drop, the
injectors are flowing properly. The actual
amount of pressure drop is calculated by
subtracting the second pressure reading from the
first pressure reading.
ENGINE
FUEL PRESSURE
RANGE
All engines EXCEPT

5.7L (VIN J) Corvette
3.1 L (VIN W) Lumina VFV
284-325 kPa
(41-47 psi)

3.1 L (VIN W) Lumina VFV
333-376 kPa
(48-55 psi)
5-25-93
PS 17399
CHARTC-2A
'
..,

11
CAUTION: TO REDUCE THE RISK OF FIRE AND
PERSONAL INJURY, WRAP ASHOP TOWEL AROUND
THE FUEL PRESSURE CONNECTION TO ABSORB ANY
FUEL LEAKAGE THAT MAY OCCUR WHEN
INSTALLING THE PRESSURE GAGE. PLACE TOWEL IN
APPROVED CONTAINER.
NOTICE: The entire test should NOT be repeated more .than
once without running the engine to prevent flooding. (This
includes any retest on faulty injectors.)
rn
Important
The injector coil test should be performed prior to this test.

Refer to Page 1 of 3.
0).
If ENGINE IS AT OPERATING TEMPERATURE, ALLOW A 10 MINUTE "COOL DOWN" PERIOD.

IGNITION "OFF."
CONNECT FUEL PRESSURE GAGE .
ENERGIZE FUEL PUMP USING AVAILABLE METHOD FOR VEHICLE (FUEL PUMP TEST CONNECTOR OR TECH 1 SCAN
TOOL ENABLE).
PLACE OPEN END OF BLEED HOSE INTO AN APPROVED GASOLINE CONTAINER ANO BLEED AIR FROM FUEL GAGE .
WITH FUEL PUMP RUNNING NOTE FUEL PRESSURE, PRESSURE SHOULD BE WITHIN SPECIFIED RANGE SHOWN ON
FACING PAGE. IF NOT, REFER TO CHART A-7.
TURN FUEL PUMP "Off." WHEN PUMP STOPS, PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY. IF
NOT, REFER TO CHART A-7
I
CONNECT FUEL INJECTOR TESTER TO AN INJECTOR.
SET AMPERAGE SUPPLY SELECTOR SWITCH TO THE "BALANCE TEST" 0.5 - 2.5 AMP POSITION.
CYCLE FUEL PUMP "ON"/"OFF"TO PRESSURIZE FUEL SYSTEM.
RECORD STABILIZED FUEL PRESSURE (1 ST PRESSURE READING SEE EXAMPLE ON FACING PAGE)
ENERGIZE FUEL INJECTOR BY DEPRESSING "PUSH TO START TEST" BUTTON.
NOTE FUEL PRESSURE THE INSTANT THE FUEL PRESSURE GAGE NEEDLE STOPS. RECORD FUEL PRESSURE READING
(2ND PRESSURE READING - SEE EXAMPLE ON FACING PAGE).
REPEAT STEP 2 ON ALL INJECTORS.

SUBTRACT 2ND PRESSURE READING FROM 1ST PRESSURE READING TO OBTAIN PRESSURE DROP VALUES .
ADD ALL PRESSURE DROP VALUES AND DIVIDE BY THE NUMBER OF FUEL INJECTORS TO GET THE AVERAGE
PRESSURE DROP.
ANY INJECTOR THAT HAS A 10 kPa (1.5 PSI) DIFFERENCE, EITHER MORE OR LESS FROM THE AVERAGE, IS
CONSIDERED FAULTY.
RETEST ANY INJECTOR THAT APPEARS FAULTY .
ANY INJECTOR THAT FAILS THE RETEST IS FAULTY AND NEEDS TO BE REPLACED .
IF NO PROBLEM IS FOUND, REVIEW "SYMPTOMS" SECTION "B" .
3-24-93
PS 17400
PCM
- - - - - - - - - 1748 LT BLU/BLK
IAC COIL "A" HIGH

IAC COIL "A LOW
1749LTGRN/WHT
IAC COIL "B" HIGH
1---------- 444 LTGRN/BLK
IAC COIL "B LOW
- - - - - - - - 1747LTBLU/WHT
:::~~J~
6-16-93
NS 15616
CHARTC-28
IDLE AIR CONTROL (IAC) CIRCUIT
The PCM controls engine idle speed with the IAC valve. To increase idle speed, the PCM retracts the IAC
valve pintle away from its seat, allowing more air to bypass the throttle bore. To decrease idle speed, it extends
the IAC valve pintle towards its seat, reducing bypass air flow. A Tech 1 scan tool will read the PCM commands
to the IAC valve in counts. Higher counts indicate more air bypass (higher idle). The lower the counts indicates
less air is allowed to bypass (lower idle).
System too lean (high air/fuel ratio). - The idle
speed may be too high or too low. Engine speed
may vary up and down and disconnecting the
1. The Tech 1 RPM control mode is used to extend
IAC valve does not help. OTC 44/64 may be
and retract the IAC valve. The valve should move
set. Tech 1 scan tool 028 voltage will be less
smoothly within the specified range. If the idle
than 300 mV (.3 volt). Check for low regulated
speed is commanded (IAC extended) too low (below
fuel pressure, water in the fuel or a restricted
700 RPM), the engine may stall. This may be
normal and would ;not indicate a problem.
injector.
System too rich (low air/fuel ratio). - The idle
Retracting the IAC beyond its controlled range
speed will be too low. Tech 1 scan tool IAC
(above 1500 RPM) will cause a delay before the
counts will usually be above 80. System is
RPM's start dropping. This too is normal.
2. This test uses the Tech 1 to command the IAC
obviously rich and may exhibit black smoke in
exhaust.
controlled idle speed. The PCM issues commands
Tech 1 scan tool 028 voltage will be fixed
to obtain commanded idle speed. The node lights
above 800 m V (.8 volt).
each should flash red and green to indicate a good
Check for high fuel pressure, leaking or
circuit as the PCM issues commands. While the
sticking injector. Silicone contaminated
sequence of color is not important if either light is
oxygen sensors Tech 1 scan tool voltage will be
"OFF" or does not flash red and green, check the
circuits for faults, beginning with poor terminal
slow to respond.
Throttle
body. - Remove IAC valve and inspect
contacts.
bore for foreign material.
IAC valve electrical connections. - IAC valve
Diagnostic Aids: A slow, unstable, or fast idle may
should be carefully checked for
connections
be caused by a non-IAC system problem that cannot be
proper
contact.
overcome by the IAC valve. Out of control range IAC
Crankcase ventilation valve. - An incorrect or
Tech 1 scan tool counts will be above 60 if idle is too
faulty
valve may result in an incorrect idle
low, and zero counts if idle is too high. The following
speed.
checks should be made to repair a non-IAC system
Refer to "Rough, Unstable, Incorrect Idle or
problem:
Stalling"
in "Symptoms," Section "6E3-B".
Vacuum leak (high idle). - If idle is too high,
If
intermittent
poor driveability or idle
stop the engine. Fully extend (low) IAC with
symptoms
are
resolved
by disconnecting the
tester. Start engine. If idle speed is above 800
IAC,
carefully
recheck
connections, valve
RPM, locate and correct vacuum leak
terminal
resistance,
or
replace
IAC.
including crankcase ventilation system. Also
check for binding of throttle blade or linkage.
CHART C-28
'2' ,
\.V
INSTALL TECH 1 SCAN TOOL,

IN PARK/NEUTRAL WITH PARKING BRAKE SET.
A/C "OFF."
SELECT RPM CONTROL. (MISC. TESTS)
CYCLE IAC THROUGH ITS RANGE FROM 700 RPM
UP TO 1500 RPM.
RPM SHOULD CHANGE SMOOTHLY.
DOESIT?
INSTALL IAC NODE LIGHT* IN IAC HARNESS.

ENGINE RUNNING. CYCLE IAC WITH TECH 1 SCAN TOOL.
EACH NODE LIGHT SHOULD CYCLE RED AND GREEN BUT
NEVER "OFF."
DO THEY?
If CIRCUIT(S) DID NOT TEST RED AND

GREEN, CHECK FOR:
FAULTY CONNECTOR TERMINAL
CONTACTS.
OPEN CIRCUITS INCLUDING
CONNECTORS.
CIRCUITS SHORTED TO GROUND OR
VOLTAGE.
FAULTY PCM CONNECTIONS OR
REPLACE PCM.
CHECKIAC
CONNECTIONS.
CHECKIAC
PASSAGES.
IF OK, REPLACE IAC.
USING THE IAC DRIVER* OR OTHER

CONVENIENT CONNECTOR, CHECK
RESISTANCE ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN
IAC TERMINALS" A" TO "B" AND "C"
TO"D".
CHECK RESISTANCE BETWEEN IAC

TERMINALS "B" AND "C" AND
"A" AND"D".
SHOULD BE INFINITE.
IDLE AIR CONTROL CIRCUIT OK.

REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
REPLACE IAC
VALVE AND
RETEST.
REPLACE IAC
VALVE AND
RETEST.
* IAC DRIVER AND NODE LIGHT REQUIRED KIT

J 37027 FROM: KENT-MOORE, INC.
CLEAR DIAGNOSTIC TROUBLE CODES, CONFIRM "CLOSED LOOP"

OPERATION, NO MALFUNCTION INDICATOR LAMP(MIL) "SERVICE
ENGINE SOON." PERFORM IAC RESET PROCEDURE PER APPLICABLE
SERVICE MANUAL AND VERIFY CONTROLLED IDLE SPEED IS CORRECT.
7-12-93
PS 18788
BLANK
SECTION C3
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

CONTENTS
General Description
Purpose
EVAP Canister
Evaporative Emission System
Evaporative Emission (EVAP) Pressure
Control Valve
Results of Incorrect Operation

Diagnosis
Evaporative Emission (EVAP) Canister
Purge Solenoid Valve
(3-1
(3-1
(3-1
(3-1
(3-1
(3-2
(3-2
Visual Check of EVAP Canister

Functional Tests
Control Valve
On-Vehicle Service
EVAP Canister
EVAP Canister Purge Solenoid Valve
EVAP Canister Hoses
C3-2
C3-2
C3-2
C3-2
C3-2
C3-2
C3-3
C3-3
(3-2
GENERAL DESCRIPTION
PURPOSE
The Evaporative Emission (EVAP) control system
used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the
fuel tank to an activated c.arbon (charcoal) storage
device (canister) to hold the vapors when the vehicle is
not operating. When the engine is running, the fuel
vapor is purged from the carbon element by intake air
flow and consumed in the normal combustion process.
EVAPCANISTER
uses a rear mounted charcoal canister to absorb fuel
vapors from the gas tank.
When gasoline vapor builds enough to overcome
the spring tension of the EVAP pressure control valve,
the vapor will flow to the canister where it is absorbed
and stored by the charcoal. Under certain operating
conditions the PCM will command the purge solenoid
valve to open. This allows the vapor to flow into the
intake manifold for combustion.
17013138
17093194
TANK TUBE
2
AIR TUBE (FRESH AIR INLET)
PURGE TUBE
NA 1349-AS
EVAPORATIVE EMISSION SYSTEM

This system has a remote mounted canister purge
control solenoid valve. The PCM operates this
solenoid valve to control vacuum to the canister.
Under cold engine or idle conditions, the solenoid
valve is closed, which prevents vacuum from being
applied to the canister.
The PCM activates (or opens) the solenoid valve
and allows purge when:
Engine is warm.
After the engine has been running a specified
period of time.
Above a specified road speed.
Figure C3-1 - Evaporative Emission Canister
Above a specified throttle opening.
EVAPORATIVE EMISSION (EVAP) PRESSURE

CONTROL VALVE
This system uses an in-line EVAP pressure control
valve for pressure relief. Refer to diagram for
installation in system. When vapor pressure in the
tank exceeds approximately 5 kPa (. 7 psi) the
diaphragm valve opens, allowing vapors to vent to the
canister.
6E3-C3-2 3.4L (L32) (VIN S} (SFI} DRIVEABILITY AND EMISSIONS

A 1.14 mm (0.045 inch) orifice in the passage leading
to the canister tube causes pressure to drop slowly,
preventing the valve from oscillating (buzzing). When
the tank pressure drops below 5 kPa (.7 psi), the valve
closes causing vapors to be held in the fuel tank.
RESULTS OF INCORRECT OPERATION
Poor idle, stalling .and poor driveability can be

caused by:
Inoperative purge solenoid valve.
Damaged canister.
Hoses split, cracked and/or not c.onnected to
the proper tubes.
Evidence of fuel loss or fuel vapor odor can be
caused by:
Liquid fuel leaking from fuel lines.
Cracked or damaged canister.
Inoperative canister control valve.
Disconnected, misrouted, kinked, deteriorated
or damaged vapor hoses, or control hoses.
If the solenoid valve is open, or is not receiving
power, the canister can purge to the intake manifold at
the incorrect time. This can ,allow extra fel during
warm-up, which can cause rough or unstable idle.
DIAGNOSIS
. EVAPORATIVE EMISSION (EVAP} CANISTER
PURGE SOLENOID VALVE
The Evaporative Emission (EV AP) canister purge
solenoid valve operation is covered irl CHART C-3 at
the end of this section.
VISUAL CHECK OF EVAP CANISTER
Cracked or damaged, replace EVAP canister.
5
4
FUNCTIONAL TESTS
Evaporative Emission (EVAP} Pressure
Control Valve
With a hand vacuum pump, apply approximately
38 cm Hg (15" Hg) to the control vacuum t~be. After
ten seconds, there should be at least 13 cm Hg (5" Hg)
vacuum remaining. Be sure the hand vacuum pump
being used does not have an internal leak and the hose
connections to control vacuum tube and pump are
secure. If after 10 seconds there is less than 13 cm (5"
Hg) vacuum, the valve,must be replaced.
With 38 cm Hg (15" Hg) vacuum still applied to the
control vacuum tube, attach a short piecE:? of hose to the
valve's tank tube side. Blow into the tube. You should
feel the air pass through the valve. If air does not pass
through, the. valve must be replaced.
ON-VEHICLE SERVICE
EVAP CANISTER
Figure (3;..3

1.
2.
3.
4.
5.

Raise vehicle.
Driver side rear wheel housing liner .
Hoses from canister.
Canister from canister bracket by releasing latch
on canister bracket.
6. Canister from vehicle.
l++l lnstal, or Connect

1. Canister to vehicle.
2. Canister to canister bracket.
3. Hoses to canister.
4. Driver side rear.wheel housing liner.
5. L9wer vehicle.
EVAP CANISTER PURGE SOLENOID VALVE

Figure C3-4
I++! Remo~e or Disconnect

2.
3.
Electrical connector and hoses from solenoid valve.

Bracket and solenoid from intake manifold.
RESTRICTION
CONTROL TUBE
DIAPHRAGM
TUBE TO CANISTER
1. Solimoid valve to intake manifold.
DIAPHRAGM SPRING
TUBETOFUELTANK
MP0436-SY
Figure C3-2 - EVAP Pressure Control Valve
[~! Tighten
Bolt to intake manifold to 10 Nm (7 lb. in.).
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3:aC3-3
FUEL TANK
- t:11,-------lVIEW A!
EVAPORATIVE'EMISSION PRESSURE CONTROL VALVE
EVAPORATIVE EMISSION CANISTER
FUEL FILLER NECK

NS 15274
Figure C3-3- EVAP Canister Mounting
2------1
I
2. Electrical connector and hoses to solenoid valve.

3
EVAP CANISTER HOSES

Refer to "Vehicle Emission Control Information"
label for routing ofEVAP canister hoses.
EVAP Canister Purge Solenoid
Valve Bolt 10 Nm (7 lb. ft.)
FUEL FEED AND RETURN PIPE ASSEMBLY

2
BOLT/SCREW
EVAPORATIVE EMISSION CANISTER PURGE

SOLENOID VALVE
NS 15646
Figure C3-4 - EVAP Canister Purge Solenoid Valve

Service
TO CRANKCASE
VENTILATION
VALVE
. [!J
.
. . ..
[I) Evaporative Emission C~nister
(I]
[il Throttle Body
Fuel Tank Vent Valve

(PressureNacuum Relief)
Remote Mounted
G]
Fuel Tank
(1)
Evaporative Emission
Pressure Control Valve
[!] Evaporative Emission

Canister
Figure C3-5- Evaporative Emissions Control System Schematic
10-8-92
NS 15846
BLANK
PCM
TO MANIFOLD
VACUUM
EVAP
CANISTER
PURGE
SOLENOID
VALVE
TO DIGITAL
EXHAUST GAS
RECIRCULATION
(EGR}VALVE
EVAP CANISTER
PURGE
CONTROL
DRIVER
- - - - - - 4 2 8 DK GRN/WHT _ __,,
10-WAY FWD LAMP
HARNESS CONNECTOR
(BLACK)
~ - 5 4 1 BRN
FUSE #6*
-----EJ....----<r--...:i
ct-----fl'"\..,..-------------~
10AMP
TO IGNITION SWITCH .....
TO COOLING
CO~~:OL
RELAY
6-17-93
NS15847
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE CHECK
EVAP canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the EVAP
canister when energized. The PCM supplies a ground to energize the solenoid valve.
If the following conditions are met with the engine running, the EVAP canister purge solenoid valve will be
energized (purge "ON").
Engine run time after start more than 1 minute.
Engine coolant temperature above 60C (140F).
Vehicle speed above 1.3 mph.
Throttle off idle, above 6%.

1. Checks to see if the solenoid valve is opened or
closed. The solenoid valve is normally closed and
should open when energized by the Tech 1.
2. This should energize the solenoid valve and allow
the vacuum to drop (purge "ON").
3.
Checks for a complete circuit. Normally, there is

ignition voltage on CKT 541 and the PCM provides
a ground on CKT 428. A shorted solenoid valve
could cause an open circuit in the PCM.
Diagnostic Aids: Normal operation of the EVAP

canister purge solenoid valve is described as follows:
With the ignition "ON," engine "OFF," the EVAP
canister purge solenoid valve should be de-energized.
CHARTC-3
SOLENOID VALVE CHECK
G).

IGNITION "ON." ENGINE STOPPED .
DISCONNECT VACUUM HOSES FROM EVAP CANISTER PURGE
SOLENOID VALVE.
AT THE SOLENOID VALVE, APPLY 34 kPa (10" Hg) OF VACUUM
TO THE MANIFOLD VACUUM SIDE OF PURGE SOLENOID
VALVE.
ABLE TO GET 34 kPa (10" Hg) OF VACUUM.
UNABLE TO GET 34 kPa (10" Hg) OF VACUUM.
WITH TECH 1 SCAN TOOL IN MISC.

OUTPUT CONTROL ENERGIZE CCP
SOLENOID.
DOES VACUUM DROP.
DISCONNECT EVAP CANISTER

PURGE SOLENOID VALVE.
BETWEEN
HARNESS CONNECTOR
TERMINALS.
ENERGIZE CCP SOLENOID IS
LIGHT"ON"?
CKT 428 .SHORTED

TO GROUND OR
FAULTY PCM.
PROBE TERMINAL "B"

AT HARNESS
CONNECTOR TERMINAL
WITH A TEST LIGHT TO
GROUND.
DISCONNECT SOLENOID VALVE.

PROBE CKT 428 WITH A TEST
LIGHTTOB+.
FAUL TY SOLENOID
VALVE.
FAUL TY SOLENOID
VALVE OR
CONNECTOR.
PROBE TERMINAL "A"

WITH TEST LIGHT TO
GROUND.
OPEN IN CKT 541.
CKT 428 SHORTS % B + .
OPEN IN CKT 428

FAULTY CONNECTION
OR FAUL TY, PCM.
7-2-93
NS 16196
6E3-C3-8 3.4L {L32) {VIN S) (SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION C4
ELECTRONIC IGNITION (El) SYSTEM

CONTENTS
General Description
Operation
System Components
24X and 3X Crankshaft
Position Sensors
Ignition Coils
Ignition Control Module
Circuits Affecting Ignition Control.
How DTC 42 is Determined
C4-1
C4-1
C4-2
C4-2
C4-2
C4-2
C4-2
C4-3
C4-3
GENERAL DESCRIPTION
The Electronic Ignition (EI) system controls fuel
combustion by providing a spark to ignite the
compressed air/fuel mixture at the correct time. To
provide optimum engine performance, fuel economy,
and control of exhaust emissions, the PCM controls
spark advance of the ignition system. Electronic
ignition has several advantages over a mechani~al
system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cool down time between firing
events.
Elimination of mechanical timing
adjustments.
Increased available ignition coil saturation
time.
OPERATION
The electronic ignition system does not use the
conventional distributor and coil. The ignition system
consists of three ignition coils, an ignition control
module, a camshaft position sensor, a dual
"Hall-effect" crankshaft position sensor, an engine
crankshaft balancer with crankshaft position sensor
interrupter ring attached to the rear, related
connecting wires, and the ignition control and fuel
metering portion of the PCM.
Conventional ignition coils have one end of the
secondary winding connected to the engine ground. In
this ignition system, neither end of the secondary
winding is grounded. Instead, each end of a coil's
secondary winding is attached to a spark plug. Each
cylinder is paired with the cylinder that is opposite it
{1-4, 2-5, 3-6).
Diagnosis
Diagnosis _
On-Vehicle Service
Ignition Coil
3X Crankshaft Position (CKP) Sensor
C4-3
C4-3
C4-4
C4-4
C4-4
C4-4
C4-4
C4-5
C4-5
These two plugs are on "companion" cylinders, i.e.,

on top dead center at the same time. When the coil
discharges, both plugs fire at the same time to
complete the series circuit. The cylinder on
compression is said to be the "event" cylinder and the
one on exhaust is the "waste" cylinder.
The cylinder on the exhaust stroke requires very
little. of the available energy to fire the spark plug.
The remaining energy will be used as required by the
cylinder on the compression stroke. The same process
is repeated when the cylinders reverse roles. This
method of ignition is called a "waste spark" ignition
system.
Since the polarity of the ignition coil primary and
secondary windings is fixed, one spark plug always
fires with a forward current flow and its "companion"
plug fires with a reverse current flow. This is different
from a conventional ignition system that fires all the
plugs with the same direction of current flow. Since it
requires approximately 30% more voltage to fire a
spark plug backwards, the ignition coil design is
improved, with saturation time and primary current
flow increased. This redesign of the system allows
higher secondary voltage to be available from the
ignition coils - greater than 40 kilovolts (40,000 volts)
at any engine RPM. The voltage required by each
spark plug is determined by the polarity and the
cylinder pressure. The cylinder on compression
requires more voltage to fire the spark plug than the
one on exhaust.
It is possible for one spark plug to fire even though
a plug wire from the same coil may be disconnected
from its "companion" plug. The disconnected plug
wire acts as one plate of a capacitor, with the engine
being the other plate. These two "capacitor plates" are
charged as a spark jumps across the gap of the
connected spark plug. The "plates" are then
discharged as the secondary energy is dissipated in an
oscillating current across the gap of the still-connected
spark plug.
6E3-C4-2 3.4L (L32) (VIN S) (SFI} DRIVEABILITY AND EMISSIONS

Secondary voltage requirements are very high with an
"open" spark plug or wire. The ignition coil has
enough reserve energy to fire the still-connected plug
at idle, but possibly not under high engine load. A
more noticeable misfire may be evident under load;
both spark plugs may then be misfiring.
must have the 3X signal to "fire" the correct ignition

coil.
The 24X interrupter ring and "Hall-effect" switch
react similarly. The 24X signal is used for better
resolution at a calibrated RPM.

SYSTEM COMPONENTS
24X and 3X Crankshaft Position Sensors
The 24X crankshaft position sensor, secured in an
aluminum mounting bracket and bolted to the front
side of the engine timing chain cover, is partially
behind the crankshaft balancer (''On-Vehicle Service,"
Figure C4-3).
The 3X crankshaft position sensor uses a two wire
connector at the crankshaft position sensor and a three
wire connector at the ignition control module. Refer to
Figure C4-1.
The 24X crankshaft position sensor contains a
"Hall-effect" switch. The magnet and "Hall-effect"
switch are separated by an air gap. A "Hall-effect"
switch reacts like a solid-state switch, grounding a
low-current signal voltage when a magnetic field is
present. When the magnetic field is shielded from the
switch by a piece of steel placed in the air gap between
the magnet and the switch, the signal voltage is not
grounded. If the piece of steel (called an interrupter) is
repeatedly moved in and out of the air gap, the signal
voltage will appear to go "ON-OFF-ON-OFF-ONOFF." Compared to a conventional mechanical
distributor, this "ON-OFF" signal is similar to the
signal that a set of breaker points in the distributor
would generate as the distributor shaft turned and the
points opened and closed.
In the case of the electronic ignition system, a
concentric interrupter ring mounted to the rear of the
crankshaft balancer has blades and windows that,
with crankshaft rotation, either block the magnetic
field or allow it to reach the "Hall-effect" switch. The
"Hall-effect" switch is called a 24X crankshaft position
sensor, because the interrupter ring has 24 evenlyspaced same-width blades and windows. The 24X
crankshaft sensor produces 24 "ON-OFF" pulses per
crankshaft revolution. The "Hall-effect" switch closest
to the crankshaft, the 3X crankshaft position sensor, is
so called because the interrupter ring has a special
wheel cast on the crankshaft that has seven machined
slots, six of which are equally spaced 60 apart. The
seventh slot is spaced 10 from one of the other slots.
As the interrupter ring rotates with the crankshaft,
the slots change the magnetic field. This will cause
the 3X "Hall-effect" switch to ground the 3X signal
voltage supplied from the ignition control module. The
ignition control module interprets the 3X "ON-OFF"
signals as an indication of crankshaft position, and
The camshaft position sensor ("On-Vehicle

Service," Figure C4-5) is located on the timing cover
behind the water pump near the camshaft sprocket.
As the camshaft sprocket turns, a magnet in it
activates the "Hall-effect" switch in the cam sensor.
When the "Hall-effect" switch is activated, it grounds
the signal line to the PCM, pulling the cam signal
line's applied voltage low. This is interpreted as a cam
signal.
The cam signal is created as piston #1 is on the
compression stroke.
When the cam signal is not received by the PCM
DTC 17 will be set.
Ignition Coil.s
Three twin-tower ignition coils are individually
mouhted to the ignition control module (Figure C4-2).
Each coil provides spark for two plugs simultaneously
(waste spark distribution). Each coil is serviced
separately.
Two terminals connect each coil pack to the
module. Each coil is provided a fused ignition feed.
The other terminal at each coil is individually
connected to the module, which will energize one coil
at a time by completing and interrupting the primary
circuit ground path to each coil at the proper time.

The ignition control module performs several
functions:
It powers the 3X crankshaft sensor circuit.
It determines the correct ignition coil firing
sequence, based on 3X pulse. This coil
sequencing occurs at start-up. After the
engine is running, the module determines the
sequence, and continues triggering the
ignition coils in proper sequence.
It sends a "3X crankshaft reference" (fuel
control) signal to the PCM. The PCM
determines engine RPM from this signal. It is
also used by the PCM to determine crankshaft
position for ignition control spark advance
calculations. The signal sent to the PCM by
the ignition control module is an "ON-OFF"
pulse occurring 3 times per crankshaft
revolution.

Circuits Affecting Ignition Control
How OTC 42 is Determined
To properly control timing, the PCM relies on the

following information:
Engine lo~d (manifold pressure or vacuum).
Atmospheric (barometric) pressure.
Engine temperature.
Intake air temperature.
Crankshaft position.
. ..
Engine sp~ed (RPM).
The IC system consists ofithe ignition coil and
. module assembly (ignition coils, electronic ignition
control module), the 3X crankshaft po.sition sensor and
the 24X crankshaft position sensor, PCM and
connecting wires. The Ignition Control Module (ICM)
connector terminals are lettered as sh.own in Figure
C4-1. These circuits perform the following ,unctions:
3X reference high - CKT 647. - The crankshaft
position s~nsor sends a signal to the electronic
ignition control module which generates a
reference pulse which is sent to the PCM. The
PCM uses this signal to calculate crankshaft
position and engine speed (also used to trigger
the injector).
3X reference low - CKT 453. - This wire is
;grounded through the module and makes sure
. the.ground circuit has no voltage drop between . .
the ignition module and the PCM; which if
open, could affect performance.
Ignition control byp~ss - CKT 424. - During
initial cranking, the PCM w,ill lqok for
syncronizing pulses from the camshaft and 3X
cranksha,ft position sensor indicating the
position #1 piston and intake valve. 5 volts
is applied to the bypass circuit the instant
these signals are received by the PCM. Thi.s
generally occurs within l or 2 revolutions. of
the crankshaft. An open or grounded bypass
circuit will set a DTC 42 and the engine will
run at base timing. A small amount of
advance is built into the ignitioncontrol
module to enhance performance.
,
IC - CKT 423. - The PCM uses this circuit to
trigger the ignition control module. The PCM
uses the crankshaft reference signal to base its
calculation of the amount of spark advance
needed under present engine conditions.
24X reference signal. - Additional to the
electroni.c ignition system is the 24X
crankshaft position sensor. Its function is to
increase idle quality and provide good low
speed driveability.
An open in the IC circuit while running will result

in the engine continuing to run although in a base
timing mode (module timing). The timing values are
stored in the ignition control module to allow for basic
engine performance.
If the IC circuit is shorted to ground, the MIL will
be turned "ON," and a DTC 42 ~be.set and the
engine wilL op,1:!rate in module timing. Either
condition may cause poor performance and reduced
fuel economy .
If the bypass line is open or grounded, the ignition
control moduli:! will not switch to IC timing mode so
the IC voltage will be low and DTC 42 will be set.
If the IQ circuit is grounded, the ignition control
module will switch to base timing an'd a DTC 42 will be
set and MIL illuminated.
of
DIAGNOSIS
If the engine cranks but will not run, CHART A-3
will be used to determine if the "IC" system is the
cause of the problem or if it is another part of the fuel
injection system.
IfDTC 42 is set, that DTC chart should be used for
diagnosis. If no DTC is set and the ignition system is
suspected, use CHART C-4F, "Misfire" for diagnosis.

An open or groun? inthe ignition control or bypass
circuit will set a DTC 42. ff a fault occurs in the
ignition control output circuit when the engine is
running, the engine may falter or quit running but
will restart and run in base timing mode once the
ignition has been cycled. A fault in either circuit will
force the ignition.system to operate on base timing (10
BTDC), which will result .in reduced performance and
fuel economy.
The PCM uses information from the engine
coolant temperature sensor in addition to RPM to
calculate the main spark advance values as follows:
High RPM
Cold engine
more advance
more advance
Low RPM
Hot engine
less advance
less advance
Therefore, detonation could be caused by high

resistance in the engine coolant temperature sensor
circuit. Poor performance could be caused by low
resistance in the engine coolant temperature sensor
circuit.
FUSE #11 *
10 AMP
IGNITION
PCM
10-WAYFWDLAMP
HARNESS CONNECTOR
{BLACK)
...,.oc;---~--- 239 PNK
G - - - - - - T O HIGH RESOLUTION 24X

CRANKSHAfT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK
GND
-i
LOW RESOLUTION
3X CRANKSHAFT
POSITION S.ENSOR
::~=IHI I
SIGNAL
MINIMUM
1--------- 424 TAN/BLK -----1

- - - - - - - - - 423WHT
IGNITION
CONTROL
MODULE
{ICM)
-----1
. IGNITION CONTROL
BYPASS
IGNITION CONTROL
121 WHT -----TACH SIGNAL

D
1--------- 647 LT B.LU/BLK -----1
3XREFHIGH
1--------- 453 RED/BlK -----1
3XREFLOW
PRIMARY
WINDING
6-16-93
NS15618

Figure C4-1 - El System with IC
DIAGNOSIS
If the Engine Cranks But Will Not Run or
immediately stalls, CHART A-3 must be used to
determine if the failure is in the ignition system or the
fuel system.
If a DTC 17. 36 or 82 is set, the appropriate DTC
chart must be used for diagnosis.
If the symptom is "Engine Miss" and the ignition
system is suspected, CHART C-4F will provide a
systematic diagnostic procedure.
ON-VEHICLE SERVICE
IGNITION COIL
1+-+I
Remove or Disconnect
1. Spark plug wires.

2. 2 screws securing coil to ignition control module.
3. Ignition coil. Refer to Figure C4-2.
It may be helpful to remove the throttle cable
bracket to gain.access to coil pack 1-4.
1-++I
1.
2.
3.
Install or Connect
Ignition coil.
2 screws, torque to 4-5 Nm (40 lb. in.).
Spark plug wires.
IGNITION CONTROL MODULE
l+-+I
1. 6-way connector, 3-way connector and 2-way

connector at ignition control module.
2. Spark plug wires from ignition coils. Refer to
Figure C.4-2.
3. 6 screws securing ignition coils to ignition control
module.
4. Disconnect coils from ignition control module.
5. Ignition control module.
1-++I Install or Connect

1.
2.
3.
4.
Ignition coils to ignition control module.

6 screws, torque to 4-5 N m (40 lb. in.).
Plug wires.
6-way connector, 3-way connector and 2-way
connector to module.
l+-+I
1.
2.
3.
4.

Serpentine belt from crankshaft pulley.
Raise vehicle on hoist.
Using 18 mm socket, remove crankshaft harmonic
balancer retaining bolt.
DRIVEABILITY AND EMISSIONS' 3.4L (L32) (VIN S) (SFI) 6E3-C4-5
l+I Remove or Disconnect

1. Sensor harness connector at module.
2. Sensor to block bolt (1).
3. Sensor from engine.
llfl'I Inspect
SPARK PLUG WIRE HARNESS ASSEMBLY

2
IGNITION COIL ASSEMBLY

NS 15844
Figure C4-2 - Ignition Control Module and Coil

Assembly (Type II Shown)
5. Crankshaft harmonic balancer using special tool

(J 38197).
6. Sensor electrical connector.
7. Sensor bolts (2). Refer to Figure C4-3.
8. Sensor.
l+I Install or Connect
Sensor 0-ring for wear, cracks or leakage. Replace

if necessary. Lube new 0-ring with clean engine
oil before installing.
l~+I Install or Con~ect

1. Sensor into hole in block.
2, Sensor to block bolt (1).
Torque to 8 Nm (71 lb. in.).
3. Sensor harness connector at module.
Starter motor.
CAMSHAFT POSITION SENSOR
Figure C4-5
l+I Remove or Disconnect

1. Crankshaft position sensor with bolt (2). Refer to
Figure C4-3.
Torque bolts (2) to 10 Nm (8 lb. ft.).
Sensor electrical connector.
Balancer on crankshaft.
Apply thread sealer GM #1052080 or equivalent
to threads of crankshaft balancer bolt. Torque
bolt to 150 N m (110 lb. ft.).
6. Lower vehicle.
7. Serpentine belt.
2.
3.
4.
5.
2.
3.
4.
5.
Throttle cable shield and bracket from TB.

Bolt (1). Refer to Figure C4-5.
Camshaft position sensor.
l+I Install or Connect

1.
2.
3.
4.
5.
Camshaft position sensor. Refer to Figure C4-4.

Bolt{l) torque to 10 Nm (8 lb. ft.).
Harness connector.
Throttle cable bracket and shield.
3X CRANKSHAFT POSITION (CKP) SENSOR
FigureC4-4
Disconnect negative battery cable.

Remove starter motor.
FRONT ENGINE COVER
24x CRANKSHAFT POSITION

SENSOR ASSEMBLY
NS 15606
Figure C4-3 - 24X Crankshaft Position Sensor
6E3-C4-6 3.4L (L32) (VIN S). (SFI) DRIVEABILITYAND EMISSIONS
KNOCK SENSOR
2
BOLT/SCREW
NS 15845
Figure C4-4 - 3X Crankshaft PO$ition Sensor

'
'
CAMSHAFT POSITION SENSOR ASSEMBLY
ENGINE BLOCK ASSEMBLY
NS 15091
Figure C4-5 - Camshaft Position Sensor
BLANK
6E3-C4-8 3.4L (L32} (VIN S} (SFI} DRIVEABILITY AND EMISSIONS
PCM
10-WAY FWD LAMP

HARNESS CONNECTOR
(BLACK)
FUSE #11 *
10 AMP
IGNITION .....- . - -......~ - - - 239 PNK
G - - - - - - - ' - T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
450BLK---=:..__
GND
YEL~
SIGNAL
PPL
-fil.l_J
MINIMUM
- - - - - - - - 424 TAN/BLK - - - - - - -
-----1
IGNITION CONTROL
BYPASS
IGNITION CONTROL
-----1
3XREF HIGH
453 RED/BLK - - - - - - - -
3XREFLOW
- - - - - - - - - 423WHT
121 WHT ---TACH SIGNAL
IGNITION
CONTROL
MODULE
(ICM)
'-------1
E - - - - - - - 647 LT BLU/BLK
PRIMARY
WINDING
6-16-93
NS15618
CHARTC-4F
MISFIRE
The Electronic Ignition (EI) system uses a waste spark method of distribution. In this type of system, the
ignition control module triggers the #1/4 coil pair resulting in both #1 and #4 spark plugs firing at the same
time. #1 cylinder is on the compression stroke at the same time #4 is on the exhaust stroke, resulting in a lower
energy requirement to fire #4 spark plug. This leaves the remainder of the high voltage to be used to fire #1
spark plug. On this application, the low resolution 3X crankshaft position sensor is mounted to the engine block
and protrudes through the block to within approximately .050" of the crankshaft reluctor. Since the reluctor is a
machined portion of the crankshaft and the sensor is mounted in a fixed position on the block, timing adj4stments
are neither possible or necessary.
plugs show no evidence of wear, damage or fouling,
an engine mechanical fault should be suspected.
Refer to "Cuts Out, Misses" in "Symptoms,"
1. Checks for voltage output of ignition system. The
companion cylinder spark plug cable in the circuit
Section "6E3-B".
must be connected to a good ground to create a
3. Plug wires should be inspected for cuts or
good spark and avoid overstressing the coil. Test
abrasions leading to shorts to ground or other
each spark plug cable with the engine idling (the
components. This would cause a weak or absent
spark yet the resistance valve when measured may
ignition must be cycled "OFF" when moving the
ST 125 tester to a different spark plug cable).
be correct.
4. If carbon tracking is evident replace coil and be
Keep disconnected spark plug leads away from
sure plug wires relating to that coil are clean and
sensors and other electronic components.
tight. Excessive wire resistance or faulty
Move quickly through this test. Don't leave
any spark plug lead disconnected for longer
connections could have caused the coil to be
damaged.
than 15 seconds.
5. If the no spark condition follows the suspected coil,
Let the engine run normally for 30 seconds
that coil is faulty. Otherwise, the ignition control
between tests to avoid an excessive buildup of
module is the cause of no spark. This test could
fuel.
2. If the spark tester fires on all wires, the ignition
also be performed by substituting a known good
system, with the exception of the spark plugs, may
coil for the one causing the no spark condition.
be considered in good working order. If the spark
DRIVEABILITY AND EMISSIONS .3.4L (L32) (VIN S) (SFI) 6E3-C4-9
CHART C-4F
MISFIRE
G)
t
t
t
t
t
IGNITION "OFF."
INSTALL SPARK TESTER J-26792 {ST-125)TO ONE SPARK PLUG WIRE.
GROUND COMPANION CYLINDER PLUG WIRE.
IDLE ENGINE AND CHECK FOR SPARK AT TESTER.
REPEAT TEST ON ALL PLUG WIRES WHILE GROUNDING COMPANION PLUG WIRES.
DOES TESTER DISPLAY A CRISP BLUE SPARK ON ALL WIRES?
CHECK THE RESISTANCE OF EACH PLUG WIRE OF THE

COIL WHICH DISPLA YEO AN INTERMITTENT OR
WEAK SPARK OR DID NOT FIRE THE SPARK TESTER.
IS WIRE RESISTANCE LESS THAN 30,000 OHMS EACH?
REMOVE AFFECTED COIL{S).

IS COIL{S) FREE OF CARBON TRACKING?
SWITCH POSITION OF COILS AT PROBLEM CYLINDER.

WILL SPARK JUMP TESTER GAP WHILE CRANKING
ENGINE?
G)
CHECK FOR:
FAULTY, WORN, OR DAMAGED SPARK PLUG{S).
PLUG FOULING, DUE TO ENGINE MECHANICAL FAULT.
If PLUGS ARE OK, REFER TO SYMPTOMS, SECTION B;
CUTS OUT, MISSES.
FAULTY IGNITION COIL. ALSO CHECK FOR FAULTY

PLUG WIRE CONNECTION{S) AND PLUG WIRE BOOT(S)
FOR CARBON TRACKING.
FAULTY IGNITION
CONTROL MODULE.
6-17-93
NS 15849
6E3-C4-10 3.4L {t.32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION CS
KNOCK SENSOR (KS) SYSTEM

CONTENTS
General Description
CS-1
CS-1
Operation
Diagnosis
CS-1
CS-1
Purpose
.............. ..
On-Vehicle Service
Knock Sensor
Knock Sensor (KS) Module
CS-1
CS-1
CS-2
GENERAL DESCRIPTION
PURPOSE
Varying octane levels in today's gasoline can cause
detonation in high performance engines. Detonation
is sometimes called spark knock.
To control spark knock, a Knock Sensor (KS)
system is used. This system is designed to retard
spark timing up to 10 to reduce spark knock in the
engine. This allows the engine to use maximum spark
advance to improve ~riveability and fuel economy.
PIEZO
CRYSTAL
OPERATION
The KS system has two major components:
KS module (located in the PCM).
Knock sensor.
The Knock Sensor (KS) detects abnormal vibration
(spark knocking) in the engine. The sensor is mounted
in the engine block near the cylinders. The sensor
produces an AC output voltage which increases with
the severity of the knock. This signal voltage is
applied to PCM input. The PCM then adjusts the
Ignition Control (IC) timing to reduce spark knocking.
LS 8461-6E
Figure CS-1 Knock Sensor (KS)
DIAGNOSIS
The Tech 1 scan tool will have two positions to
check for diagnosing this circuit. The "knock signal"
parameter is used to monitor the input signal from the
knock sensor. This display position will display "Yes"
when knock is being detected. "Spark retard" is the
indication of how much the PCM is retarding the
spark.
OTC 43 is designed to diagnose the knock sensor
and wiring so problems encountered with this circuit
should set the OTC. However, if no DTC 43 was set
but the KS system is suspected because detonation was
the customer's complaint, refer to CHART C-5.
ON-VEHICLE SERVICE
KNOCK SENSOR
!++I Remove or Disconnect

1.
KNOCK SENSOR
BOLT/SCREW
NS 15845
Figure CS-2 Knock Sensor Assembly
6E3-C5-2 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS

2. Raise vehicle.
3 Starter motor.
4. KS wiring harness connector from knock sensor.
5. Knock sensor from engine block.

1.
Removal of the plug-in knock sensor module can be

accomplished by two methods as illustrated.
Method 1:
1.
Knock sensor into engine block. Be sure threads

are clean. Do not over tighten knock sensor. Over
torquing could damage the sensor.
Apply two opposing forces on either side of the

latch mechanism as shown below and pull unit up
from the header. Reinstallation is accomplished
by pushing the unit toward the header.
l~I Tighten
Tighten to 19 Nm (14 lb. ft.).
2. KS wiring harness connector to the knock sensor.
3. Starter motor.
4. Lower vehicle.
METHOD 1
KNOCK SENSOR {KS) MODULE

1.
Wiring harness from Powertrain Control Module

(PCM).
2. Mounting bracket from PCM.
3. Access cover from PCM.
rn
Important
APPLY PRESSURE IN
DIRECTION OF ARROWS
NS16216
Figure CS-4 - Knock Sensor Module Removal
DO NOT remove any other screws.
Method 2:
2. Apply force toward the plug-in knock sensor

module with the thumb or forefinger with an
opposing force on the opposite side of the module as
shown below. Reinstallation is done as stated in
Method 1.
'
~
I
METHOD2
APPLY PRESSURE IN
DIRECTION OF ARROW
NS 16217
NS 16215
Figure CS-3- Knock Sensor (KS) Module
BLANK
6E3-C5-4 3.4L (L32} (VINiS} (SFI} DRIVEABIUTYANO EMISSIONS
PCM
KNOCK
SIGNAL
. . - - - - - - - - 496 DK BLU
-------1
(20
SV
KNOCK
SENSOR
6-15-93
NS15039
CHARTC-5
KNOCK SENSOR (KS) SYSTEM CHECK
The Knock Sensor (KS) is used to detect engine detonation and the PCM will retard the ignition control
timing based on the signal being received. The circuitry within the knock sensor causes the PCM's 5 volts to be
pulled down so that under a no knock condition CKT 496 would measure about 2.5 volts. The knock sensor
produces an AC signal which rides on the 2.5 volts DC voltage. The amplitude and frequency are dependent upon
the knock level.
The PCM used with this engine contains a knocksensor module which contains the spark control logic that
retards spark timing which in turn reduces detonation.

1. With engine idling, there should not be a knock
signal present at the PCM, because detonation is
not likely under a no load condition.
2. Tapping on the engine lift hook bracket should
simulate a knock signal to determine if the sensor
is capable of detecting detonation. If no knock is
detected, try tapping on engine block closer to
sensor before replacing sensor.
3. If the engine has an internal problem which is
creating a knock, the knock sensor may be
responding to the internal failure.
4. This tests the integrity of the Knock Sensor (KS)

module.
Diagnostic Aids: While observing knock signal on

the Tech 1 scan tool, there should be an indication that
knock is present when detonation can be heard.
Detonation is most likely to occur under high engine
load conditions.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C5.-S
CHARTC-5
G)
IF DIAGNOSTIC TROUBLE CODE {OTC) 43 IS SET, USE THE OTC CHART.

ENGINE MUST BE IDLING AT NORMAL OPERATING TEMPERATURE.
USE TECH 1 TO OBSERVE KNOCK SIGNAL.
IS KNOCK INDICATED?
TAP ON ENGINE BLOCK WHILE OBSERVING KNOCK SIGNAL.
G) IF AN ENGINE KNOCK CAN BE HEARD, REPAIR THE
TECH 1 SHOULD INDICATE KNOCK WHILE TAPPING ON

ENGINE BLOCK.
DOESIT?
BASIC ENGINE PROBLEM. IF NO AUDIBLE KNOCK IS

HEARD, FOLLOW THE STEPS:
IGNITION "OFF."
CONNECT DVM TO KNOCK SENSOR AND

ENGINE GROUND.
SET DVM ON 2 VOLT A.C. SCALE.
IGNITION "ON," ENGINE "ON."

IS A SIGNAL INDICATED ON DVM?
(v
IGNITION "OFF."
DISCONNECT KNOCK SENSOR ELECTRICAL
CONNECTOR.
CONNECT DVM TO KNOCK SENSOR

TERMINAL AND ENGINE GROUND.
SET DVM ON 2 VOLT A.C. SCALE.
IGNITION "ON," ENGINE "ON."
SYSTEM IS OPERATING
PROPERLY. REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
CHECK CKT 496 FOR BEING

NEAR A SPARK PLUG WIRE
OR
A FAULTY PCM CONNECTION
OR
FAULTY PCM.
TAP ON ENGINE BLOCK NEAR SENSOR.

IS A SIGNAL INDICATED ON DVM WHILE
TAPPING ON ENGINE BLOCK?
POOR CONNECTION AT KNOCK

SENSOR HARNESS CONNECTOR
OR
KNOCK SENSOR MODULE NOT
SEATED PROPERLY
OR
FAlJL TY KNOCK SENSOR MODULE.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL {SERVICE ENGINE SOON).
4-15-93
NS 16218
BLANK
SECTION C6
SECONDARY AIR INJECTION (AIR) SYSTEM

CONTENTS
General Description
Purpose
Operation of System Components
Operation

Diagnosis
Operational Checks
AIR Pump
(6-1
(6-1
(6-1
(6-1
(6-2
C6-2
(6-2
(6-2
Hoses and Pipes

Check Valve

On-Vehicle Service
AIR Pump
AIR Check Valve
AIR Pipes and Hoses
C6-3
C6-3
C6-4
C6-4
C6-4
C6-4
C6-4
GENERAL DESCRIPTION
PURPOSE
The Secondary Air Injection (AIR) system helps

reduce Hydrocarbon (HC), Carbon Morioxide (CO), and
Oxides of Nitrogen (NOx) exhaust emissions. It also
heats up the oxidation catalytic converter quickly on
engine start-up so conversion of exhaust gases can
occur sooner.
OPERATION OF SYSTEM COMPONENTS

The system (Figure C6-l) includes:
AIR pump. - The AIR pump is located in the
left front of the underhood compartment and
supplies the air (oxygen) to the AIR system.
This electric air pump pressurizes air from the
engine air cleaner and pumps it through the
check valve and into the exhaust manifold.
The AIR pump is controlled by the PCM.
Battery voltage to the AIR pump is controlled
by the AIR pump relay. An integral stop valve
prevents air flow through the pump during
"OFF" periods. When the PCM provides a
ground circuit for the r.elay, battery voltage is
allowed to power up the AIR pump and
integral stop valve. The AIR pump motor is
protected by a 20 amp fuse and has its own
remote ground.
Check valve. - The check valve prevents back
flow of exhaust gases into the pump in the
event of an exhaust backfire.
Necessary plumbing. - As shown in Figure C62.
AIR INJECTION PUMP
2
3
AIR INJECTION PIPE
EXHAUST MANIFOLD
INTAKE MANIFOLD
5
6
CHECK VALVE
AIR INJECTION HOSE (AIR TO EXHAUST
PORT)
AIR INJECTION HOSE (TO AIR CLEANER

ASSEMBLY)
10-12-92
NS 15887
Figure C6-1 -AIR System Operation
OPERATION
The AIR pump with integral stop valve is
controlled by the PCM. The PCM will turn "ON" the
AIR pump and opens the stop valve by providing the
ground to complete the circuit which energizes the AIR
pump relay. When air (oxygen) to the catalyst is
desired the PCM turns "ON" both the stop valve and
AIR pump.
6
7
HOSE ASSEMBLY
PIPE ASSEMLBY
10
PIPE ASSEMBLY
CLAMP
CHECK VALVE
AIR INJECTION PUMP HOSE
NUT
BOLT/SCREW
PIPE ASSEMBLY
INSTAL.L TO EXHAUST
MANIFOLD AS SHOWN
NS 15850
Figure C6-2 - AIR System
The PCM turns "ON" the AIR pump after start-up any
time engine coolant temperature is above about 12C
(55F). The AIR pump will operate for a maximum of
about 3 minutes, or until the system enters "Closed
Loop" operation. At the same time the PCM turns the
AIR pump "OFF," it also de-energizes the integral stop
valve solenoid so no air is directed to the exhaust ports.
The air system will be disabled under the following
conditions:
When the PCM recognizes a problem and sets a
diagnostic trouble code.
When the fuel system is operating in "Closed
Loop."
The AIR pump has been "ON" for about three
minutes.
.
RPM is greater than 3200 for greater than 5
seconds.
MAP is greater than 86 kPa.
MAP is less than 11 kPa.
Engine coolant temperature less than 12C
(55F).
Battery voltage is less than 10 volts or greater
than 16 volts.
Power Enrichment (PE) is detected.
RE SULTS OF INCORRECT OPERATION

If no air (oxygen) flow enters the exhaust stream,
HC and CO emission levels will be too high during cold
start conditions.
Air flowing to the exhaust stream at all times
could increase temperature of the oxidation catalytic
converter.
DIAGNOSIS
The diagnosis of the AIR system is covered below,
and in CHART C-6 at the end of this section.
'
OPERATIONAL CHECKS
AIR Pump
The AIR pump is a regenerative turbine type
which is permanently lubricated and requires no
periodic maintenance.
If the vehicle has been sitting overnight, refer to
CHART C-6. If the engine is at or near normal
operating temperature use the following procedure:
Using the Tech 1 scan tool, select "Miscellaneous Test"
then "Output Test." Select "AIR System" in "Output
Test" directory. Observe oxygen sensor voltage for
right (Bank 1) oxygen sensor.

Using the f arrow enable the "Output Test" for the
AIR system. The "Output Test" will energize the AIR
pump for only about 5 seconds. When the "Output
Test" is enabled, the right (Bank 1) oxygen sensor
voltage should remain under 400 m V because air is
being directed to the right bank exhaust port. If the
voltage remains low during the "Output Test/' the AIR
pump and integral stop valve are operating
satisfactorily.
If the voltage does not remain low when the
"Output Test" is commanded "ON," proceed as follows.
ll'l'I Inspect
1. For a seized AIR pump (refer to CHART C-6).
2. Hoses, tubes and all connections for leaks and
proper routing.
3. For air flow going to the exhaust manifold.
4. AIR pump for proper mounting.
Hoses and Pipes
ll'l'I Inspect
4. If a leak is suspected on the pressure side of the

system or if a hose or pipe has been disconnected
on the pressure side, the connections should be
checked for leaks with a soapy water solution.
With the AIR pump running, bubbles will form if a
leak exists.
Check Valve
ll'l'I Inspect
1. A check valve should be inspected whenever the
hose is disconnected from a check valve or
whenever check valve failure is suspected. (An
AIR pump that had become inoperative and had
shown indications of having exhaust gases in the
outlet port would indicate check valve failure.)
2. Remove the check valve and blow through the
check valve (toward the exhaust manifold), then
attempt to blow through the other side of the check
valve. Flow should only be in one direction
(toward the exhaust manifold). Replace valve
which does not operate properly.
1. Hose or pipe for deterioration or holes.

2. All hoses or pipe connections, and clamp tightness.
3. Hose or pipe routing. Interference may cause
wear.
ABS HYDRAULIC MODULATOR
LEFT SIDE FRAME RAIL
AIR PUMP
AIR PUMP ELECTRICAL CONNECTOR
AIR BRACKET
HOSE TO AIR CLEANER

NS 15265
Figure C6-3 -AIR Pump Service
ON~VEHICLE SERVICE
AIR PUMP
Figure C6-3

1.
2.
3.
4.
5.

Raise vehicle.
Harness connector from AIR pump.
Outlet and inlet hoses.
Air pump mounting bolts (3) from bracket.

1.
2.
AIR pump to bracket.

Mounting bolts (3).
l~I Tighten
Bolts to 12 N m(9 lb. ft.).

Outlet and inlet hoses to pump.
Harness connector to AIR pump.
5. Lower vehicle.
7. Check AIR system for proper operation (refer to
CHARTC-6).
3.
4.
AIR CHECK VALVE

Refer to Figure C6-2.

1. Check valve clamp.
2. Hose from check valve.
3. Left check valve pipe.
4. Unscrew check valve from AIR pipe.

1.
Screw check valve onto AIR pipe.
l~I Tighten
Check valve to AIR pipe 19 Nm (14 lb. ft.).
Air pipe to exhaust manifold.
3. Air hose to check valve.
4. Check valve clamp.
2.
AIR PIPES AND HOSES

For "On-Vehicle Service" procedures, refer to
Figure C6-2.
Check Valve
AIR Pump Bolts
19 Nm (14 lb. ft.)

12 N m (9 lb. ft.)
BLANK
PCM

TO
FUSE #7*
IGNITION~441 BRN--------~
SWITCH
20 AMP
RUST
it------502RED
FUSE LINK
K
SECONDARY AIR
INJECTION PUMP
RELAY CONTROL
SECONDARY
AIR INJECTION
PUMP
RELAY*
t
10-WAY FORWARD
LAMP HARNESS
CONNECTOR (BLACK)
....------78 RED----'
.-----78 RED----~
SECONDARY AIR INJECTION (AIR) PUMP

FROM
AIR
CLEANER ___,.
ASSEMBLY
TO
EXHAUST
PORTS
~-------78RED--~
' - - - - - - - - - - - 7 9 RED----'
6-25-93
NS 15883
CHARTC-6
SECONDARY AIR INJECTION {AIR) SYSTEM CHECK
3.4L {VIN S) F CARLINE {SFI)
11
11
During cold starts, above 12C (55F), the PCM completes the ground circuit to the air pump relay which
energizes the air pump and integral stop valve. Air is directed to the right side exhaust port whenever the engine
is started. Whenever the fuel system goes to "Closed Loop," or the air pump has been "ON" for more than
approximately 3 minutes, the PCM opens the ground circuit to the air pump relay, and the air pump. is
de-energized and integral stop valve closes.

1. This is a system performance test. If both the AIR
pump and AIR check valve are functioning
properly, the amount of fresh air flowing past the
028 will cause a false lean condition (low voltage).
Move quickly through these first two steps.
2. Checks the PCM's ability to shut "OFF" the AIR
pump. Once turned "OFF," the AIR pump should
stay "OFF" for at least 200 seconds.
3. Checks for battery voltage for the energizing coil

and switching portions of the AIR pump relay.
4. Checks for an open control circuit. Grounding the
diagnostic "Test" terminal or using the Tech 1
"Output Test" will energize the AIR pump relay if
the PCM and circuits are normal.
CHARTC-6
SECONDARY AIR INJECTION (AIR)

SYSTEM CHECK
11

CORRECT ANY PCM DTC(s) BEFORE ENTERING THIS
COOLANT TEMPERATURE BETWEEN 20C AND 60C.
ENGINE IDLING IN OPEN LOOP.
IS AIR PUMP WORKING?
[$
IGNITION "OFF."
CHECK UNDERHOOD ELECTRICAL CENTER
FUSE #7 FOR BEING OPEN OR FUSE LINK "K".
ARE FUSE AND FUSE LINK OK?
ENGINE STILL OPERA TING IN OPEN LOOP .

RUN ENGINE TO 3300 RPM .
AIR PUMP SHOULD TURN "OFF" AFTER
APPROXIMATELY 5 SECONDS.
DOES IT?
[$
REMOVE AIR PUMP RELAY.
PROBE TERMINAL "E1" AND "ES"
OF UNDERHOOD ELECTRICAL
CENTER WITH A TEST LIGHT
CONNECTED TO GROUND.
15 LIGHT "ON" IN BOTH CIRCUITS?
REPAIR SHORT
TO GROUND
IN CKTs441,
78 OR 502.
[$
REMOVE AIR
PUMP RELAY .
DOES AIR PUMP
STOP?
[$]
[$
PROBE TERMINAL "E2" OF AIR

PUMP RELAY HARNESS WITH A
TEST LIGHT CONNECTED TO B +.
ENTER MISC. TESTS.
ENTER OUTPUT TESTS.
ENTERAIRRELAY.
ENERGIZE TECH 1.
DOES LIGHT ILLUMINATE?
[$
IGNITION "OFF."
JUMPER TERMINAL "E4" TO
TERMINAL "E1" Of AIR PUMP RELAY
HARNESS USING A FUSED JUMPER.
IGNITION "ON."
IS AIR PUMP ON?
CKT4360PEN
OR
FAULTY
CONNECTIONS
OR
FAULTY PCM.
[$]
DISCONNECT AIR PUMP
CONNECTOR.
PROBE TERMINALS "A"
AND "B" WITH A TEST
LIGHT TO GROUND.
IS LIGHT ON?
PROBE CKT
436AT AIR
PUMP RELAY
HARNESS
WITH A TEST
LIGHTTOB+.
DOES LIGHT
ILLUMINATE?
$
CKT(S)78
SHORTED
TOB+.
[$
REPAIR OPEN
IN CIRCUIT
THAT DID
NOT LIGHT.
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
[$]
CKT436
GROUNDED
OR FAULTY
PCM.
IGNITION "ON,"
ENGINE "OFF."
DISCONNECT HOSE
GOING TO THE AIR
CHECK VALVE.
GROUND DIAGNOSTIC
"TEST" TERMINAL OR
INSTALL TECH 1 AND
ENTER AIR SYSTEM
"OUTPUT TEST." IS AIR
PRESENT AT THE END
OF THE HOSE THAT
WAS DISCONNECTED?
FAULTY
AIR
PUMP
RELAY.
DISCONNECT
AIR PUMP
CONNECTOR.
PROBE
TERMINAL
"B" OFAIR
PUMP
ELECTRICAL
CONNECTOR
WITH A TEST
LIGHT TO
GROUND.
ENTER MISC .
TESTS.
ENTER
OUTPUT
TESTS.
ENTER AIR
RELAY.
ENERGIZE
TECH 1.
DOES LIGHT
ILLUMINATE?
$
NO
TROUBLE
FOUND.
[$]
$
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
OPEN GROUND
CIRCUIT OR
FAULTY AIR
PUMP MOTOR.
$]
FAULTY AIR
PUMP
ELECTRICAL
CONNECTION
OR
FAULTY AIR
PUMP.
[$
CKT78
OPEN.
7-3-93
NS 15933
BLANK
DRIVEABIUTY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C7-1
SECTION C7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

CONTENTS
General Description
Purpose
Operation
Digital EGR Valve
EGRControl
C7-1
C7-1
C7-1
C7-1
C7-2
GENERAL DESCRIPTION
PURPOSE
The EGR system is used to lower NOx (Oxides of
Nitrogen) emission levels caused by high combustion
temperature. It does this by decreasing combustion
temperature.
SOLENOID & MOUNTING PLATE ASSEMBLY
EGR BASE PLATE
EGR BASE GASKET
INSULATOR GASKET
EGRBASE
ARMATURE ASSEMBLY
SCREW ASSEMBLY
Figure C7-1 Digital EGR Valve
9P0161-XV
Diagnosis

Results of Incorrect EGR System
Operation
On-Vehicle Service
Digital EGR Valve
C7-2
C7-2
C7-2
C7-2
The main element of the system is the digital EGR

valve.
The digital EGR valve feeds small amounts of
exhaust gas back into the intake manifold and then
into the combustion chamber.
OPERATION
Digital EGR Valve

The digital (EGR) valve is designed to accurately
supply EGR to an engine, independent of intake
manifold vacuum. The valve controls EGR flow from
the exhaust to the intake manifold through three
orifices which increment in size to produce seven
combinations. When a solenoid is energized, the
armature, with attached shaft and swivel pintle is
lifted, opening the orifice.
The flow accuracy is dependent on metering orifice
size only, which results in improved control.
The swivel pintle feature ensures good sealing of
exhaust gas, reducing the need of critical assembly
alignment. In addition, the effects of EGR leakage on
idle quality are reduced because the shaft and seals
are exposed to exhaust pressure instead of manifold
vacuum. The shafts are sealed from the exhaust
chamber by floating seals held in place by the seal
spring. These springs also hold the upper seals that
seal the armature cavity in the solenoids.
The solenoid coils are fastened together to
maximize reliability and to seal the coils from the
environment. The coils use a common power terminal
with individual ground terminals.
The digital EGR valve is opened by the PCM
"quad-driver," grounding each respective solenoid
circuit. This quad-driver activates the solenoid, raises
the pintle, and allows exhaust gas flow into the intake
manifold. The exhaust gas then moves with the
air/fuel mixture into the combustion chamber. If too
much exha.ust gas enters, combustion will not occur.
For this reason, very little exhaust gas is allowed to
pass through the valve, with virtually none at idle.
The EGR valve is usually open under the following
conditions:
Warm engine operation.
Above idle speed.
6E3-C7-2 3.4L (L32),(VIN S) (SFI) DRIVEAB,ILITY AND EMISSIONS
ON-VEHICLE SERVICE
EGRCONTROL
To regulate EGR flow, the PCM controls the EGR
solenoids to vary the amount of EGR flow. The PCM
uses information from the following sensors to
regulate the solenoid:
Engine Coolant Temperature (ECT) sensor.
Manifold Absolute Pressure (MAP).
DIAGNOSIS
DIGITAL EGR VALVE
I+-+! Remove or Disconnect

2. Electrical connector at solenoid.
3. Two (2) base to flange bolt/screws.
4. Digital EGR valve. Refer to Figure C7-2.
!-++! Install or Connect
An EGR flow check diagnosis of the digital EGR

system is covered in CHART C-7.
1.
RE SULTS OF INCORRECT EGR SYSTEM

OPERATION
3.
With too much EGR flow at idle, cruise, or cold

operation, any of the following conditions may occur:
Engine stops after cold start.
Engine stops at idle after deceleration.
Car surges during cruise.
Rough idle.
Too little or no EGR flow' allows combustion
temperatures to get too high. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
2.
EGR valve gasket with "UP" readable after

positioning on adaptor.
EGR valve assembly.
Two (2) bolt/screws finger tight.
rn
Important
When tightening digital EGR valve bolts, they

must be in the following sequence:
!~! Tighten
1.
2.
Torque each bolt/screw to 15 Nm (11 lb. ft.).

Apply additional torque to each bolt/screw to
30 Nm (22 lb. ft.).
\
SHIELD NUT
J:11,..
SHIELD
GASKET
DIGITAL EGR VALUE ASSEMBLY
BOLT/SCREW (2)
BOLT/SCREW (4)
TUBE ASSEMBLY
GASKET
BOLT/SCREW (4)
10
GASKET
11
ADAPTOR
12
STUD (2)
13
SHIELD
NS 16235
Figure C7-2 - Digital EGR Valve Assembly
BLANK
TO EVAP CANISTER
PURGE
DIGITALEGR
SOLENOID VALVE
ASSEMBLY
SOLENOID]
VALVE -
RELAY
r:,
L.!..J
- - - 541BRN
- - - 698BRN
FAN CONTROL
ELECTRICAL CENTER
PCM
FUSE #6
10AMP
:,, IGNITION
699 RED
698
BRN
EGR #2 CONTROL
812
699 RED
697 LT BLU - - - - - - - - - - - - - 6 9 7 LT BLU
3-
EGR #1
CONTROL
::::L
NTROL-=-
_a_
6-16-93
NS 15638
CHARTC-7
EXHAUST GAS RECIRCULATION (EGR) FLOW CHECK
The digital (EGR) valve is designed to accurately supply EGR to an engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust to the intake manifold through three orifices which
increment in size to produce seven combinations. When a solenoid is energized, the armature with attached shaft
and swivel pintle is lifted, opening the orifice.
The flow accuracy is dependent on metering orifice size only, which results in improved control.

1. DTC(s) should be diagnosed using appropriate
charts before preparing a functional check.
2. This step activates each solenoid individually. As

you energize #1 or #2 solenoid, the engine RPM
should drop. #3 solenoid has the largest port and
may stall the engine when energized.
III Important
If the digital EGR valve shows signs of excessive heat (a melted condition), check the exhaust system for
blockage (possibly a plugged converter) using the procedure found on CHART B-1. If the exhaust system is
restricted, repair the cause. One possibility is an injector which is open due to one of the following:
A. Stuck.
B. Grounded driver circuit.
C. Possibly defective PCM.
If this condition is found, the oil should be checked for possible fuel contamination.
DRIVEABIUTY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C7-5
CHARTC-7
EXHAUST GAS RECIRCULATION (EGR) FLOW CHECK
G)

CHECK TECH 1 SCAN TOOL FOR DIAGNOSTIC TROUBLE CODES.
IF DIAGNOSTIC TROUBLE CODES ARE PRESENT, REFER TO THOSE CHARTS FIRST.
G)
USING TECH 1 SCAN TOOL, SELECT EGR OUTPUT TEST (MISCELLANEOUS).

START ENGINE AND ALLOW IDLE TO STABILIZE.
ENERGIZE EGR SOL #1, RPM SHOULD DROP SLIGHTLY.*
ENERGIZE EGR SOL #2, ENGINE SHOULD HAVE A ROUGH IDLE.*
ENERGIZE EGR SOL #3, ENGINE SHOULD IDLE ROUGH OR STALL.*
DID IDLE QUALITY RESPOND AS INDICATED FOR EACH SOLENOID?
EGR SYSTEM IS OK.

NO PROBLEM FOUND.
CHECK EGR VALVE, EGR TRANSFER TUBE, ADAPTOR, GASKETS,

FITTINGS AND ALL PASSAGES FOR DAMAGE, LEAKAGE OR
PLUGGING. IF OK, REPLACE EGR VALVE.
THESE STEPS MUST BE DONE VERY QUICKLY, AS THE PCM WILL

ADJUST THE IDLE AIR CONTROL VALVE TO CORRECT IDLE SPEED.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL(SERVICE ENGINE SOON).
4-15-93
NS 16236
BLANK
SECTION CS
AUTOMATIC TRANSMISSION CONTROL SYSTEM

CONTENTS
General Description
Input Information
Information Sensors and Swi.tches
Transmission Fluid Temperature (TFT)
Sensor
C:8-1
C8-1
(8-1
(8-1
(8-1
Transmission Range (TR) Pressure

Switch Assembly
Brake Switch
Output Information
. .. . . . . .. . . . . .
(8-2
(8-2
1-2 Shift Solenoid

2-3 Shift Solenoid
3-2 Control Solenoid
Pressure Control Solenoid (PCS)
Torque Converter Clutch (TCC)
Solenoid ;
On-Vehicle Service
Internal Transmission Components
C8-4
C8-4
C8-4
C8-5
C8-5
C8-5
C8-5
C8-5
(8-4
C8-4
GENERAL DESCRIPTION
INPUT INFORMATION
Information Sensors and Switches
POWERTRAIN CONTROL MODULE

(PCM)
Figure CB-1
The Powertrain Control Module (PCM) is an
electronic device which monitors various inputs to
control various transmission functions including shift
quality and transmission diagnostics. The PCM
receives various input information from sensors,
switches, and components to process for use within its
control program. Based on this input information, the
PCM controls various transmission output functions
and devices.
The PCM uses the following information sensors to

gather data for electronically controlling transmission
functions:
sensor.
Transmission Range (TR) pressure switch
assembly.
Vehicle Speed Sensor (VSS).
Brake switch.

Sensor
1 ACCESS COVER
2 PROM (MEM-CAL)
5-31-92
65 2548-6E
Figure CS-1 - Powertrain Control Module
The TFT sensor is a thermistor (a device that

changes resistance according to changes in
temp'1rature) used to indicate transmission fluid
temperature. High sensor resistance produces high
signal input voltage which corresponds to low fluid
temperature. Low sensor resistance produces low
signal input voltage which corresponds to high fluid
temperature. The PCM uses the TFT sensor signal
input to determine the following:
TCC apply and release schedules.
Hot mode determination.
Shift quality.
The TFT sensor is part of the transmission range
fluid pressure switch assembly and is attached to the
control valve body within the transmission.

Transmission Range (TR) Pressure Switch
Assembly
Figure CB-3
This device is a set of five pressure switches (two
normally closed and three normally open), that detect
fluid pressure within the valve body passages. The
five pressure switches are connected to three signal
circuits referred to as range signals A, B, C.
Valid Combination Chart

"ON"
0 volts/"OFF"
B+
D4
D3
D2
D1
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
Illegal
Illegal
ON
ON
OFF
ON
ON
ON
Range Signal
Park
Rev
Neutral
ARROW
P N
S
R
C B
The combination of pressure switch states determine

the voltage signal (B + or 0) on each range signal to
the PCM. These three range signals are then
interpreted by the PCM to indicate the transmission
range selected. The transmission range fluid pressure
switch assembly contains the trans fluid temperature
sensor and attached to the control valve body within
the transmission.
(INTERNAL)
ARROW

Figure CB-4
FUNCTION
CAVITY
A
1-2 SHIFT SOLENOID CONTROL CKT
PRESSURE CONTROL SOLENOID (HIGH)
PRESSURE CONTROL SOLENOID (LOW)
BOTH SHIFT SOLENOIDS, TCC SOLENOID,

AND 3-2 CONTROL SOLENOID IGNITION
(B +) FEED CKT
TRANSMISSION FLUID TEMPERATURE

(TFT) SIGNAL CKT

(TFT) SENSOR GROUND CKT
RANGES~NALACKT
RANGE SIGNAL
c CKT
RANGE SIGNAL e CKT
3-2 CONTROL SOLENOID CONTROL CKT
TCC SOLENOID CONTROL CKT

3-27-93
MS 13631
Figure CS-2 - Harness Connector
This device contains a permanent magnet

surrounded by a coil of wire producing a magnetic field
which is interrupted by rotor teeth pressed on an
output shaft. This device is used to provide an output
shaft speed signal to the control module. The control
module uses the vehicle speed sensor signal input to:
Calculate vehicle speed, trans output speed,
TCC slip speed.
,
Control shift quality.
The VSS is attached to the output shaft housing.
DRIVEABILITY AND EMl$SIONS 3 .4t ( L32) (VIN S) (SFI) 6E3-C8-3
@8 80
BOTTOM
MS 13676
Figure CB-3. Transmission Range (TR) Pressure Switch

.
Assembly
CHART
Gear
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
6E3~cs-4 3.4L (L32) (VI.N S) (SFI) DRIVEABILITY AND EMISSIONS
Brake Switch
This electrical switch is used to indicate brake
pedal status. This switch is normally closed when the
brake pedal is not applied. When the brake pedal is
applied the switch will open, changing the signal to
the PCM. The PCM uses this signal to de-energize the
TCC solenoid when brake pedal is applied. The brake
switch is located on the brake pedal mounting bracket.
OUTPUT INFORMATION
Based on input information, the PCM controls
various transmission output functions and devices.
1-2 shift solenoid.
2-3 shift solenoid.
3-2 .:ontrol solenoid.
Pressure Control Solenoid (PCS).
Torque Converter Clutch (TCC) solenoid.
1-2 SHIFT SOLENOID

2
2-3 SHIFT SOLENOID

MS 13675-7A
Figure CS-5 - 1-2 Shift Solenoid or 2-3 Shift Solenoid
1-2 Shift Solenoid

Figure CB-5
This electrical device is used to control fluid flow
acting on the 1-2 and 3-4 shift valves. The solenoid is a
normally open exhaust valve that is used with the 2-3
shift solenoid to allow four different shifting
combinations. The solenoid is attached to the control
valve body within the transmission.
2-3 Shift Solenoid

Figure CB-5
acting on the 2-3 shift valves. The solenoid is a
MS 13678-7A
Figure CS-6 - 3-2 Control Solenoid

Figure CB-6
acting on the 3-2 s)lift valve, which then controls the
2-4 band apply rate and 3-4 clutch release rate. It is a
pulse width modulated solenoid that operates on a
negative duty cycle. This solenoid controls the 3-2
downshift feel and is attached to the control valve body
within the transmission.
PRESSURE CONTROL
SOLENOID
ELECTRICAL CONNECTORS
MS 10090-7A
Figure CS-7 - Pressure Control Solenoid (PCS)
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-C8-5

FigureCB-7
ON-VEHICLE SERVICE
This electrical device is used to control fluid line

pressure by controlling actuator feed limit fluid flow
acting on an internal spool valve and spring pressure.
The solenoid is a normally closed solenoid valve that
controls fluid pressure when operating on a duty cycle.
The solenoid is attached to the control valve body
Torque Converter Clutch (TCC) Solenoid

FigureCB-8
This electrical device is used to control fluid acting
on the TCC converter clutch valve, which then controls
TCC apply and release. This solenoid is attached to
the transmission case assembly extending into the
pump cover.
MS 13679-7A
Figure CB-8 - Torque Converter Clutch (TCC)

Solenoid
INTERNAL TRANSMISSION COMPONENTS

The following list of components will be serviced in
SECTION 7 A14A:
1 - 2 shift solenoid.
3 - 2 control solenoid.
Pressure control solenoid.
TCC solenoid with internal wiring harness.
Any service that requires removal o{ the pan.

Refer to SECTION 7 for Vehicle Speed Sensor
(VSS) service. The VSS is located on the transmission.
6E3-C8-6 3.4l (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
WIRING HARNESS ASSEMBLY
3-2 CONTROL SOLENOID
TORQUE CONVERTER CLUTCH SOLENOID
1-2 SHIFT SOLENOID
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY
TRANSMISSION FLUID TEMPERATURE SENSOR

(PART OF TR PRESSURE SWITCH ASSEMBLY)
2-3 SHIFT SOLENOID
MS 13680
Figure CS-9 Electrical Components
TRANSMISSION ELECTRICAL CONNECTOR

THE TRANSMISSION WIRING CONNECTOR IS A VERY IMPORTANT PART OF THE
TRANSMISSION OPERATING SYSTEM. ANY INTERFERENCE WITH THE
ELECTRICAL CONNECTION CAN CAUSE THE TRANSMISSION TO SET DIAGNOSTIC
TROUBLE CODES (DTC)s AND/OR AFFECT PROPER OPERATION.
THE FOLLOWING ITEMS CAN AFFECT THE ELECTRICAL CONNECTION:
-
BENT PINS IN THE CONNECTOR FROM ROUGH HANDLING DURING

CONNECTION AND DISCONNECTION.
WIRES BACKING AWAY FROM THE PINS OR COMING UNCRIMPED (IN

EITHER INTERNAL OR EXTERNAL WIRING HARNESS).
DIRT CONTAMINATION
DISCONNECTED.
PINS IN THE INTERNAL WIRl~G CONNECTOR BACKING OUT OF THE

CONNECTOR OR PUSHED OUT DURING RECONNECTION.
EXCESSIVE TRANSMISSION FLUID LEAKING INTO THE CONNECTOR,

WICKING UP INTO THE EXTERNAL WIRING HARNESS, AND DEGRADING
OF THE WIRE INSULATION. *
VEHICLE HARNESS
ENTERING THE CONNECTOR WHEN
WATER/MOISTURE INTRUSION IN THE CONNECTOR.

-
LOW PIN RETENTION IN THE EXTERNAL CONNECTOR FROM EXCESSIVE

CONNECTION AND DISCONNECTION OF THE WIRING CONNECTOR
ASSEMBLY.
PIN CORROSION FROM CONTAMINATION.
THE PRESENCE OF TRANSMISSION FLUID IN THE TRANSMISSION

CONNECTOR IS NOT HARMFUL IN ITSELF. THE FLUID ONLY AFFECTS THE
EXTERNAL HARNESS WIRING INSULATION IF THE FLUID WICKS UP TO THE
HARNESS.
SQUEEZE
HERE
POINTS TO REMEMBER WHEN WORKING WITH THE TRANSMISSION WIRING

CONNECTOR ASSEMBLY:
-
TO REMOVE THE CONNECTOR, SQUEEZE THE TWO TABS TOWARDS EACH

OTHER AND PULL STRAIGHT UP (REFER TO THE ILLUSTRATION).
CAREFULLY LIMIT TWISTING OR WIGGLING THE CONNECTOR DURING

REMOVAL. BENT PINS CAN OCCUR.
DO NOT PRY
THE CONNECTOR OFF WITH A SCREWDRIVER OR OTHER
TRANSMISSION
CONNECTOR
TOOL.
-
TO REINSTALL THE EXTERNAL WIRING CONNECTOR, FIRST ORIENT THE

PINS BY LINING UP THE ARROWS ON EACH HALF OF THE CONNECTOR.
PUSH THE CONNECTOR STRAIGHT DOWN INTO THE TRANSMISSION
WITHOUT TWISTING OR ANGLING THE MATING PARTS.
THE CONNECTOR SHOULD CLICK INTO PLACE WITH A POSITIVE FEEL
AND/OR NOISE.
WHENEVER THE TRANSMISSION EXTERNAL WIRING CONNECTOR IS
DISCONNECTED FROM THE IN.TERNAL HARNESS AND THE ENGINE IS
OPERATING DTC(s) WILL SET.
CLEAR THESE DTC(s) AFTER
RECONNECTING THE EXTERNAL CONNECTOR.
1-6-93
NS 15891
Figure CS-10. Transmission Electrical Connector
4L60E TRANSMISSION FLUID CHECKING PROCEDURE

Warm the transmission to normal operatin~ temperature by driving the v.ehicle about 15 miles (24 km).
Operating temperature is 180-200F (82-94 C).
2. Park vehicle on a level surface, place shift lever in "P" park and apply the parking brake.
3. Check fluid level on the dipstick (read the lower level).
4. If fluid level is low, add only enough DEXRON-IIE to bring the fluid level into the hot area.
* It is important to check fluid level when the transmission has reached operating temperature. The hot range
is calibrated correspond to the correct fluid level range for fluid between 180 and 200F(82-94C).
1.
lcoLo
10111
HOT CHECK RANGE (180-200F, 82-92C)

: CHECK FLUID COLOR I
CHECK FLUID LEVEL
HIGHI~
REMOVE
EXCESS
FLUID.
I
LIGHT BROWN
NOTICE: TRANSMISSION
FLUID MAY TURN DARK
WITH NORMAL USE AND
DOES
ALWAYS
NOT
INDICATE CONTAMINATION
OR OXIDATION.
REPLACE COOLER.
LOW
ADD FLUID TO
OBTAIN PROPER
LEVEL.
I FOAM
CONTAMINANTS
IN FLUID
FLUID
LEVEL
HIGH
I
NON TRANSPARENT PINK
DRAIN FLUID TO
DETERMINE IF
THERE IS
CONTAMINATION.
I
DRAIN FLUID TO
DETERMINE
SOURCE OF
CONTAMINATION.
CHECK FOR EXTERNAL

LEAKS. REFER TO
"LEAK INSPECTION
POINTS" SECTION
7A14A FOR POSSIBl,.E
LEAK.
CORRECT LEAK
CONDITION. REFER
TO "ON-VEHICLE
SERVICE" "FLUID
LEAK DIAGNOSIS
AND REPAIR
SECTION 7A14A.
NOTICE:
A VERY SMALL
AMOUNT OF MATERIAL IN THE
BOTTOM OF THE PAN IS A
NORMAL CONDITION.
CHANGE FLUID
AND FILTER,
"ON-VEHICLE
SERVICE"
SECTION 7A14A.
REMOVE
EXCESS
FLUID.
TRANSMISSION
OVERHAUL {OR
SRTA) REQUIRED
(REFER TO
SECTION 7A14B.)
LARGE PIECES OF
METAL OR OTHER
MATERIAL IN THE
BOTTOM PAN.
TRANSMISSION
OVERHAUL (OR
SRTA) REQUIRED
(REFER TO
SECTION 7A14B.)
I
ADD NEW FLUID
CHECK FLUID LEVEL
ADD NEW FLUID
IF "ON-BOARD DIAGNOSTIC" {OBI>) SYSTEM CHECK HAS BEEN

PERFORMED CONTINUE WITH DIAGNOSIS, OTHERWISE PERFORM
OBD SYSTEM CH ECK.
IF DIAGNOSTIC TROUBLE CODES ARE NOT STORED, REFER TO
"FUNCTIONAL TEST PROCEDURE" SECTION 7 A 14A.
Figure CS-11 - 4L60E Transmission Fluid Checking Procedure
CHECK FLUID LEVEL

5-11-93
NS 15874
BLANK
6E3-C8-10 3;4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
PCM
TRANSMISSION RANGE
B+
- - - - - - - - - 1224PNK
B+
- - - - - - - - 1225 DK BLU
B+
1226 RED
TRANSMISSION
CONNECTOR
..._
1
I
1
-------1227BLK/YEL
1-,
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
MAP
SENSOR
5V
6-16-93
PS 18513
CHARTC-8A
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY CIRCUIT CHECK
11
The Transmission Range (TR) switch assembly consists of five pressure switches (two normally closed and
three normally open), and a TFT sensor combineg. into one unit and mounted on the valve body. The PCM
supplies battery voltage to each range signal. By grounding one or more of these circuits through various
combinations of the pressure switches, the PCM detects what manual valve position has been selected by the
vehicle operator. With ignition "ON" and engine "OFF," PIN will be indicated. When the transmission electrical
connector is disconnected, the ground potential for the three range signals to the PCM will be removed, and with
ignition "ON," 02 will be indicated.

manual valve position actually selected.
3. This test checks a short to ground or an open in
any one of the three circuits.

"ON" = 0 volts/"OFF" = B +
A
Park
Rev
Neutral
D4
D3
D2
D1
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
Illegal
Illegal
ON
ON
OFF
ON
ON
ON
Range Signal
Expected Readings
Diagnostic Aids: Refer to accompanying chart for

various NB!C range combinations. Check all wiring
connectors for proper terminal tension.
7A14A for further information.
CHARTC-8A
TRANSMISSION RANGE {TR) PRESSURE
SWITCH ASSEMBLY CIRCUIT CH ECK
3.4L {VIN S) F" CARLINE {SFI)
11
G)

ALL DTC(s) HAVE BEEN RECORDED AND THEN CLEARED.

DOES EACH SELECTED TRANSMISSION RANGE MATCH THE SCAN TOOL "TRANS RANGE SW" DISPLAY?
IGNITION "OFF."
WITH J 39200 TO GROUND, CHECK VOLTAGE AT HARNESS
ON CIRCUIT(S) THAT DID NOT INDICATE B +, CHECK FOR AN

VERIFY THAT CKT(s) 1224, 1225, OR 1226 A.RE NOT

CHECK" SECTION 7A14A (4L60E) OR 7A17A
(4L80E) OF THE APPROPRIATE SERVICE MANUAL.
4-27-93
PS 17065
6E3-C8-12 3.4L (L32) (VIN S) (SFI) ORIVEABILITYAND EMISSIONS
PCM
8 GRY -+- TO INTERIOR LIGHTS
(DIMMING)
4 1
BLK/WHT
553 LT BLU
2NDGEAR
START SWITCH
SIGNAL
---------------11
1493 DK BLU
--------------1
20
AMP
2NDGEAR
START
INDICATOR
LAMP FEEDBACK
TOIGN
SWITCH
6-16-93
PS 18514
CHARTC-88
2nd GEAR START SWITCH INDICATOR LAMP CONTROL CIRCUIT CHECK
3.4L (VIN S)
11
F" CARLINE (SFI)
The 2nd gear start switch enables the operator to select a 2nd gear start for increased traction. When 2nd gear
start is selected, the 2nd gear start switch input signal is momentarily toggled to zero volts. The PCM then turns
"ON" the 2nd gear start mode indicator lamp and de-engerizes the 1-2 shift solenoid enabling 2nd gear. During
light and medium acceleration conditions the vehicle will start in 2nd gear when selected. However, znd gear
starts will be overridden and first gear starts will occur if a hard acceleration condition (WOT) is required.
Normal 1st gear start mode is obtained by toggling the 2nd gear start switch again, or when the ignition switch is
cycled "OFF" then "ON."

1. This step checks the entire 2nd gear start switch
circuit for a malfunction.
2. At this point, the external circuit is operating
correctly.
Diagnostic Aids: If the electrical circuit checks OK

and 2nd gear starts are not correct, there may be a
mechanical/hydraulic malfunction. Refer to
"Automatic Transmission Diagnosis" in SECTION
7A14A.
DRIVEABILITY AND EMISSIONS 3.4l {L32) {VIN S) {SFI) 6E3-C8-13
CHARTC-88
2nd GEAR START SWITCH INDICATOR LAMP CONTROL
CIRCUIT CHECK
INSTALL SCAN TOOL.

PRESS THE 2ND GEAR START SWITCH AND OBSERVE THE
INDICATOR LAMP WITHIN THE SWITCH.
IS IT "ON" WHEN 2ND GEAR START MODE IS SELECTED?

OBSERVE "2ND GEAR START SWITCH" ON SCAN
TOOL DISPLAY WHILE PRESSING THE 2ND GEAR
START SWITCH TWICE.
IS "ON" DISPLAYED WHEN THE 2NDGEAR
START SWITCH IS PRESSED, AND "OFF"
DISPLAYED WHEN RELEASED?
2ND GEAR START SWITCH INDICATOR

LAMP CONTROL CIRCUIT OKAY.
IGNITION "OFF," DISCONNECT 2ND GEAR

START SWITCH CONNECTOR, IGNITION "ON."
WITH TEST LIGHT TO GROUND, PROBE
IGNITION VOLTAGE CIRCUIT TO SWITCH.
IS TEST LIGHT "ON?"
REFER TO 2ND GEAR START SWITCH SIGNAL

CIRCUIT CHECK FOR DIAGNOSIS.
WITH TEST LIGHT.JUMPER IGNITION VOLTAGE

CIRCUIT TO 2ND GEAR ST ART INDICATOR LAMP
CONTROL CIRCUIT AT CONNECTOR.
WITH FUSED WIRE JUMPER TO GROUND, PROBE 2ND
GEAR START SWITCH SIGNAL CIRCUIT SEVERAL TIMES.
DOES TEST LIGHT FLASH "ON" AND "OFF?"
REPLACE FAULTY
2ND GEAR START
SWITCH.
REPAIR OPEN OR SHORT IN 2No

GEAR START SWITCH INDICATOR
LAMP CONTROL CIRCUIT TO PCM.
6-23-93
PS 18647
PCM
8 GRY - - TO INTERIOR LIGHTS
(DIMMING)
4 1
553 LTBLU
BLK/WHT
--------------1
1493 DK BLU
2NDGEAR
START SWITCH
SIGNAL
B+
-------------1
2NDGEAR
START
INDI.CATOR
LAMP FEEDBACK
TOIGN
SWITCH
6-16-93
PS 18514
CHARTC-8C
2nd GEAR START SWITCH SIGNAL CIRCUIT CHECK
11
The 2nd gear start switch enables the operator to select a 2nd gear start for increased traction. When 2nd gear
start is selected, the 2nd gear start switch input signal is momentarily toggled to zero volts. The PCM then turns
"ON" the 2nd gear start mode indicator lamp and de-engerizes the 1~2 shift solenoid enabling 2nd gear. During
light and medium acceleration conditions the vehicle will start in 2nd gear when selected. However, 2nd gear
starts will be overridden and first gear starts will occur if a hard acceleration condition (WOT) is required.
Normal 1st gear start mode is obtained by toggling the 2nd gear start switch again, or when the ignition switch is
cycled "OFF" th~n "ON."

1. This step checks the entire 2nd gear start switch
signal circuit for a malfunction.
correctly.
Diagnostic Aids: If the electrical circuit checks OK

and 2nd gear starts are not correct, there may be a
mechanical/hydraulic malfunction. Refer to
"Automatic Transmission Diagnosis" in SECTION
7Al4A.
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-cs.:1 s
CHARTC-8C
2nd GEAR START SWITCH SIGNAL CIRCUIT CHECK
INSTALL SCAN TOOL

IGNITION "ON", ENGINE "OFF."
OBSERVE "2nd GEAR START SWITCH" ON SCAN TOOL DISPLAY, WHILE
PRESSING THE 2nd GEAR START SWITCH TWICE.
IS "ON" DISPLAYED WHEN 2nd GEAR START SWITCH IS PRESSED, AND
"OFF" DISPLAYED WHEN RELEASED?
IGNITION "OFF ...

DISCONNECT THE 2nd GEAR START SWITCH CONNECTOR.
IGNITION "ON."
WITH TEST LIGHT TO GROUND, PROBE 2nd GEAR START SWITCH
SIGNAL CIRCUIT AT CONNECTOR WHILE OBSERVING .. 2nd GEAR
START SWITCH" ON SCAN TOOL DISPLAY.
IS "ON" DISPLA YEO DURING PROBE AND "OFF" DISPLAYED WHEN
REMOVED?
WITH TEST LIGHT TO B +, PROBE THE

GROUND CIRCUIT AT CONNECTOR.
IS TEST LIGHT "ON"?
2nd GEAR START SWITCH

SIGNAL CIRCUIT CHECK OKAY.
REPAIR OPEN OR SHORTED 2nd GEAR

START SWITCH SIGNAL CIRCUIT TO THE
PCM.
REPAIR OPEN GROUND CIRCUIT TO

SWITCH.
6-21-93
PS 18648

PCM
TRANSMISSION
WIRING
CONNECTOR ASM.
1-2 SHIFT
SOLENOID
1-2 SHIFT SOLENOID

CONTROL
1222 LT GRN
------------1
#11 IGNITION
239 P N K - - - c ( ~ TO IGNITION
10 AMP
SWITCH
T02-3
SHIFT
SOLENOID
T03-2
CONTROL
SOLENOID
6-16-93
PS 18516
CHARTC-8D
TRANSMISSION 1-2 SHIFT SOLENOID CIRCUIT CHECK
3.4L {VIN S) "F,i CARLINE (SFI)
The 1-2 shift solenoid is used to control fluid flow acting on the 1-2 and 3-4 shift valves. The solenoid is a
normally open exhaust valve that is used with the 2-3 shift solenoid to allow four different shifting combinations.
The solenoid is attached to the control valve body within the transmission. Ignition voltage is supplied directly to
the 1-2 shift solenoid. The Powertrain Control Module (PCM) controls the solenoid by providing the ground path
through CKT 1222.

1. This test checks 1-2 shift solenoid and the internal
transmission wiring harness for shorts.
2. This test checks for power to 1-2 shift solenoid from
the ignition through the fuse.
Diagnostic Aids: Check all connections for the

transmission.
An open in the ignition feed circuit can cause
CHART 4L60E
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
Gear
"
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-C8-17
CHARTC-80
TRANSMISSION 1-2 SHIFT
SOLENOID CIRCUIT CHECK
INSTALL TECH 1.

IGNITION
ENGINE "OFF."
ENTER MISC"ON."
TESTS/TRANSMISSION/ 1-2 SOLENOID.
COMMAND 1-2
SHIFT SOLENOID "ON"/"OFF" THREE TIMES WHILE LISTENING
AT BOTTOM OF TRANSMISSION PAN (USE STETHESCOPE IF 'NECESSARY).
~;:
IGNITION "OFF."
INSTALL J 39775 JUMPER HARNESS/PROBE KIT ON THE EXTERNAL WIRING ,CONNECTOR.
CONNECT TEST LIGHT FROM CAVITY "E" OF J 39775 TO GROUND.
IS TEST LIGHT "ON"?
INSTALL TEST LIGHT FROM CAVITIES "E" TO" A" OF J 39775.

COMMAND 1-2 SHIFT SOLENOID "ON"/''OFF" THREE TIMES.
IS TEST LIGHT "ON" WHEN COMMANDED "ON," AND
CHECK CKT 1222 FOR AN OPEN OR SHORT FROM THE

TRANSMISSION .EXTERNAL WIRING CONNECTOR TO
THE CONTROL MODULE CONNECTOR.
IF OKAY, REPLACE PCM.
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
''

EXTERNAL TRANSMISSION WIRING CHECK OKAY.

IN SECTION 7A14A (4L60E) OR 7A17A (4L80E).
4-13-93
PS 17094
PCM
TRANSMISSION WIRING
CONNECTOR ASM.
2-3 SHIFT
SOLENOID
2-3 SHIFT SOLENOID

CONTROL
r---,
1223 Y E L / B L K - - - - - - - - - - - 1
#11 IGNITION
- - - 2 3 9 P N K - - < ~ TO
10 AMP
IGNITIO.N
SWITCH
TO TCC
SOLENOID
TO 1-2 SHIFT
SOLENOID
TO 3-2 CONTROL
SOLENOID
06-16-93
PS 18510
CHARTC-8E
TRANSMISSION 2-3 SHIFT SOLENOID CIRCUIT CHECK
The 2-3 shift solenoid is used to control fluid flow acting on the 2-3 shift valves. The solenoid is a normally
open exhaust valve that is used with the 1-2 shift solenoid to allow four different shifting combinations. '.l'he
solenoid is attached to the control valve body within the transmission. Ignition voltage is supplied directly to the
2-3 shift solenoid. The Powertrain Control Module (PCM) controls the solenoid by providing the ground path
through CKT 1223.

transmission wiring for shorts.

transmission.
CHART4L60E
Gear
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
o'RIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C8-19
CHARTC-8E

SOLENOID CIRCUIT CH ECK
INSTALL TECH 1.
ENTER MISC TESTS/TRANSMISSION/ 2-3 SOLENOID.
COMMAND 2-3 SHIFT SOLENOID "ON" /"OFF" THREE TIMES
WHILE LISTENING AT BOTTOM OF TRANSMISSION PAN
(USE STETHOSCOPE IF NECESSARY).
IGNITION "OFF."
(ADDITIONAL DTCs WILL SET.)
INSTALL J 39775 JUMPER HARNESS/PROBE KIT ON THE
CONNECT TEST LIGHT FROM CAVITY "E" OF J 39775 TO
GROUND.
15 TEST LIGHT "ON"?
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
INSTALL TEST LIGHT FROM CAVITIES "E" TO "B" OF

J 39775.
COMMAND 2-3 SHIFT SOLENOID "ON" /"OFF"
THREE TIMES.
15 TEST LIGHT "ON" WHEN COMMANDED ON, AND
"OFF" WHEN COMMANDED OFF?
CHECK CKT 1223 FOR AN OPEN OR SHORT

FROM CONTROL MODULE TO TRANS
WIRING CONNECTOR.
IF OK, REPLACE CONTROL MODULE.

CHECK OK.
REFER TO "INTERNAL WIRING
HARNESS CHECK," IN SECTION
7A14A (4L60E)OR 7A17A (4L80E).
REPAIR OPEN OR SHORT TO GROUND IN

THE IGNITION VOLTAGE FEED CIRCUIT TO
THE TRANSMISSION.
IF THE FUSE 15 OPEN, CHECK THE
TRANSMISSION INTERNAL WIRING
HARNESS OR SOLENOID FOR SHORT TO
GROUND.
4-13-93
PS 17093

TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
3-2CONTROL
SOLENOID
PCM
r"---,I
3-2 CONTROL
SOLENOID
"I
14---
TOTCC
SOLENOID
TO 2-3
SHIFT
SOLENOID
#11 IGNITION
239 PNK ~ I G N I T I O N SWITCH
10A
TO 1-2
SHIFT
SOLENOID
l
6-16-93
MS 18517
CHARTC-8F
TRANSMISSION 3-2 CONTROL SOLENOID CIRCUIT CHECK
.3.4L (VIN S) "F" CARLINE (SFI)
Hydraulically, the 3-2 control solenoid coordinates the apply rate of the 2-4 band with the hydraulic release of
the 3-4 clutch during a 3-2 downshift.
The PCM continually monitors the 3-2 circuit duty cycle depending on the commanded state of the circuit.
When the transmission is in first gear the duty cycle of the solenoid is equal to O ("OFF"). When the transmission
is in second gear or higher the duty cycle of the solenoid will be about 90% ("ON"). When the transmission
downshifts, 3-2, the duty cycle of the solenoid will drop.

1. This test checks the function of the .3-2 control
solenoid and the internal transmission harness.
2. This test chficks for power. to, the 3-2 control
solenoid from the igr1ition through the fuse.

transmission connector.
If OK, refer to "Symptom Diagnosis" in SECTION
7A14A.
The 3-2 .control solenoid feedback normally
oscillate "ON/OFF" when the duty cycle is applied.
multiple DTC(sl to set.
CHARTC-8F
TRANSMISSION 3-2 CONTROL

SOLENOID CIRCUIT CH ECK
INSTALL TECH 1.
ENTER MISC TESTS/TRANSMISSION/ 3-2 SOL.
COMMAND 3-2 CONTROL SOLENOID "0%/100% .. THREE
TIMES WHILE LISTENING AT BOTTOM OF TRANSMISSION PAN
IGNITION "OFF."
GROUND.
IS TEST LIGHT "ON"?
INSTALL TEST LIGHT FROM CAVITIES "E" TO "S" OF J 39775.

COMMAND 3-2 CONTROL SOLENOID "0%/100%" THREE
TIMES.
IS TEST LIGHT "ON" WHEN 3-2 CONTROL SOLENOID IS
COMMANDED "ON" TO "100% ", AND "OFF" WHEN
COMMANDED TO "0% "?
REMOVE J 39775 FROM THE EXTERNAL WIRING

CONNECTOR AND INSTALL IT ON THE TRANSMISSION
INTERNAL WIRING CONNECTOR.
WITH J 39200-DVM MEASURE RESISTANCE ACROSS "E"
AND "S" OF J 39775.
IS RESISTANCE 9-140?
CLEAR DTC(s)
AND RETEST.
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSIS AIDS."
REPAIR OPEN OR SHORT

TO GROUND IN THE
IGNITION VOLTAGE FEED
CIRCUIT TO THE
TRANSMISSION.
CHECK FOR OPEN OR SHORT IN 3-2

CONTROL CIRCUIT.
If OK, REPLACE PCM.
REPLACE 3-2 CONTROL SOLENOID OR INTERNAL

WIRING HARNESS.
REFER TO "VALVE BODY" IN "ON-VEHICLE
SERVICE" IN SECTION 7 A 14A FOR REPLACEMENT
PROCEDURE.
4-13-93
MS 13465
TCC
SOLENOID
TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
PCM
r---,
.---.--------+-1 T
TCCCONTROL
. . . - - - - - - - - - - - - - - 422 TAN/BLK
#11 IGNITION
10A
SWITCH
T03-2
CONTROL
SOLENOID
T02-3
SHIFT
SOLENOID
628-93
PS18515
CHARTC-8G
TRANSMISSION TCC SOLENOID CIRCUIT CHECK
then controls TCC apply and release. The PCM monitors TP voltage, vehicle speed and other inputs to determine
when to energize the TCC solenoid. Ignition voltage is supplied directly to the TCC solenoid. The Powertrain
Control Module (PCM) controls the solenoid by providing the ground path through CKT 422.

transmission harness or TCC solenoid.

If OK refer to "Symptom Diagnosis" in SECTION
7A14A.
CHARTC-8G
CIRCUIT CHECK
INSTALL TECH 1 .
RECORD THEN CLEAR DTCs .
ENTER MISC TESTS/TRANSMISSION/TC( SOLENOID .
COMMAND TCC SOLENOID "ON"/"OFF" THREE TIMES WHILE LISTENING AT
IGNITION "OFF."
INSTALL J 39775 JUMPER HARNESS/PROBE KIT ON THE EXTERNAL WIRING CONNECTOR.
CONNECT TEST LIGHT FROM CAVITY "E" OF J 39775 TO GROUND .
IS TEST LIGHT "ON"?
SJ
INSTALL TEST LIGHT FROM CAVITIES "E" TO "T"

(4L60E) OR "E" TO "S" (4L80E) OF J 39775.
COMMANDTCC SOLENOID "ON"/"OFF" THREE TIMES.
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."

CHECK CKT 422 (4L60E) OR CKT 1350 (4L80E) FOR


SECTION 7A14A (4L60E) OR 7A17A (4L80E).
4-13-93
PS 17530
BLANK
SECTION C10
A/C COMPRESSOR CLUTCH CONTROL

CONTENTS
General Description
Operation
Diagnosis
C10-1
C10-1
C10-1
GENERAL DESCRIPTION
In order to improve. engine operation, and protect
the NC compressor and clutch during Wid.e Open
Throttle (WOT) performance, the A/C compressor
operation is controlled by the PCM.
OPERATION
The A/C electrical system consists of an A/C
control head; A/C refrigerant low pressure cutoff
switch, an A/C refrigerant pressure. sensor, an
evaporator temperature sensor, a control relay, the
compressor clutch, and the PCM.
When A/C is selected "ON" through the A/C
control head, a 12 volt signal is supplied to the NC
request input of the PCM. The PCM will poll the NC
refrigerant pressure sensor and A/C evaporator
temperature sensor before enabling the compressor
clutch control relay. If either switch detects a pressure
or temperature variation above or below a calibrated
acceptable range, the clutch relay will not be enabled.
When the PCM determines that the system
temperature and pressure are within acceptable
ranges, the NC compressor clutch relay will be
enabled, allowing voltage to be applied to the A/C
clutch and NC status input of the PCM. The A/C
status input informs the PCM that the relay has closed
and voltage is applied to the clutch, via the A/C
compressor low pressure cutoff switch. The A/C
compressor low pressure cutoff switch is closed when
there is sufficient system pressure (depending on
refrigerant charge and ambient temperature). The
PCM will also turn the cooling fan "ON" when NC is
requested. Refer to "Cooling Fan Control," Section
"6E3-C12" for more information on cooling fan
operation. NC is controlled by the PCM so that the
PCM can increase idle speed before turning ''ON" the
clutch or disable the clutch during WOT or high
coolant temperatures.
DIAGNOSIS
The PCM will energize the A/C clutch whenever
the engine is running and A/C has been requested,
unless any of the following conditions are met:
Wide Open Throttle (WOT).
On-Vehicle Service
A/CRelay
C10-1
C10-1
NC head pressure greater than 492 psi or less

than 1 psi (as determined by the A/C
refrigerant pressure sensor).
. Evaporator temperature .sensor less than 1C
(33F).
Low ignition voltage.
IAT greater than 151C (304F).
Engine speed greater than 5200 RPM.
ECT greater than 124C (255F).
CHART C-10 should be used for diagnosing the
electrical portion of the NC circuit. SECTION lB of
the service manual should be used for diagnosing the
refrigerant portion of the system.
The Tech 1 will be used in diagnosing the system,
as it has the ability to monitor the NC request input to
the PCM, NC status, NC system pressure, as well as
displaying when the PCM has commanded the A/C
clutch "ON."
ON-VEHICLE SERVICE
A/C RELAY

1.
2.
3.

Cover from underhood electrical center.
Relay from underhood electrical center.

1.
2.
3.
Relay to underhood electrical center.

Cover to underhood electrical center.
For removal and replacement procedures of A/C
components, refer to SECTION lB of the service
manual.
ABS IGN
A/C COMPRESSOR
RELAY
ABS
RELAY
COOLANT FAN
RELAY,#1
AIR PUMP
RELAY
00
w
w
w
INJECTOR
ABS BAT
~~
FANS/ACTR
FOG LTS
INJECTOR
OY 0.0
AIR PUMP
~#8[1
NOT USED
IGNITION
R HDLP DR
~
LHDLP DR
A/C-CRUISE
COOLANT FAN
RELAY, #2
.ASR/TCS
FOG LIGHTS
RELAY
COOLANT FAN
RELAY, #3
TOP VIEW
#4EI
~#8~
#78
o
502
lffl)
641
84
[j}
@}
84
58 C8J E1 sEJ C8J 00 sG C8J 8 sE) C8JB

#38
B,
G,
0,
01
4
4
! !
rn ~4
0
8
2
#12EJ
#118
l.
#GEi
#5
ff2
502
#18
....
1m
sB C8J 8 sE) C?1 Bs~ C?1 8 sE] C?1 ~

c EL
B ~
E ~
D El
3
#108
#98
BACK VIEW
NS 15595
Figure C10-1 -A/C Clutch Control Relay Location
DRIVEABILITY AND EMISSIONS .3.4L {L32) {VIN S) {SFI) 6E3-C10-3
BLANK
6E3-C10-4 3.4L (L32) {VIN S) (SFI) DRIVEABILITY AND EMISSIONS
TOIATAND
MAP SENSOR
A/C PRESSURE
SENSOR
452BLK-----------.'---------I
SENSOR GROUNDS
----------+-------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY-------,
A/C
EVAPORATOR
TEMPERATURE
SENSOR
PCM
452BLK--------4-----'
732DKBLU------+-----------I
VP FUSE #3
416GRv-------e----------------ll
A/C
.._--,~TOTPAND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - - - ~ - - - - - - - 7 6 2 DK GRN/WHT
2 5 AMP
FUSE #12 *
IGNITION
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
SWITC~139PNK---,
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
..---..,
-------------~
I
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
A/C
0 C ] A Br-59DKGRN
COMPRESSOR
CLUTCH
- - - - 4 5 0 BLK
----i-,
7-2-93
NS 15598
CHARTC-10
1
(Page 1 of 2)
A/C COMPRESSOR CLUTCH CONTROL CIRCUIT DIAGNOSIS
3.4L (VIN S) .. F" CARLINE (SFI)
The A/C compressor clutch control relay is PCM controlled to delay A/C clutch engagement after the A/C is
turned "ON." This allows the PCM to adjust engine RPM before the A/C compressor clutch engages.
The PCM will engage the A/C clutch anytime A/C has been requested unless any of the following conditions
exist:
High engine RPM.
Low system pressure.
High coolant temperature.
Wide open throttle.
High A/C system pressure.
Any A/C DTC set.
The PCM determines A/Chas been requested by receiving a voltage signal from the A/C control head. When
the A/C control switch closes, the A/C request input has 12 volts applied to it. This is shown on the Tech 1 as A/C
request "YES." A 3-wire A/C refrigerant pressure sensor is used to monitor A/C system pressure. If the A/C
refrigerant pressure is greater than 430 psi or lower than Opsi, the A/C clutch will not engage.
A faulty A/C refrigerant pressure sensor will set a DTC 66 or 67. If the A/C refrigerant pressure sensor signal
wire becomes open or shorted to ground, DTC 66 will set. If the signal circuit is shorted to voltage, a DTC 70 will
set. If the A/C clutch engages and no pressure change is detected, a DTC 67 will set.
When a request for A/C has been detected by the PCM, the PCM will ground the A/C compressor clutch
control relay drive circuit, the relay contacts will close, and current will flow through the relay to the A/C
compressor clutch.

1. Checks the PCM's ability to control the A/C clutch
control relay.
2. Checks for grounded CKT 459 to PCM.
Diagnostic Aids: Before using CHART C-10, be

sure no DTC(s) are stored. The PCM will not energize
the NC compressor clutch with a stored DTC.
CHART C-10
(Page 1 of 2)

CONTROL CIRCUIT DIAGNOSIS
t
t
t
t
CHECK .. A/CH FUSES.

ENGINE AT NORMAL OPERATING TEMPERATURE.
CORRECT ANY DIAGNOSTIC TROUBLE CODES.
A/C REFRIGERANT PRESSURE NORMAL.
ENGINE IDLING.
A/C "OFF."
IS A/C CLUTCH MECHANICALLY ENGAGED?
WITH ENGINE IDLING AT NORMAL OPERATING

TEMPERATURE, TURN A/C "ON" AND "OFF."
DOES A/C CLUTCH CYCLE "ON" AND "OFFH?
PLACE A/C SELECT IN A/C MODE.

TECH 1 SHOULD DISPLAY A/C
REQUEST "YES."
DOES IT?
NO TROUBLE
FOUND. A/C
CLUTCH
CIRCUIT OK.
ENGINE STILL RUNNING.

TECH 1 SHOULD DISPLAY A/C REQUEST "NO."
DOES IT?
DISCONNECT A/C
RELAY.
PROBE CKT 459 WITH
IS TEST LIGHT "ON"?
CKT 762 SHORTED

TO VOLTAGE
OR
FAULTY A/C
CONTROL HEAD.
PROBE CKT 59 WITH

A TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
CKT 459 SHORTED

TO GROUND
OR
FAULTY PCM .
r-- -----,
I REFER TO
I
: CHARTC-10. :
I PAGE 2 OF 2. I
..,..______________________
L--------.J
CHECKFORSHORTTO
GROUND IN CKT 241 OR 762.
CHECK FOR OPEN CKT

762 OR 241 OR
FAULTY AC SELECT
SWITCH OR FAUL TY
PCM CONNECTION OR
FAULTY PCM.
CKT59
SHORTED TO
VOLTAGE.
6-17-93
NS 16213

TOIATAND
MAP SENSOR
l"-;::===~
A/C PRESSURE
SENSOR~
- ~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
..,..-----1
1/P FUSE #3
PCM
452BLK
SENSOR GROUNDS
380RED/BLK
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
416GRY-------,
-------+---....,
732 DK BLU - - - - - - + - - - - - - - - - - - t
452 BLK
416GRv----------------------1
A/C
'------' TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 DKGRN/WHT
25 AMP
IGNITION
FUSE #12 *
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
SWITC~139PNK---,
20AMP
....----tB1 t - - e - - - - - - '
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
,---,
11------------...t
I
59 DK GRN
-----+1
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
L--....1
A/C
D ~ A B1 - - - 5 9 DK GRN
COMPRESSOR
CLUTCH
- - - - 4 5 0 BLK -----J_-,
7-2-93
NS 15598
CHARTC-10
{Page 2 of 2)
A/C COMPRESSOR CLUTCH CONTROL CIRCUIT DIAGNOSIS

The A/C clutch control relay is PCM controlled to delay A/C clutch engagement after the A/C is turned "ON."
This allows the PCM to adjust engine RPM before the A/C clutch engages.
The PCM will engage the A/C clutch anytime A/C has been requested unless any of the following conditions
exist:
High engine RPM.
Low system pressure.
Any A/C DTC set.
Wide open throttle.
The PCM can determine A/C has been requested by a voltage signal received from the A/C control head.
When the A/C select switch closes, the A/C request voltage signal is applied to the PCM A/C request input. This
is shown on the Tech 1 as A/C request "ON." A 3-wire A/C refrigerant pressure sensor is used to monitor A/C
system pressure. If the A/C refrigerant pressure is greater than 430 psi or lower than O psi, the A/C clutch will
not engage.
The A/C refrigerant pressure sensor uses DTCs 66, 67 and 70 to indicate sensor or sensor circuit
malfunctions. If the A/C refrigerant pressure sensor signal wire becomes open or shorted to ground, DTC 66 will
set. If the signal line is shorted to voltage a DTC 70 is set. If the A/C clutch engages and no pressure change is
detected, a DTC 67 will set.
When a request for A/C has been detected by the PCM, the PCM will ground the A/C clutch control relay
drive circuit, the relay contacts will close, and current will flow through the relay to the A/C compressor clutch
via the A/C compressor low pressure cutoff switch.
CHART C-10
(Page 2 of 2)
,-------------~
: FROM CHARTC-10 :
I
PAGE 1 OF2
L-

11
----------~
DOES TECH 1 DISPLAY A/CCLUTCH "ON?"
REFER TO APPROPRIATE DTC FOR DIAGNOSIS.
DOES TECH 1 DISPLAY A/C STATUS "ON?"
IGNITION "OFF."
DISCONNECT A/C
CLUTCH CONNECTOR.
IGNITION "ON"
ENGINE "ON."
PROBE "CKT 59" WITH
A TEST LIGHT TO
GROUND.
IS LIGHT "ON"?
IGNITION "OFF."
REMOVE A/C RELAY.
IGNITION "ON."
USING A TEST LIGHT, PROBE BOTH IGNITION
FEED CIRCUITS CIRCUITS FROM A/C RELAY
HARNESS TO GROUND.
NO LIGHT ONE OR BOTH
LIGHT "ON" BOTH
CONNECT TEST
LIGHT BETWEEN
A/C COMPRESSOR
CLUTCH HARNESS
CONNECTOR
TERMINALS.
JUMPER CKT 139 TO

CKT59.
A/C STATUS "ON"?
OPEN OR
SHORT TO
GROUND IN
CKT59 FROM
SPLICE TO
CLUTCH.
FAUL TY CLUTCH
CONNECTION
OR
FAULTY A/C
COMPRESSOR
CLUTCH COIL.
OPEN CKT450
OR
FAULTY
GROUND
CONNECTION.
OPEN IN
CIRCUIT THAT
DID NOT
LIGHT.
IGNITION "ON."
GROUND
DIAGNOSTIC
"TEST" TERMINAL.
PROBE TERMINAL
"85" (CKT 459) WITH
A TEST LIGHT TO
B+.
FAULTY PCM
CONNECTION
OR OPEN A/C
STATUS
CIRCUIT
FROM SPLICE
TO PCM OR
FAULTY PCM.
OPEN
A/C
CIRCUIT
FROM
RELAY
TO
SPLICE.
LIGHT
"ON"
FAULTY
A/C
RELAY.
OPEN OR SHORT
TO VOLTAGE IN
CKT4590R
FAULTY PCM
CONN.OR
FAULTY PCM.
6-18-93
NS 16214
BLANK
SECTION C12
COOLING FAN CONTROL

CONTENTS
GeneralDescription
Operation , ,
C12-1
C12-1
Diagnosis
On-Vehicle Service
C12-1
C12-1
GENERAL DESCRIPTION
ON-VEHICLE SERVICE
This vehicle utilizes an electric cooling fan for

engine and A/C condenser cooling. The fan operates
under certain conditions as outlined below.
Cooling system component replacement can be

found in SECTION 6B.
OPERATION
The engine coolant fan is controlled by the PCM
via the coolant fan relay. A calibrated set of criteria
programmed into the PCM will energize the fan relay.
The following conditions control the fan:
Engine Coolant Temperature (ECT) sensor
signal indicating 109C (228F) or greater will
turn the coolant fan "ON."
Engine Coolant Temperature (ECT) sensor
signal indicating 98C or less will turn the fan
"OFF."
The fan will turn "ON" if A/C is requested and
vehicle speed is less than 56 km/h (35 mph).
If vehicle speed is greater than 113 km/h (70
mph) the fan is disabled and will not turn
"ON."
If A/C is requested and refrigerant. pressure
sensor indicates approximately 20 psi or
greater the fan is turned "ON."
When the PCM is operating in backup the fan
will be "ON."
When any A/C DTC is set the fan will be "ON."
DIAGNOSIS
The following C-12 circuits charts will diagnose
the PCM controlled cooling fans.
3
LEFT SIDE WHEELHOUSE
2
RELAY CENTER
HEADLAMP ACTUATOR MODULE

NS 15935
Figure C12-1 - Cooling Fan Relay
6E3-C12-2 3.4L {L32) {VIN S) {SFI) DRIVEABILITY ANO EMISSIONS

PCM
B+
FUSE LINK
~402RED
10-WAY INLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
335 DKGRN
COOLING
FAN
CONTROL
RELAY*
COOLING FAN CONTROL
10AMP
~#6
TOIGN
409 LT BLU
150 BLK---i--,
TO DIGITAL EGR,
EVAPPURGESOLVALVE
A/C
SELECT SWITCH
1/P FUSE #3
A/CREQUEST
TO ~ 2 4 1 B R N ~ - - - - - - IGNITION
25 AMP
.
SWITCH
452BLK-----------------1
A/C PRESSURE
SENSOR
380 RED/BLK - - - - - - - - - - - - - - 1
416GRY
----------------11
SENSOR GROUND
SENSOR SIGNAL
5VREF
7-3-93
NS 15936
CHART C-12
.{Page 1 of 2) .
COOLING FAN CONTROL CIRCUIT DIAGNOSIS

The electric cooling fan is controlled by the PCM, based on inputs from the Engine Coolant Temperature
(ECT) sensor, the NC control switches, vehicle speed, and state of the NC refrigerant pressure sensor. The PCM
controls the fan by grounding CKT 335 which energizes the fan control relay. Battery voltage is then supplied to
the fan motor.
The PCM grounds CKT 335 when engine coolant temperature is over about 109C (228F), or when A/C has
been requested and the A/C refrigerant pressure is about 1655 kPa (240 psi). Once the PCM turns the relay
"ON," it will keep it "ON" for a minimum of 30 seconds, or until vehicle speed exceeds 113 km/h (70 mph).
Also, ifDTC 14 or 15 sets or the PCM is in backup, the primary fan will run at all time.

1. With the diagnostic terminal grounded, the
cooling fan control driver(s) will close, which
should energize the fan control relay(s).
2. If the NC pressure is above 240 psi (1655 kPa) or
circuit is open, the fan would run whenever NC is
requested. .
3. With A/C clutch engaged and the NC refrigerant
pressure sensor is functioning properly, the fan
should come "ON" when pressure exceeds about 20
psi. Under very cold ambient conditions, the fan
will remain "OFF." This signal should cause the
PCM to energize the cooling fan control relay.
4. This will determine if the NC refrigerant pressure

sensor is faulty or if the PCM or circuitry is faulty.
Diagnostic Aids: If the owner complained of an

overheating problem, it must be determined if the
complaint was due to an actual boilover, a hot light or
temp. gage indicated over heating.
If the gage or light indicates overheating, but no
boilover is detected, the gage circuit should be
checked.
CHARTC-12

INDICATING LESS THAN 98C (208F).
IGNITION "ON," ENGINE "OFF," A/C "OFF."
COOLING FAN SHOULD BE "OFF."
IS IT?
(Page 1 of 2)

GROUND DIAGNOSTIC TEST TERMINAL, OR

SELECT COOLING FAN "OUTPUT" TEST ON TECH 1.
FAN SHOULD TURN "ON."
DOESIT?
UNGROUND DIAGNOSTIC TEST

TERMINAL OR EXIT OUTPUT TEST.
START AND IDLE ENGINE.
A/C "OFF."
FAN SHOULD BE "OFF" WHILE
TEMPERATURE IS UNDER 98C (208F)].
ISIT?
REMOVE COOLING FAN CONTROL RELAY.

FAN SHOULD STOP.
DOES IT?
----,
REFERTO I
: CHART
:
I C-12
1
1
1 (2 OF 2)
I
L------.l
CKT 335 SHORTED TO

GROUND OR FAUL TY PCM.
FAUL TY CALIBRATION OR PCM.

WITHA/C
WITHOUT
A/C
ENGINE IDLING, A/C "OFF."

USE A TECH 1 SCAN TOOL AND CHECK A/C REFRIGERANT PRESSURE SENSOR.
DOES TECH 1 SCAN TOOL DISPLAY PRESSURE GREATER THAN 240 psi(1655 kPa)?
Ci)r ----------------------,
:
:
I
:
I
ENGINE IDLING, A/C "ON...

IF A/C IS INOPERATIVE SEE CHART
C-10.
FAN SHOULD TURN "ON" WHEN
A/C IS REQUESTED AND HEAD
PRESSURE EXCEEDS ABOUT
20psi.
:
I
:
I
----------------------~
NO TROUBLE
FOUND. REFER TO
"DIAGNOSTIC AIDS"
OF FACING PAGE.
DISCONNECT A/C REFRIGERANT PRESSURE SENSOR.

DOES SCAN INDICATE ZERO A/C PRESSURE?
OPEN CKT 452 OR FAULTY

SENSOR CONNECTOR
OR FAULTY SENSOR.

MEASURE VOLTAGE BETWEEN CONNECTOR TERMINAL "B" AND" A".
VOLTMETER SHOULD DISPLAY ABOUT 5 VOLTS.
DOES IT?
MEASURE VOLTAGE BETWEEN

CONNECTOR TERMINAL "B" AND "C."
VOLTMETER SHOULD READ 5 VOL TS.
DOESIT?
CKT 380 OPEN OR

SHORTED TO GROUND
OR FAULTY PCM
CONNECTION OR PCM.
MEASURE VOLTAGE BETWEEN CONNECTOR

TERMINAL "B" AND GROUND.
VOLTMETER SHOULD DISPLAY ABOUT 5 VOL TS.
DOES IT?
CKT452 OPEN
OR FAUL TY PCM
CONNECTION
OR PCM.
CKT 416 OPEN OR

SHORTED TO GROUND
OR FAUL TY PCM
CONNECTION OR PCM.
6-17-93
NS 16220
6E3-C12.:4 3.4L {L32) {VIN 4) {SFI) DRIVEABILITY AND EMISSIONS

PCM
B+
FUSE LINK
~402RED
10-WAY INLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
COOLING FAN CONTROL
335DKGRN
COOLING
FAN
CONTROL
RELAY*
541 BRN
10AMP
TOIGN
409LTBLU
150 BLK------------i~
TO DIGITAL EGR,
EVAP PURGE SOL VALVE
_
. A/C
1/P FUSE #3
SELECT SWITCH
TO ~ 2 4 1 B R N ~ - - - - - - - - - - - - 7 6 2 D K G R N / W H T
IGNITION
25 AMP
SWITCH
452BLK--------------------------------------------------1
A/C PRESSURE
SENSOR
380 RED/BLK
--------------------------------------------1
416GRv------------------------------------------------------1
A2
A/CREQUEST
SENSOR GROUND
SENSOR SIGNAL
5VREF
7.3.93
NS) 15936
CHART C-12
{Page 2 of 2)
COOLING FAN C.ONTROL CIRCUIT DIAGNOSIS

1. 12 volts should be available to CKT 541 and CKT
402 of the relay when the ignition is "ON."
2. This test checks the ability of the PCM to ground
CKT 335.
The Malfunction Indicator Lamp (MIL) "Service

Engine Soon" should also be flashing at this point.
Ifit isn't flashing, refer to CHART A-2.
3. If the fan does not turn "ON" at this point, CKT
409 .or CKT 150 is open, or the cooling fan motor is
faulty.
CHART C-12
I
(Page 2 of 2)
FROM
CHART

C-12
(1 OF 2)
l
,
REMOVE COOLING FAN CONTROL RELAY.

IGNITION "ON, ENGINE "OFF."
PROBE UNDERHOOD ELECTRICAL CENTER CAVITIES "01" AND "OS"
WITH A TEST LIGHT CONNECTED TO GROUND.
LIGHT "ON" BOTH
DIAGNOSTIC TEST TERMINAL GROUNDED.

PROBE CKT 335 WITH A TEST LIGHT
CONNECTED TO 12 VOL TS.
REPAIR OPEN OR SHORT TO GROUND

IN CIRCUIT THAT DID NOT LIGHT.
JUMPER CAVITIES "01" AND "04" TOGETHER

USING A FUSED JUMPER.
FAN SHOULD RUN. DOES IT?
OPEN OR SHORT TO VOLTAGE IN CKT 335, OR

FAULTY CONNECTION AT PCM ORA FAULTY PCM.
WITH CAVITIES STILL JUMPERED, AS ABOVE,

CONNECT A TEST LIGHT ACROSS THE COOLING
FAN MOTOR HARNESS CONNECTOR "A" AND
"B" TERMINALS.
PROBE CKT 409 ON COOLING FAN MOTOR

HARNESS CONNECTOR WITH A TEST LIGHT
OPEN IN GROUNDCKT 150.
REPAIR OPEN IN CKT 409 BETWEEN

RELAY AND COOLING FAN MOTOR.
6-17-93
NS 16221
6E3-C12-6 3.4l (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION C13
CRANKCASE VENTILATION SYSTEM

CONTENTS
General Description
Operation
Diagnosis
C13-1
C13-1
C13-1
C13-2
GENERAL DESCRIPTION
A crankcase ventilation system is used to provide
scavenging of crankcase vapors. Fresh air from the air
cleaner is supplied to the crankcase, mixed with blowby gases and then passed through a crankcase
ventilation valve into the intake manifold (Figure
C13-1).
Functional Check of Crankcase

Ventilation Valve
On-Vehicle Service
C13-2
C13-2
OPERATION
The primary control is through the crankcase
ventilation valve (Figure C13-2) which meters the flow
at a rate depending on manifold vacuum.
To maintain idle quality, this valve restricts the
flow when intake manifold vacuum is high. If
abnormal operating conditions arise, the system is
designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent tube into the
air inlet duct to be consumed by normal combustion.
CHECK VALVE
45 0068-6E
Figure C13-2- Crankcase Ventilation Valve Cross

Section

A plugged valve or hose may cause:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Oil in throttle body or plenum.
Sludge in engine.
A leaking valve or hose would cause:
Rough idle.
Stalling.
High idle speed.
c:> CLEAN AIR
-+
VOLATILE OIL FUMES
----- MIXTURE OF AIR AND FUMES
CRANKCASE VENTILATION VALVE
TO THROTTLE BODY
CRANKCASE VENT HOSE
CRANKCASE VENTILATION VALVE HOSE
TO INTAKE MANIFOLD
SS 1725-6E
Figure C13-1 - Crankcase Ventilation Flow (Typical)
6E3-C13-2 3.4L (L32) (VIN .S) (SFI) DRIVEABILITY AND EMISSIONS
!VIEWA!
CRANKCASE VENTILATION VALVE HARNESS ASSEMBLY
2
UPPER INTAKE MANIFOLD

NS 15884
Figure C13-3 - Crankcase Ventilation System Service
DIAGNOSIS
FUNCTIONAL CHECK OF CRANKCASE
VENTILATION VALVE
If an engine is idling rough, check for a clogged
crankcase ventilation valve or plugged hose. Check
valve part number to be sure the correct valve is
installed. Replace as required. Use the following
procedure:
1. Remove valve from rocker arm cover.
2. Run the engine at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at the valve,
check for plugged hoses, manifold port or
valve. Replace plugged or deteriorated hoses.
4. Turn "OFF" the engine and remove valve.
Shake valve and listen for the rattle of check
needle inside the valve. If valve does not
rattle, replace valve.
With this system, any blow-by in excess of the

system capacity (from a badly-worn engine, sustained
h~avy load, etc.) is exhausted into the inlet duct and is
drawn into the engine.
.
Proper operation of the crankcase ventilation
system is dependent upon a sealed engine.
If oil sludging or dilution is noted and the
crankcase ventilation system is functioning properly,
check engine for possible cause and correct to ensure
that system will function as intended.
ON-VEHICLE SERVICE
An engine which is operated without any
crankcase ventilation can be damaged. Therefore, it is
i0.1portant to replace the valve at intervals shown in
SECTION OB.
Periodically, inspect the hoses and clamps and
replace any showing signs of deterioration.
ROCKER COVER ASSEMBLY
GROMMET
GROMMET
NS 15885
Figure C13-4 - Crankcase Ventilation System Service
CRANKCASE VENT PIPE
AIRDUCT
CLAMP
NS 15886
Figure C13-5 - Crankcase Vent Pipe Installation
BLANK
SECTION C14
AIR INTAKE SYSTEM

CONTENTS
General Description
Air Intake System
On-Vehicle Service
(14-1
(14-1
(14-1
GENERAL DESCRIPTION
AIR INTAKE SYSTEM
Air intake system draws outside air in past the
louvered cover of the forward mounted air cleaner.
The air cleaner a.ssembly is remotely mounted (refer to
Figure C14-2). The air then enters the engine by
flowing through the air intake duct throttle body and
into the intake manifold. The air is then directed into
the intake manifold runners, through the cylinder
heads and into the cylinder.
ON-VEHICLE SERVICE
NOTICE: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced use the correct part number fastener for
that application. The correct torque value must be
used, as specified, during reassembly to assure
proper retention of all parts, or damage to the part
may result.
AIR CLEANER FILTER/AIR CLEANER
ASSEMBLY
!++! Remove or Disconnect

1.
Loosen clamp at rear air intake duct at throttle

body.
2. IAT sensor electrical connector.
3. Retainer from upper radiator support.
4. Crankcase vent pipe from rear air intake duct.
5. Loosen clamp that joins rear air intake duct to air
cleaner outlet duct and remove rear air intake
duct.
AIR intake hose.
6. Slide air cleaner housing and air cleaner outlet
duct up as a whole assembly.
7. Release latches from air cleaner housing.
8. Air cleaner filter.
Air Cleaner Filter/

Air Cleaner Assembly
C14-1
C14-1

1.
2.
3.
4.
5.
6.
7.
8.
Air cleaner filter into air cleaner housing.

Snap air cleaner latches into place.
Slide air cleaner assembly into retainers.
Rear air intake duct to throttle body and tighten
clamp.
IAT sensor electrical connector.
Retainer to upper radiator support.
Crankcase vent pipe to rear air intake duct.
AIR intake hose.
(I] Important
Clamp assembly tension adjustment screw

should be located on the side of the intake duct
for optimum clamp force. This is important for
proper sealing.
Clamp,
Rear Air Intake Duct
Clamp,
Air Cleaner Outlet Duct
3.5 Nm (31 lb. in.)

3.5 Nm (31 lb. in.)
REAR AIR INTAKE DUCT

{WITH INTAKE AIRUMPERATURE SENSOR)
2
AIR CLEANER OUTLET DUCT
AIR CLEANER ASSEMBLY
FRONT AIR INTAKE. DUCT
UPPER RADIATOR MOUNTING PANEL

NS 15934
Figure C14-1 -Air Intake Components
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) INDEX-1

SECTION
PAGE
A
Acceleration Enrichment Mode
A/C Clutch Circuit Diagnosis
General Description
Diagnosis
Chart C-10 ,
On-Vehicle Service
A/C Request Signal
General Description
Diagnosis
Air 'Bypass Valve
Air Intake System
General Description
On-Vehicle Service
C2-2
. C10-1
C10-1
C10-4
Cl0-1
Chart C-6:
Secondary Air Injection System
(.heck
Chart C-7:
Exhaust Gas Recirculation (EGR) Flow
Check
Chart C-8:
System
Cl-6
C10-4
C6-1
C14-1
C14-1
C14-1
B
Backfire
B-17
Basic Procedure
A-1
Battery Voltage Correction Mode . C2-2
Before Using
B-2
c
Camshaft Position Sensor C1-7, C4-2
Crankshaft Position Sensor (24X)
C1-7, C4-2
Crankshaft Position Sensor (3X)
C1-6, C4-2
ChartA-1:
No MIL (Service Engine Soon)
A-28
ChartA-3:
Engine Cranks But Will Not Run
A-30
ChartA-7:
A-32
Fuel System Diagnosis
Chart 8-1:
B-24
Restricted Exhaust System Check
ChartC-10:
MAP Output Check
C1-14
Chart C-2A:
Injector Coil/Balance Test Procedure
C2-16
Chart C-28:
Idle Air Control (IAC) Valve Check
C2-22
Chart C-3:
Check
C3-6
Chart C-4F:
Misfire
C4-8
Chart C-5:
Knock Sensor System Check
CS-4
PAGE
SECTION
Chart C-10:
A/C Compressor Clutch Control
Circuit Diagnosis
Chart C-12:
Cooling Fan Control
Circuit Diagnosis
Chuggle
Clear Flood Mode
Closed Loop
Component Locations
Cooling Fan Control
General Description
Diagnosis
Service
General Description
Diagnosis
On-Vehicle Service
Cuts Out
. . . . . . . . . . . . .. . . . .
. . . . . . . . . . . . . . . . . . . ..
C6-6
C7-4
C8-4
Cl0-4
Ct2-2
B-6
C2-1
C2-1
A-3
C12-1
C12-1
C12-1
C13-1
C13-2
C13-2
B-10
. . . . . . .. .
A-16,28
c2~2
Deceleration Mode
Detonation
B-8
B-16
Dieseling, Run On
A-38
OTC 13
A-40
DTC14
A-42
OTC 15
A-44
DTC16
A-46
OTC 17
A-48
DTC21
A-50
DTC22
A-52
DTC23
A-54
DTC24
A-56
DTC25
A-58
DTC28
A-60
DTC33
A-62
DTC34
A-64
DTC35
A-66
DTC36
. . . . . . .. . . . . . . . . . . . . . .
. . .. . . . . . . .... . . .. .. . .
. . .. . . .. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .. . . .
. . . . . . . .. .. . . . . . . . . . . .
. . ... . . ........ . . . . . . .
. . . . . . . . . . . . . . . . . . . ...
2-INDEX 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

SECTION
PAGE
SECTION
PAGE
DTC37
DTC39
DTC41
DTC42
DTC43
DTC44
DTC45
DTC46
OTC 51
DTC53
DTC54
DTC58
DTC59
DTC61
DTC63
DTC64
DTC65
DTC66
DTC67
DTC68
DTC69
DTC70
OTC 71
DTC72
DTC73
DTC75
DTC76
DTC77
DTC79
DTC80
DTC82
DTC85
DTC86
DTC87
DTC90
DTC93
DTC96
DTC98
DTC99
A-68
A-70
A-72
A-74
A-76
A-78
A-80
A-82
A-129
A-84
A-86
A-88
A-90
A-92
A~94
A-96
A-98
A-100
A-102
A-104
A-106
A-108
A-110
A-112
A-114
A-116
A-118
A-120
A-122
A-124
A-126
A-129
A-130
A-129
A-132
A-134
A-136
A-138
A-138
Diagnosis
On-Vehicle Service
EVAP Canister
EVAP Canister Hose
EVAP Pressure Control Valve
General Description
Diagnosis
On-Vehicle Service
Exhaust Emissions Excessive (Odors)
Exhaust Gas Recirculation (EGR) System
Exhaust System Check Restricted
Cl-8
Cl-10
C3-1
C3-3
C3-2
C3-1
. .....
. .. . ..
. . .. . . . . . .
. .. . . . . . . .
. . . . . ..
. ...... .
. . .. . . .
. ...... .
.. . . . ..
. ..... .
. . . . . . . . .. .
. .. .. . . .. .
. ... . . . . . .
... . . . .
. . .. . .. . . .
. ..... ....
. . . .. . .. . .
.. . . . . .
. . . . . . . . .. .. . . . . . . . .
E
EE PROM
General Description
On-Vehicle Service
Functional Check
EGR System
General Description
On-Vehicle Service
Engine Coolant Temperature Sensor
General Description
Cl-2
Cl-10
Cl-10
C7~1
C7-2
Cl-3
C3-1
C3-2
C3-2
8-15
C7-1
8-24
F
Fan(s) Cooling
Fuel Injectors
General Description

Diagnosis

Fuel Pressure Connection Assy.

Fuel Pump Relay
Fuel Rail
Fuel System Pressure Check
C12-1
C2-3
C2-2
C2-5
C2-10
C2-6
C2-2
A-32
C2-3
A-32
A-36
H
Hard Start
Hesitation
IATSensor
General Description
Diagnosis
On-Vehicle Service
Idle Air Control System Check
General Description
Ignition Control (IC)
Incorrect Idle
Information Sensors
Injector Balance Test
lntermittents
Introduction
8-5
8-9
C1-4
C1-8
Cl-11
C2-22
C2-4
A-72, 74,
C4-1
8-12
C1-3
(2-16
8-3
GE
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) INDEX-3

PAGE
SECTION
K
Cl-10,
CS-2
Knock Sensor Module

General Description
Diagnosis
On-Vehicle Service
CS-1
CS-1
CS-1
CS-4
SECTION
PAGE
Poor Fuel Economy

Poor Performance
General Description
Diagnosis
B-14
6E3-B
Function
Functional Check
On-Vehicle Service
Pressure Regulator
Pump, Al R
Cl-1
Cl-8
Cl-1
Cl-10
Cl-9
(2-3
CG-1
L
Q
Lack Of Power
Light, MIL (Service Engine Soon)
Light, One to Four
Long Term Fuel Trim
B-7
A-28
C8-2
Cl-2
M
MAP Sensor
General Description
Diagnosis
On-Vehicle Service
Output Check
Memory
Misses
Cl-8
R
Reference Signal
Restricted Exhaust Check
Rough Idle
Cl-4
Cl-8
Cl-12
C1-16
Cl-2
B-10
N
Negative Backpressure EGR Valve
No DLC Data
No Mil (Service Engine Soon)
Quad-Drivers
C7-1
A-16
A-28
0
On-Board Diagnostic (OBD) System
Check
A-16
Oxygen Sensor (025)

General Description
Diagnosis
On-Vehicle Service
Cl-4
Cl-8
Cl-11
Run Mode
Run On
s
Sag
Scan Data
General Description
Diagnosis

On-Vehicle Service
Sensor Information
Sluggish
Spark Knock
Spongy
Stalling
Starting Mode
Cl-6
B-24
B-12
(2-2
B-16
Stumble
Surges
Symptom Charts
System Voltage
B-9
A-18
CG-1
CG-2
CG-4
CG-4
Cl-3
B-7
B-8
B-7
B-12
(2-1
B-9
B-6
B-18
A-84
T
General Description
PCM Connector Terminal End View
PCM Diagnostic Trouble Codes
PCM Inputs
PCM Wiring Diagrams
. . . . . . . . .. ..
Cl-6
A-11
A-23
Cl-8
A-5
Throttle Body Unit

General Description
On-Vehicle Service
General Description
. . . . . . .. .. . .
C2-4
(2-14
Cl-5
4-INDE>t 3.4L (L32} (VIN S} (SFI) DRIVEABILITY AND EMISSIONS

PAGE
SECTION
Diagnosis
On-Vehicle Service
Torque Converter Clutch (TCC) System
General Description
Diagnosis
Typical Tech 1 Data Definitions
C1-8
C1-12,
C2-12
CS-1
CS-4
A-20
A-18
u
Unstable Idle

A-4
8-12
SECTION
PAGE
v
General Description
Diagnosis
On-Vehicle Service
C1-5
C1-9
C1-12
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-1
SECTION A
ENGINE COMPONENTS/WIRING DIAGRAMS/

DIAGNOSTIC CHARTS
BASIC PROCEDURE
If you have not reviewed the basic information on
how to use the diagnostic procedures, go to the
"Introduction" of this section. The facing page of each
chart in this section will provide a general circuit
description and in some instances, alternate diagnostic
steps or other diagnostic aids specific to that chart or
circuit.
(PCM) diagnosis. The "On-Board Diagnostic (OBD)

System Check" verifies the system is functioning
correctly. Some special considerations to keep in mind
while making the "On-Board Diagnostic (OBD)
System Check" are:
Blocking Drive Wheels

The vehicle drive wheels must always be blocked
while checking the system.

SYSTEM CHECK
The OBD system check m.u.st always be the
starting point of any Powertrain Control Module
CONTENTS
............................................
Component Locations
PCM vyiring Diagram (1 of 7) .
PCM Connector Terminal End View (1 of 4)
On-Board Diagnostic (OBD) System Check (Start Diagnosis Here)
Engin, Tech 1 Data
Transmi~sio.n Tech 1 Data
, .._ . .,:-
Engine and Transmission Tec.h .1 D~ta Definitions
No Malfunction Indicator Lamp (MIL)- ChartA-l r

Output/Field Service Enable Circuit- Chart A-2
Engin~ Cranks But Will Not Run - Chart A-3 , ~
Fuel Pump Relay Circuit - Chart A-5
Fuel System Diagnosis - Chart A-7 ( 1 of 3)
OTC 11 - Malfunction Indicator Lamp (MIL) Circuit

OTC 13 -Bank 1 (Left) Heated Oxygen Sensor (H02S) Circuit (Open Circuit)
OTC 14- Engine Coolant Temperature (ECT) Sensor Circuit (Signal Voltage Low,
High Temperature Indicated)

DJC 15- Engine Coolant Temperature (ECT) Sensor Circuit (Signal Voltage High,
Low Temperature Indicated)
DTC 16- Distributor Ignition System (Low Resolution Pulse)
DTC 18-lnjector Circui~(s)
DTC 21 - Throttle Position (TP) Sensor Circuit (Signal Voltage High)
DTC 22 - Throttle Position (TP) Sensor Circuit (Signal Voltage Low) ,

DTC 23 - Intake Air Temperature (IAT) Sensor Circuit (Signal Voltage High,
LowTempera~ure Indicated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 24-Vehicle Speed Sensor (VSS) Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 25-lntake Air Temperature (IAT) Sensor Circuit (Signal Voltage Low,
High Temperature ln~icated)
OTC 26-Evaporative Emission (EVAP) Canister Purge Solenoid Valve Circuit

OTC 27-Exhaust Gas Recirculation (EGR) Vacuum Control Signal Solenoid Valve Circuit
DTC 28- Transmission Range (TR) Pressure Switch Assembly Fault
PageA-3
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Page A-12
Page A-16
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PageA-26
PageA-28
PageA-30
PageA-32
PageA-34
PageA-40
PageA-42
PageA-44
PageA-46
PageA-48
PageA-50
PageA-52
PageA-54
PageA-56
PageA-58
PageA-60
PageA-62
Page A-64
PageA-66
6E3-A-2 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

DTC 29 - Secondary Air Injection (AIR) Pump Circuit
DTC 32 - Exhaust Gas Recirculation (EG R) ( 1 of 2)
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage High - Low Vacuum) - -
DTC 34- Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage Low - High Vacuum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 36- Distributor Ignition System (Faulty High Resolution Pulse or
Extra Low Resolution Pulse Detected)
DTC 37 - Brake Switch Stuck "ON"
DTC 38 - Brake Switch Stuck "OFF"
DTC 41 - Ignition Control (IC) Circuit (Open Circuit)
DTC 42 - Ignition Control (IC) Circuit (Shorted or Grounded Circuit)

.................. .
DTC 43 - Knock Sensor (KS) Circuit
DTC 44 - Bank 1 (Left) Heated Oxygen Sensor (H02S) Circuit (Lean Exhaust Indicated)
DTC 45 - Bank 1 (Left) Heated Oxygen Sensor (H02S) Circuit (Rich Exhaust Indicated)
DTC 46- PASS-KeyII Circuit

DTC 47 - Knock Sensor (KS) Module Circuit or Module Missing
DTC 48 - Mass Air Fl ow (MAF) Sensor Circuit
DTC 50 - System Voltage Low
DTC 51 - EEPROM Programming Error ~

DTC 53 - System Voltage High
OTC 55 - Fuel Lean Monitor
DTC 58- Transmission Fluid Temperature (TFT) Sensor Cim.iit Low

(High Temperature Indicated)
DTC 59- Transmission Fluid Temperature (TFT) Sensor Circuit High
(Low Temperature Indicated)
DTC 61 - A/C System Performance
DTC 63 - Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Open Circuit)
DTC 64- Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Lean Exhaust Indicated)
DTC 65 - Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Rich Exhaust Indicated)
DTC 66 -A/C Refrigerant Pressure Sensor Circuit (Open or Shorted)
DTC 67 -A/C Refrigerant Pressure Sensor Circuit (Pressure Sensor or A/C Clutch Circuit Problem)
DTC 68 -A/C Relay Circuit (Shorted Circuit)
DTC 69 -A/C Clutch Circuit
DTC 70-A/C Clutch Relay Driver Circuit

DTC 71 -A/C Evaporator Temperature Sensor Circuit
DTC 72 - Vehicle Speed Sensor Loss

DTC 73- Pressure Control Solenoid (PCS) Circuit (Current Error)
OTC 74- Traction Control System (TCS) Circuit Low
DTC 75 - Transmission System Voltage Low
DTC 77 - Cooling Fan Relay Control Circuit

DTC 79 - Transmission Fluid Overtemp
OTC 80- Transmission Component Slipping
DTC 81 -Transmission 2-3 Shift Solenoid Circuit

DTC 82 - Transmission 1-2 Shift Solenoid Circuit
OTC 83 - Reverse Inhibit System (Manual Transmission)
OTC 84 -Automatic Transmission 3-2 Control Solenoid Circuit
DTC 84- Skip Shift Solenoid Circuit (Manual Transmission Only)
DTC 85 - Transmission TCC Stuck "ON"
DTC 90 - Transmission TCC Solenoid Circuit

DTC91-SkipShiftLampCircuit
DTC 97 - VSS Output Circuit
DTC 99 - Tach Output Circuit
... ...... . ...... ... .. . ... .. . . . ...
Page A-68
PageA-70
PageA-74
PageA-76
PageA-78
PageA-80
PageA-82
PageA-84
PageA-86
PageA-88
PageA-90
PageA-92
PageA-94
PageA-96
PageA-98
Page A-100
PageA-103
Page A-104
Page A-106
Page A-108
PageA-110
PageA-112
PageA-114
PageA-116
PageA-118
Page A-120
Page A~122
PageA-124
Page A-126
PageA-128
Page A-130
PageA-132
PageA-134
PageA-136
Page A-138
PageA-140
Page A-142
PageA-144
PageA-146
PageA-148
PageA-150
PageA-152
PageA-154
PageA-156
Page A-158
PageA-160
PageA-162
PageA-164
DRIVEABILITY AND EMISSIONS 5. 7L {VIN P) 6E3-A-3
II
F"
CARLINE
RPO: LT1
5.7L
VIN CODE:P
V8
SFI
N15
COMPUTER HARNESS

Battery junction block
PCM harness grounds
C6 1/Pfuse panel
Underhood electrical center
A/C clutch relay
Cooling fan relay(s)
AIR pump relay
C9 Fuel pump prime connector
C10 Ignition test connector
C1
C2
C3
C4
cs
D CONTROLLED DEVICES 0
1
2
3
5
9
12
cs
NOT PCM CONNECTED
. t"
N1 Cran k case vent I 1a ,on va 1ve
NS Engine Temp. Sensor (gage overheat)
N7 Oil pressure sensor
N14 Cooling fans (with C60)
N15 Cooling fan (without C60)
N17 EVAP canister (not shown), located in
left rear, near filler tube.
15
20
21
Fuel injector(s)
Idle Air Control (IAC) valve
Fuel Pump (FP) relay
Transmission electrical connector
Secondary Air Injection (AIR) pump
EGR vacuum control signal solenoid
valve
EVAP canister purge solenoid valve
Reverse inhibit solenoid (MIT only)
(Transmission mounted, not shown)
Skip Shift solenoid (MIT only)
, (Transmission mounted, not shown)
(Q)
Q
c
D
E
G
L
M
INFORMATION SENSORS
sensor
Heated Oxygen Sensor (H02S)
Throttle Position (TP) sensor
sensor
A/C refrigerant pressure sensor
Intake Air Temperature (IAT) sensor
Knock sensor (KS)
A/C evaporator temperature sensor
(Mounted on transmission, not
shown)
Mass Air Flow (MAF) sensor
Brake switch
Exhaust Gas Recirculation (EGR) valve
SIR system components. Refer to

Section 9J of the service manual, for
"Cautions" and information on SIR
system components.
Figure A-1 Component LQcations 5.7L (VIN P) "F" Carline
6-25-93
MS 12725
6E3-A-4 5.7L {VIN P) ORIVEABILITY AND EMISSIONS
PCM
448 WHT/BLK
-------1
451 BLK/WHT
-i
C230
OUTPUT/FIELD SERVICE EIIIABLE
' - - - - - - - - - 416GRY _ _ _.....,
Figure A-2 - PCM Wiring Diagram 5.7L (VIN P) "F" Carline (1 of 7)
6-25-93
MS 10083
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-A-5
PCM
VEHICLE SPEED SENSOR
I-Mg
~
0 ----
VSS SIGNAL
401
TO CRUISE CONTROL
G
PPL
TRANSMISSION MOUNTED
MODULE AND ...oc....---c(~ 817 DK GRNMIHT
INSTRUMENT PANEL
C220
~-----------------------496DKBLU
VSSGROUND
VSS OUTPUT
KS SIGNAL
BANK 1 (LEFT) HEATED OXYGEN SENSOR (Hois)
KNOCK
SENSOR(KS)
o-------1653TANMIHT
H02SLOW
t - - - - - - - 1 6 6 5 PPLMIHT
H02S HIGH
450 BLK
HEATING
ELEMENT - - - -
541 BRN - - - - - .
ENGINE
_j__GROUND
BANK 2 (RIGHT) HEATED OXYGEN SENSOR (H02S)
TO
IGNITION
t---------1667TAN
H02SLOW
--------1666PPL
H02S HIGH
~ ~ENGINE
1
~ROUND
450 B L K - - - - -
HEATING
ELEMENT L - - - - - 1 - -
541 BRN
3000RN
#6
(U/H)
MASS
AIR
FLOW
(MAF)
SENSOR
451 BLK/WHT--i _ENGINE

439PNK
~ROUND
-=-
#5 (1/P)
T0~~3PNK-.TO
OTHER
C230
15 AMP
IGNITION
CIRCUITS
EXHAUST GAS RECIRCULATION (EGR)
VACUUM CONTROL SIGNAL
SOLENOID VALVE
F::-3 I
F::-3
~ F::-3 I
541 BRN"i A
435GRY
EVAPORATIVE EMISSION (EVAP)

CANISTER PURGE SOLENOID VALVE
' - - - - - - 5 4 1 BRN~ A
BI
428DKGRNMIHT
EGR VACUUM CONTROL

SIGNAL SOLENOID VALVE
CONTROL
EVAP CANISTER PURGE
SOLENOID VALVE CONTROL
REVERSE INHIBIT
SOLENOID
' - - - - - - - - 5 4 1 BRN
1652 LT GRN
REVERSE INHIBIT
SOLENOID CONTROL
587 GRY
SKIP SHIFT
SOLENOID CONTROL
MANUAL TRANSMISSION
SKIP SHIFT SOLENOID
' - - - - - - - - - - 5 4 1 BRN
~B
F::-3 I
A
MANUAL TRANSMISSION
(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK.

= LOCATED IN UNDERHOOD ELECTRICAL CENTER.
(U/H)
Figure A-3 PCM Wiring Diagram 5.7L (VIN P) "F" Carline (2 of 7)
6-29-93
MS 10121
6E3-A-6 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
TO INSTRUMENT CLUSTER
~ 2
C200
f f " ' \ , J ( ( ~ 340 ORN
PCM BATTERY
34 0 ORN
PCM BATTERY
09~K
PCM IGNITION FEED
439PNK
PCM IGNITION FEED
10 AMP
TO THEFT DETERRENT MODULE
81
~N~~3PNK
C200
PCM
~C
#4(1/P)
~~ ~~ ~~ 1002 RED
TO THEFT
DETERRENT MODULE
G
K
C210
TO MASS AIR
FLOC
23
C 0
15AMP
J
~ 465 DK GRN,WHT
C220
451 BLK WHT
FUEL PUMP RELAY

CONTROL
-i
FU EL PUMP (FP) RELAY

TO
A1
D
FUEL - 1 2 0 G R Y ~ t - - - - - - - 1 2 0 G R Y - < ~
PUMP
C405
C210 FUEL PUMP PRIME CONNECTOR
INJECTOR #1 CONTROL
#10(U/H)
7.5AMP
t----844 LT BLU/BLK
INJECTOR #4 CONTROL
- - - - 8 4 6 YEL/BLK
INJECTOR #6 CONTROL
J.--.C.''----877 RED/BLK
INJECTOR #7 CONTROL
,__....,B~~(-A--1745 LT GRN/BLK
INJECTOR #2 CONTROL
FUSE
BLOCK
JUNCTION
INJ#2
1746PNK/BLK
INJECTOR #3 CONTROL
.____,B"-'l~(~A'----845 BLK/WHT
INJECTOR #5 CONTROL
__,.~Ba........1~( A
#9(U/H)
7.5AMP
8
'---- ~ ( A
878 DK BLU,WHT
IGNITION SYSTEM
TEST CONNECTOR
...----------~632PNK/BLK
t - - - - - - - - - - 6 3 2 PNK/BLK
. . . . - - - - - - - - - - - 631 RED
1----------- 631 RED
. . . . - - - - - - - - 430 PPL/WHT
- - - - - - - - - 430 PPL/WHT
. . . - - - - - - - 453 RED/BLK
- - - - - - - - - 453 RED/BLK
ENGINE
GROUND
11
TO
j.-- 450 BLK

10AMP
INJECTOR #8 CONTROL
DISTRIBUTOR REFERENCE
LOW SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
IGNITION
COIL
MODULE
IGNITION~(
)
BLACK
# 11 \U/HJI
CONNECTOR
239
""'i
PNK
423WHT
IGNITION CONTROL
IGNITION
COIL
----------1
BLACK CONNECTOR
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER
(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK
Figure A-4- PCM Wiring Diagram 5.7L (VIN P) "F" Carline (3 of 7)
7-8-93
MS 10125
PCM
(AIR) PUMP RELAY
E
l----<~KE-----436BRN
C100
. - - - - - - - - 7 8 RED----.1
...------78RED
AIR PUMP RELAY

CONTROL
B+~502RED
#7(U/H)
82
441 BRN ~ 3 0 0 O R N - - - < ~
20 AMP
C200
...------150 BLK - - - - ,
_j_
SECONDARY AIR
INJECTION (AIR)
PUMP
IGNrnON
TO
D
INSTRUMENT ...l(E------~lK,------121 WHT
PANEL
C230
TO PERFORMANCE/TRACTION _ _ _ _ _ _ _ 553 LT BLU
CONTROL PROGRAM SWITCH
INTEGRAL STOP
VALVE SOLENOID
TO PERFORMANCE/TRACTION--------- 1493 DK BLU

E
A14 r - - - - - - < l l ~ - - - - - 4 6 4 TAN/BLK
C220
D
ELECTRONIC BRAKE
AND TRACTION
CONTROL MODULE
(EBTCM)
------<K--- 463 ORN/BLK

C220 D
---------c~ 832 LT BLU

C100
TACHOUTPUT
PERFORMANCE MODE
SWITCH SIGNAL
PERFORMANCE
MODE INDICATOR
LAMP CONTROL
EBTCM TP SENSOR
SIGNAL
TRACTION CONTROL
SYSTEM SPARK RETARD
REQUEST
TRACTION CONTROL
SYSTEM" ACTIVE"
TO THEFT
E
DETERRENT' ...l ( E - - - - - - - ( < - - 229 DK BLU
MODULE
C230
TO OTHER CIRCUITS
#9(1/P)
T 0 ~ 3 9 PNK IGNITION
10 AMP
B
......---i,-c:;,9---~f---419 BRN/WHT
MIL
C230
H
.___-.c;:;;..>----~Kr---375WHT
SKIP SHIFT LAMP
C230
IAC
MALFUNCTION
INDICATOR LAMP
(MIL) CONTROL
SKIP SHIFT LAMP
CONTROL (MANUAL
TRANSMISSION
ONLY)
1747 LT BLU/WHT
IACCOIL "A" HIGH
1748 LT BLU/BLK
IACCOIL "A" LOW
1749 LT GRN/WHT
IAC COIL "B" HIGH
444 LT GRN/BLK
IAC COIL "B" LOW

(1/P) LOCATED IN INSTRUMENT PANEL FUSE BLOCK
6-30-93
MS 10122
PCM
r-
ENGINE
tlL_451 BLKIWHT----.
GROUND
PARK/
NEUTRAL
POSITION
SWITCH
TO HA :CH RELEASE RELAY
( )
((
C230
# 2 1/P
..------141 B R N - - - - - - - - - - ~
20AMP
- - - - 2 4 LT GRN---'TO BACKUP LAMPS
4340RN/BLK
4340RN/BLK- C15
PARK NEUTRAL POSITION

SIGNAL (A/T ONLY)
,. TO IGNITION
- - - - - - 5 YEL----;~ TO STARTER SOLENOID

- - - - - 2 6 9 YEL ____.. TO THEFT DETERRENT RELAY
TO OTHER
CIRC ITS
#12 (U/H)
,---------139PNK~3PNK--TOIGNITION
20AMP
#3 (1/P)
TO IGNITION~ 300 ORN ~
TO
25AMP
HVAC
241 BRN
BLOWER ._,_66LTGRN
TO REAR
SWITCH
DEFOG SYSTEM
HVAC
CONTROL C
ASSEMBLY
F
C100
A 762 DK GRN/WHT ~
139PNK
A/C
CLUTCH
RELAY
,---..,
I
I KII
84
-k(~:-----7-------I
59 DKGRN
------
1~ 5 9:s::::l-~-----~----A-K..J
A/C
COMPRESSOR
CLUTCH
TO
IGNITION
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/C REQUEST SIGNAL

A/CCLUTCH
RELAY CONTROL
A/CCLUTCH STATUS
..----*'---
REFRIGERANT
PRESSURE
SENSOR
PROBE
(INSERTED IN
EVAPORATOR)
C230
380 RED/BLK
416GRY
1 - - - - - - 7 3 2 DK BLU
SENSOR GROUND
A/C REFRIGERANT PRESS.
SENSOR SIGNAL
5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER
452 CIRCUITS
#6
(U/H)
COOLING
FAN
COOLING FAN (WITHOUT C60)

J
-------------------<4K..-------~335DKGRN
COOLING FAN
RELAY CONTROL
C100

Figure A-6 PCM Wiring Diagram S. 7L (VIN P) "F" Carline (S of 7)
6-29-93
NS 15653
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A.;.9

COOLING FANS (WITH C60)
EARLY PRODUCTION
PCM
J
.------335DKGRN-----~((~-----335DKGRN
C100
PRIMARY COOLING
FAN RELAY CONTROL
~ - - 4 0 9 LT BLU
_r--150BLK
TO
OTHER
CIRCUITS
#6(U/H)
4 0 2 R E D ~ B + JUNCTION
541
402
RED
~BRN
TO
IGNITION
(FAN 2)
SECONDARY
COOLING
FAN
504BRN
r150BLK
SECONDARY
COOLING
FAN RELAY
(U/H)
H
' - - - - - - - 4 7 3 OK BLU -------<i~K,------473 DK BLU
C100
SECONDARY COOLING
FAN RELAY CONTROL
COOLING FANS (WITH C60)

LA TE PRODUCTION
TO
IGNITION
~~~
FUSE UNK
t-1---,
402 RED
#6
(U/H)
.-----e-541
BRN
COOLING FAN
(LEFT SIDE)
541 BRN COOLING FAN RELAY #1 (U/H)
532 BLK
J2
541 BRN
J3
504BRN
J1
150BLKl
COOLING FAN RELAY #3 (U/H)
-=-
402RED
_ _ _ _ _ _ _F_1.. 504 BRN

335
DKGRN
-------1 B
473
DKBLU
15
0 BLK
miO
~
COOLING FAN
(RIGHT SIDE)
C100
r,
I'---------------'-<~-'
H
--,---473 DK BLU
I
'----------------------ir-<~K~lr--~335DKGRN
L'.J
COOLING FAN RELAY #2

&#3CONTROL
CONTROL
7-8-93
PS 17943
PCM
BRAKE SWITCH
(NORMALLY CLOSED)
#9 (1/P)
T O ~ 39PNK
IGNITION
10 AMP
SWITCH
* (20-400)
TORQUE
CONVERTER
CLUTCH
(TCC)
SOLENOID
TRA::~~lSION
SHIFT
INTErLOCK
--~"1' 'f'
'
583 LT BLU/BLK
- - - - - - - - 422 TAN/BLK
687WHT
3-2
CONTROL
SOLENOID
#11 {U/H)
10 AMP
SWITCH
TCC SOLENOID
CONTROL
3-2CONTROL
SOLENOID
CONTROL
(20-400)
1-2 SHIFT
SOLENOID
1222 LTGRN
1-2 SHIFT
SOLENOID
CONTROL
TRANSMISSION
CONNECTOR
2-3 SHIFT
SOLENOID
1223 YEUBLK
*
PRESSURE
CONTROL
SOLENOID
(PCS)
(3-80)
1229 LT BLU/WHT
...
2-3 SHIFT
SOLENOID
CONTROL
..
PCS "LOW"
1228 RED/BLK
TRANSMISSION
FLUID
TEMPERATURE
(TFT) SENSOR
{INTERNAL)
1224 PNK
RANGE
SIGNAL HAU
- - - - - - - - 1225 DK BLU
RANGE
SIGNAL "B"
1226 RED
RANGE
SIGNAL "C"
- - - - - - - - 1227 YEUBLK
TFTSIGNAL
470BLK
TRANSMISSION RANGE (TR)

SENSOR
GROUND
ECT
SENSOR
= UNDERHOOD ELECTRICAL CENTER

= INSTRUMENT PANEL FUSE BLOCK
(U/P)
AT20c (68F)
(1/P)
Figure A-8- PCM Wiring Diagram 5.7L (VIN P) "F" Carline (7 of 7)
7-9-93
PS 18400
"F" CARLINE
PCM CONNECTORS
* USE J 39700-A BREAKOUT BOX
5. 7L (VIN P)
RPO: LT1
C
KNOCK SENSOR MODULE D
(CLEAR)
ACCESS COVER
(BLUE)
PCM
I
~
~
!-(3
~
==={====
A
(RED)
B
(BLACK)
PS 17345
NOTICE: Do not backprobe PCM connectors! The connectors are sealed for operation in an underhood
environment. Backprobing may damage the seal which coulcl eventually cause the connector to fail due to
corrosion.
This information applies to the PCM connector charts on the next four pages. These charts may be used with
the J 39700-A breakout box in conjunction with J 39700-110 and J 39700-140 cables and high impedance digital
multimeter J 39200 to obtain voltage present for each circuit listed. Install the breakout box between the PCM
connectors and the PCM. The breakout box PIN numbers correspond w.ith the PCM connector PIN numbers.
Voltage may vary slightly, but should be very close. Certain exceptions are called out in the chart legend below.
The following conditions must be met before checking typical voltages:
Key"ON":
DVM negative (black) lead connected to a known good ground.
Scan tool not installed.
All accessories "OFF."
Battery fully charged.
Engine running:
All conditions listed above.
Engine at normal operating temperature.
Engine at idle/closed throttle/operating in "Closed Loop."
In park or neutral.
Chart Legend:
(1) Less than .5 volt when system enabled.
(2) Battery voltage for first two seconds with ignition "ON."
(3) Varies.
(4) Varies with temperature.
(5) Battery voltage when in gear.
(6) Less than .5 volt with brake pedal applied.
(7) Battery voltage with A/C "ON."
(8) Varies with altitude.
* Less than .5 volt.
6E3-A-12 5.7L {VIN P) DRIVEABILITY AND EMISSIONS
PCM CONNECTOR .. A" (RED)

VOLTAGE
PCM PIN/FUNCTION
CKT#
WIRE COLOR
KEY
"ON"
ENG
"RUN"
A1
A2
PCM GROUND
451
BLK/WHT
0*
O*
A3
INJECTOR #1 CONTROL
1744
BLK
B+
B+
A4
INJECTOR #4 CONTROL
844
LT BLU/BLK
B+
B+
AS
INJECTOR #6 CONTROL
846
YEL/BLK
B+
B+
A6
INJECTOR #7 CONTROL
877
RED/BLK
B+
B+
A7
FP RELAY CONTROL
465
DKGRN/WHT
0 (2)
B+
EGR VACUUM CONTROL SIGNAL SOLENOID

VALVE CONTROL
435
GRY
B + (1)
B + (1)
AB
A9
A10 SECONDARY/HIGH SPEED COOLING FAN

RELAY CONTROL
32
O O 16
00
473
DKBLU
B + (1)
B + (1)
00
00
00
DKGRN
A11 PRIMARY/LOW SPEED COOLING FAN RELAY

CONTROL
335
A 12 EBTCM TP SENSOR SIGNAL
464
TAN/BLK
A13 TACH OUTPUT
121
WHT
A 14 AIR PUMP RELAY CONTROL
436
BRN
A 15 TRANS MODE LAMP CONTROL
1493
DKBLU
B + (1)
B + (1)
00
00
00
00
00
B + (1)
B + (1)
00
00
00
00
A16
00
A17
17001
A18 PCMGROUND
551
TAN/WHT
O*
O*
A19 INJECTOR #2 CONTROL
1745
LTGRN/BLK
B+
B+
845
BLK/WHT
B+
B+
1746
PNK/BLK
B+
B+
878
DKBLU/WHT
B+
B+
A23 TRACTION CONTROL SYSTEM SPARK RETARD

REQUEST
463
ORN/BLK
B+
B+
5.7L (VIN P)
RPO: LT1
A24
229
DKBLU
2.5
2.5
A31 VSS GROUND
401
PPL
O*
O*
A32 VSS SIGNAL
400
YEL
(3)
(3)
A25 FUEL ENABLE SIGNAL
FRONT VIEW
32 PIN
PCM CONNECTOR ,.A,,
(RED)
A26
A27
A28
A29
A30
Figure A-9 PCM Connector Terminal End View 5.7L (VIN P) "F" Carline (1 of 4)
7-1-93
PS 16996
PCM CONNECTOR "B" (BLACK)

VOLTAGE
PCM PIN/FUNCTION
CKT#
WIRE COLOR
KEY
"ON''
ENG
"RUN"
81
A/C REQUEST SIGNAL
762
DKGRN/WHT
O* (7)
O* (7)
82
LOW RESOLUTION SIGNAL
453
RED/BU<
OORS
(3)
83
DISTRIBUTOR REFERENCE LOW SIGNAL
632
PNK/BLK
O*
0*
BS
IGNITION CONTROL
423
WHT
O*
(3)
86
SENSOR GROUND
470
BLK
O*
0*
87
TRANSMISSION 1-2 SHIFT SOLENOID
1222
LTGRN
B+
0*
BS
VSSOUTPUT
817
DKGRN/WHT
6.5
7.5
84
32 0
0 16
00
89
00
810
00
00
811
812 TRANSMISSION 2-3 SHIFT SOLENOID
1223
YEL/BLK
B+
0*
813 TRANSMISSION 3-2 CONTROL SOLENOID

(AUTO MA TIC)
OR SKIP SHIFT SOLENOID CONTROL
(MANUAL)
687
OR
587
WHT
OR
GRY
B+
OR
B+
B+
OR
B+
814 DISTRIBUTOR IGNITION FEED
631 .. RED
B+
B+
815 PCM BATTERY FEED
340
ORN
B+
B+
816 SENSOR GROUND
452
BLK
O*
O*
00
00
00
00
00
00
00
00
00
00
17001
817
818
819 MAF SENSOR SIGNAL
492
YEL
4.3 (3)
820 HIGH RESOLUTION SIGNAL
430
PPL/WHT
2.6 (3)
O* (7)
O* (7)
FRONT VIEW
32 PIN
PCM CONNECTOR ''B"
(BLACK)
5.7L (VIN P)
RPO: LTI
B21 A/CCLUTCH STATUS
59
DKGRN
822
823
824
825
826
827
828 5 VOLT REFERENCE
474
GRY
829 5 VOLT REFERENCE
416
GRY
830 PCM IGNITION FEED
439
PNK
B+
B+
340
ORN
B+
B+
832
Figure A-10- PCM Connector Terminal End View S.7L (VIN P)
. F,. Carline (2 of 4)
6-29-93
PS 16997
PCM CONNECTOR "C" (CLEAR)

PCM PIN/FUNCTION
CKT#
VOLTAGE
WIRE COLOR
KEY "ON"
ENG "RUN"
C1
IACCOIL "A" HIGH
1747
LTBLU/WHT
(3)
(3)
C2
IAC COIL "A" LOW
1748
LT BLU/BLK
(3)
(3)
cs
IAC COIL "B" LOW
444
LTGRN/BLK
(3)
(3)
C6
IAC COIL "B" HIGH
1749
LTGRN/WHT
(3)
(3)
C7
BANK 2 {RIGHT) H02S LOW
1667
TAN
O*
O*
CB
BANK 2 {RIGHT) H02S HIGH
1666
PPL
(3)
.1 TO .9 (3)
C3
C4
C9
C10
832
LTBLU
B+
B+
C13 PERFORMANCE MODE SWITCH

SIGNAL
553
LTBLU
B+
B+
C14 BRAKE SWITCH SIGNAL
583
LTBLU/BLK
B+ (6)
B+ (6)
C15 PNP SIGNAL
434
ORN/BLK
O* (5)
O* (5)
C16 TRANSMISSION PRESSURE CONTROL

SOLENOID HIGH
1228
RED/BLK
O*
6.4
C11 TRACTION CONTROL SYSTEM

"ACTIVE" SIGNAL
C12
32 O O 16
00
00
00
00
00
00
00
00
00
00
00
00
00
00
17 0 0 1
C17
C18
.
C19 BANK 1 {LEFT) H02S LOW
1653
TAN/WHT
O*
O*
C20 BANK 1 {LEFT) H02S HIGH
1665
PPL/WHT
(3)
.1 TO .9 (3)
C21 IAT SENSOR SIGNAL
472
TAN
3.9 (4)
3.7 (4)
C22 TP SENSOR SIGNAL
417
DKBLU
.68
.70
C23 MAP SENSOR SIGNAL
432
LTGRN
4.7 (8)
1.1 (8)
FRONT VIEW
32 PIN
PCM CONNECTOR
c"
(CLEAR)
5.7L (VIN P)
RPO: LT1
C24
410
YEL
2.3 (4)
2.2 (4)
C28 TRANSMISSION RANGE SIGNAL" A"
1224
PNK
B+
B+
C29 TRANSMISSION RANGE SIGNAL "B"
1225
DKBLU
O*
O*
C30 TRANSMISSION RANGE SIGNAL "C"
1226
RED
B+
B+
451
BLK/WHT
O*
O*
C25 ECT SENSOR SIGNAL

C26
C27
C31
C32 PCM GROUND
Figure A-11 - PCM Connector Terminal End View 5. 7L (VIN P) "F" Carline (3 of 4)
6-29-93
PS 16998
11
PCM CONNECTOR D" (BLUE)

VOLTAGE
PCM PIN/FUNCTION
CKT#
551
WIRE COLOR
KEY
"ON"
ENG
"RUN"
TAN/WHT
O*
0*
O*
1.3
B+
B+
D1
PCM GROUND
D2
TRANSMISSION PRESSURE CONTROL SOLENOID LOW
1229
LTBLU/WHT
D3
PCM IGNITION FEED
439
PNK
REVERSE INHIBIT SOLENOID CONTROL
1652
LTGRN
04
05
06
D7
32 0
B + (1)
B + (1)
00
O*
B + (1)
00
B + (1)
B + (1)
00
TAN/BLK
B+
00
RED/BLK
(3)
(3)
D8
A/C CLUTCH RELAY CONTROL
459
D.KGRN/WHT
D9
MIL CONTROL
419
BRN/WHT
010 EVAP CANISTER PURGE SOLENOID VALVE CONTROL
428
DKGRN/WHT
D11 TRANSMISSION TCC SOLENOID
422
012 A/C REFRIGERANT PRESSURE SENSOR SIGNAL
380
16
00
00
00
00
013
00
00
014
00
015 SKIP SHIFT LAMP CONTROL
375
WHT
B+
B+
00
00
016
00
017
17001
018
019
020 OUTPUT/FIELD SERVICE ENABLE
448
WHT/BLK
496
DKBLU
1.6
1.5
732
DKBLU
1.4 (4)
1.4 (4)
1227
YEL/BLK
2.5 (4)
1.6 (4)
800
TAN
(3)
(3)
021
022 KS SIGNAL
FRONT VIEW
32 PIN
PCM CONNECTOR
IID"
(BLUE)
023
024 A/C EVAPORATOR TEMPERATURE SENSOR SIGNAL
025
5.7L (VIN P)
RPO: LT1
026
027
028 TRANSMISSION FLUID TEMPERATURE SENSOR
SIGNAL
029
030 SERIAL DATA
031
032
Figure A-12 - PCM Connector Terminal End View 5.7L (VIN P)
,,
..
F Carline (4 of 4)
6-2993
PS 16999
6E3-A-16 5.7l {VIN P) DRIVEABILITY AND EMISSIONS
PCM
PCM BATTERY FEED
PCM BATTERY FEED
------,!
TO OTHER CIRCUIT,...S
#9 (1/P)
_
TO IGNITION-<>-------.~1------ 39 PNK
10 AMP
TO OTHER
CIRCUITS
In\
----~-..-.----c((-MALFUNCTION
INDICATOR
LAMP (Mil)
#5(1/P)
1SAMP
C230
.-----439PNK
PCM IGNITION FEED
439PNK
TO MASS AIR
FLOW SENSOR
448 WHT/BLK
PCM IGNITION FEED
TO IGNITION--------- 3 PNK
419 BRN/WHT
C230
.-----~t-K--C230
OUTPUT/ FIELD SERVICE

ENABLE
451BLKIWHT---:=.__
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

5.7L (VIN P) "F" CARLINE (SFI)
The On-Board Diagnostic (OBD) system check is an organized approach to identifying a problem created by
an electronic engine control system malfunction. It must be the starting point for any driveability complaint
diagnosis, because it directs the service technician to the next logical step in diagnosing the complaint.
Understanding the chart and using it correctly will reduce diagnostic time and prevent the unnecessary

1. This step is to determine if the Tech 1 can establish
communication with the Powertrain Control
Module (PCM). If there is no communication
between the PCM and the Tech 1, no data will be
displayed. Refer to SECTION 8A~50 for serialdata
circuit diagnosis.
2. Comparison of actual control system data with the
typical values is a quick check to determine if any
parameter is not within limits. Keep in mind that
a base engine problem (i.e. advanced cam timing)
may substantially alter sensor values.
3. Installation of a scan tool will provide a ground
path for the PCM and may hide a driveability
complaint due to poor PCM grounds.
4. If multiple DTCs are stored, start with the lowest
numbered DTC first, unless DTC chart indicates
'. n_ot to.
5. If the actual data is not within the typical values

established, the charts in "Component Systems,"
Section "6E3-C" will provide a functional check of
the suspect component or system.
rn
Important
This vehicle is equipped with a Powertrain Control

Module (PCM) utilizing an Electrically Erasable
Programmable Read Only Memory (EEPROM).
When diagnostics call for replacement of the PCM,
the new PCM must be programmed. Refer to
"PCM Replacement and Programming
Procedures" in "Powertrain Control Module (PCM)
and Sensors," Section "6E3-Cl".

NOTE MALFUNCTION INDICATOR LAMP (MIL).
ISMIL "ON"1

SYSTEM CHECK
5. 7L (VIN P)
11
F" CARLINE (SFI)
r- --------,
I
USE CHART A-1.
L- ---------.l
VERIFY TECH 1 FUNCTION ON ANOTHER VEHICLE. IF TECH 1 OPERATES

PROPERLY, REFER TO SECTION 8A50 FOR DIAGNOSIS OF SERIAL DATA CIRCUIT.
USING A TECH 1, TURN "OFF" MIL.

DOES MIL TURN "OFF"1
: USE DTC 51 CHART. :
r- --------,
I USE CHART A-1. I

.....,i;;;;;;;;;;;;;;;;;;;;;;;;;;;:.,_____________________....;,L,..----------.l
r- --------,
I USE
L-
CHART A-3.
---------.J
USING A JUMPER WIRE, GROUND OUTPUT/FIELD

SERVICE ENABLE CIRCUIT AT DLC. MIL SHOULD
FLASH.
DOESIT1.
...
: USE CHART A-2. :
r
I
--------,
USE CHART A-2.
L---------.l
COMPARE SCAN TOOL ENGII\IEITRANSMISSION DATA WITH TYPICAL

VALUES SHOWN ON FOLLOWING PAGES.
r- --------------------,
REFER TO APPLICABLE OTC CHART.
NOTICE: FOR TRANSMISSION DRIVEABILITY SYMPTOMS, REFER TO

7A 14A TRANSMISSION DIAGNOSIS "FUNCTIONAL TEST PROCEDURE."
ARE VALUES NORMAL OR WITHIN TYPICAL RANGES1
----------------------,
,;'\1 REFER TO "SYMPTOMS" IN

~ : SECTION B FOR ENGINE DIAGNOSIS.
L-----------------------~
('";'\: REFER TO INDICATED "COMPONENT(S) :

\.::J, SYSTEM" CHECKS IN SECTION C.
1
L-------------------------J
5-18-93
NS 15782
6E3-A-18 5.7l (VIN P) DRIVEABILITY AND EMISSIONS

If after completing the On-Board Diagnostic (OBD) system check and finding the Tech 1 diagnostics
functioning properly and nq DTQ(s) displayed,the "Engine/Transmission Tech 1 Data Values" may be used for
comparison with values obtained _on the vehicle being diagnosed. The "Engine/Transmission Tech 1 Data
Values," are art average of display. values recorded from normally operating vehicles and are intended to
represent what a normally functioning system would display.
ASCAN TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED. AND
THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER. THE USE OF A FAUL TY SCAN TOOL CAN
RESULT IN MISDIAGNOSIS AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed below are used in this manual for diagnosis. If a scan tool displays other
parameters, the values are not recommended by General Motors for use in diagnosis. For more description on the
values and use of the Tech 1 to diagnose PCM inputs, refer to the applicable section in "Component Systems,"
Section "6E3-C". If all values are within the range illustrated, refer to "Symptoms," Section "6E3-B".
ENGINE TECH 1 DATA

Idle I Lower Radiator Hose. Hot I Closed Throttle I Park or Neutral I Closed Loop I Accessories off
SCAN Position
Units Displayed . Typical Data Value
Refer To Section "C1" and:
Engine Speed
RPM
100 RPM from desired
Desired Idle
Eng Cool Temp.
Intake Air Temp.
RPM
C0 /F 0
C0 /F 0
MAP
BARO
Th rot Position
Throttle Angle
Left H02S Bnk 1
Loop Status
Right H02S Bnk 2
Loop Status
ST Fuel TR Bnk 1
LT Fuel TR Bnk 1
ST Fuel TR Bnk 2
LT Fuel TR Bnk 2
Fuel Trim Cell
Fuel Trim Enable
Spark Advance
Mass Air Flow
Knock Retard
Knock Signal
Lo Res. Signal
High Res. Signal
lnj. Pulse Width Bnk 1
lnj. Pulse Width Bnk 2
Idle Air Control
Learned IAC
EGR Duty Cycle
System Voltage
AIR Control
Fuel EVAP Purge
Injector Fault
TCS/ASR Active
Fan Ctrl PCM A 10
Fan Ctrl PCM A 11
A/C Request
A/CClutch
A/CStatus
A/C Refrig Pressure
A/C EVAPTemp
Skip Shift Active
MPH
Trans Range Switch
kPaNolts
kPaNolts
Volts
Percentage
Millivolts
Open/Closed Loop
Millivolts
Open/Closed Loop
Counts
Counts
Counts
Counts
Cell Number
No/Yes
# of Degrees
Grams Per Second
Degrees of Retard
No/Yes
Milliseconds
Yes/No
Milliseconds
Milliseconds
Counts
Counts
Percentage
Volts
Off/On
Percentage
No/Yes
No/Yes
Off/On
Off/On
No/Yes
Off/On
Off/On
Psi, Volts
co;Fo
No/Yes
km/h
Park/Neutral, Reverse
DriveA, Drive 3,
Drive 2, Low, Invalid
PCM commanded (based on temp.)

85C- 105C (185F - 221F)
10C - 90C (50F - 194F)
(Depends on underhood temperature)
20- 48/1-2 (Varies with altitude)
70- 100/3.5-4.5 (Varies with altitude)
.3- .9
0%
10-1000 mV and varying
Closed Loop
10-1000 mV and varying
Closed Loop
Varies
118-138
Varies
118-138
16to 18 (depends on Air Flow & RPM)
Yes
Varies (PCM controlled)
Varies
0
No (Yes, when detonation is detected)
Varies
Yes
1-4, may vary
1-4, may vary
5-50
5- 50
0%
12.0-14.5
Off
0%
No
No
Depends on A/C refrigerant pressure,
and engine coolant temperature
No
Off
Off
Varies (Depends on temp.)
Varies
No
0
Park/Neutral
"C2"
"C2", DTC21
"C2"
DTC44,45
DTC4{45
DTC64,65
DTC64,65
,,c4"
"C2"
"CS"
"C5'1
"C4"
"C4"
"C2"
"C2"
"C2"
"C2"
"C7"
"60"
"CG"
"C3"
"C12"
"C12"
"ClO"
"ClO"
"ClO"
"ClO"
"DTC71"
"DTC84"

Park/Neutral Pos
Mph Km/h
TCC Brake Switch
TCC Solenoid
1 - 2 Shift Sol
2 - 3 Shift Sol
A/B/C Rng
Perf Mode Sw
Engine or Trans DTC
Knock Sensor
Time From Start
P-N--/-R-DL
Mph/Km/h
Closed/Open
Off/On
Off/On
Off/On
Off/On
Open/Closed
No/Yes
OK/Open/Grounded
Hrs/Min/Sec
Park/Neutral (P-N--)
0
Closed
Off
On
On
Off/On/Off
No
OK
Varies
C1-A
"CB"
"CB"
"CB"
"CB"
"CB"
"CB"
TRANSMISSION TECH 1 DATA

Idle I Lower Radiator Hose Hot I Closed Throttle I Park or Neutral I Closed Loop I Accessories off
SCAN Position
Units Displayed Typical Data Value
Refer To Section "C8" and:
Engine Speed
RPM
100 RPM From desired
Trans Output Spd
Eng Cool Temp
Trans Fluid Temp
Throt Position
Throttle Angle
A/8/C RNG
Trans Range Sw
Commanded Gear
Adaptable Shift
1-2 Sol 2-3 Sol
CTR FDBK 1/2 2/3
3-2 Control Sol
3-2 Control FDBK
Hot Mode
TCC SI i p Speed
TCC Solenoid
CTR FDBK TCC Sol
Desired PCS
Actual PCS
PCS Duty Cycle
MPH Km/h
TCS/ASRActive
Cruise Engaged
TCC Brake Switch
Kickdown Enabled
1-2 Shift Time
2-3 Shift Time
1-2 Shift Time Error
Curr Adapt Cell
Performance Mode Switch
Pref Lamp FDBK
Pref Mode Status
Eng or Trans DTC
Park/Neutral Pos
System Voltage
RPM
C"/F 0
C0 /F 0
Volts
Percentage
Off/On
Invalid, Rev,
Drive 4, Drive 3,
Drive 2, Low,
Park/Neut
1-4
No,Yes
Off/On
OK, Fault
Percentage
OK, Fault
No, Yes
RPM
Off/On
OK/Fault
Amps
Amps
Percentage
0-255
No, Yes
No, Yes
Applied/Released
No, Yes
Seconds
Seconds
Seconds
%TP
No/Yes
OK, Fault
Normal/Ped
Yes, No
P-N--/-R-DI
Volts
ORPM
85C- 105( (185F - 221F)
82C- 94C (180F - 200F)
0.3 - 0.9V
0%
Off/On/Off
"C2"
"C2"
Park/Neut
1
No
On/On
OK/OK
0%
OK
No
50 RPM From Engine Speed
Off
OK
1.01 Amps
L01 Amps
40%-60%
0
No
No
Released
No
0
0
0
0
No
OK
Normal
No
Park/Neutral (P-N--)
12.0- 14.5V
"C1"
"C1-A"
7-12-93
MS 12479
ENGINE AND TRANSMISSION TECH 1 DATA DEFINITIONS

A list of each data message displayed on the Tech 1 scan tool will be explained in.two groups; "Engine" or
"Transmission." This information will assist in emission or driveability problems. The displays can be viewed
while the vehicle is being driven. Always perform the "On-Board Diagnostic (OBD) System Check" first. The
"OBD System Check" will confirm proper system operation.
With the Tech 1 connected, the ASR system may be disabled and the "Service ASR" lamp may turn "ON."
ENGINE DATA
ENGINE SPEED Range 0-9999 RPM - Engine speed is
computed by the PCM from the distributor reference
input (low resolution circuit). It shouldrerhain close to
desired idle under various engine loads with engine
idling.
THROT POSITION Range 0-5.00 Volts - Used by the
PCM to determine the amount of throttle demanded by

the driver. The display should read 0.36-0.96 volt at
idle to greater than 4 volts at wide open throttle.
THROTTLE ANGLE Range O - 100% - Computed by the
DESIRED IDLE - Range 0-3187 RPM - The idle speed
that is commanded by the PCM. The PCM will

compensate for various engine loads based on engine
coolant temperature to keep the engine at the desired
speed.
ENG COOL TEMP Range 40C to 151C, -40F to 304F
PCM from TP sensor voltage (throttle position) and

at idle.
HEATED OXYGEN SENSORS (BANK 1 AND 2) Range
0-1132 mV - Represents the exhaust oxygen sensor
- The Engine Coolant Temperature (ECT) sensor is

mounted in the coolant pump and sends engine
temperature information to the PCM. The PCM
supplies 5 volts to the ECT sensor circuit. The sensor
is a thermistor which changes internal resistance as
temperature changes. When the sensor is cold
(internal resistance high), the PCM monitors a high
signal voltage and interprets it as a cold engine. As
the sensor warms (internal resistance decreases), the
voltage signal will decrease and the PCM will
interpret the lower voltage as a warm engine.
output voltage. Should fluctuate constantly within a

range between 10 mV (lean exhaust) and 1000 mV
(rich exhaust) when operating in "Closed Loop."
INTAKE AIR TEMP - Range -40C to 151C, -40F to

304F - The PCM converts the resistance of the intake
SHORT TERM FUEL TRIM Range 0-255 Counts - Short
air temperature sensor to degrees. Intake Air

Temperature (IAT) is used by the PCM to adjust fuel
delivery and spark timing according to incoming air
density.
MAP - Range 10-105 kPa/0.00-5.00 Volts - The
Manifold Absolute Pressure (MAP) sensor measures

the change in the intake manifold pressure from
engine load and speed changes. As intake manifold
pressure increases, the air density in the intake
manifold also increases and additional fuel is required.
BARO Range 10-105 kPa/0.00-5.00 Volts - The BARO
reading displayed is determined from the MAP sensor

at ignition "ON," engine "OFF," and WOT conditions.
The BARO reading displayed represents barometric
pressure and is used to compensate for altitude
differences.
LOOP STATUS Tech 1 Displays OPEN or CLOSED -
"Closed Loop" displayed indicates that the PCM is

controlling fuel delivery according to oxygen sensor
voltage. In "Open Loop," the PCM ignores the oxygen
sensor voltage and bases the amount of fuel to be
delivered on TP sensor, engine coolant, and MAP
sensor inputs only.
term fuel trim represents a short-term correction to

fuel delivery by the PCM in response to the amount of
time the oxygen sensor voltage spends above or below
the 450 m V threshold. If the oxygen sensor voltage
has mainly remained less than 450 mV, indicating a
lean air/fuel mixture, short term fuel trim will
increase and the PCM will add fuel. If the oxygen
sensor voltage stays mainly above the threshold, the
PCM will reduce fuel delivery to compensate for the
indicated rich condition.
LONG TERM FUEL TRIM Range 0-255 Counts - Long
term fuel trim is derived from the short term fuel trim
value and is used for long-term correction of fuel
delivery. A rnlue of 128 counts indicates that fuel
delivery requires no compensation to maintain a
14.7:1 air/fuel ratio. A value less than 128 counts
indicates that the fuel system is rich and fuel delivery
is being reduced (decreased injector pulse width).

A value greater than 128 counts indicates that a lean
condition exists and the PCM is compensating by
adding fuel (increased injector pulse width).
FUEL TRIM CELL - Range 0-255 - Fuel trim cell is
dependent upon engine speed and MAP sensor
readings. Fuel trim cell indicates which cell is
currently active.
FUEL TRIM ENABLE Tech 1 displays NO/YES - If the
Fuel Trim Enable system is learning "YES" the long
term fuel trim is responding to the short term fuel
trim. If the Fuel Trim Enable indicates "NO" then
long term fuel trim will not respond to changes in
short term fuel trim.
SPARK ADVANCE Tech 1 range 0-255 - This is a
display of the spark advance (IC) calculation which the
PCM calculates and then provides all spark advance to
the ignition system. The PCM computes the desired
spark advance using data such as engine coolant
temperature, RPM,. load, vehicle speed, and operating
mode. There is no adjustment for spark advance.
MASS AIR FLOW - Tech 1 range 0-512 - Displays grams
per second. The PCM converts the mass air flow
sensor input signal into grams per second, indicating
the amount of air flow entering the engine.
KNOCK RETARD Range 0 to 128 - Indicates the
amount of spark advance the PCM is removing from IC
in response to the Knock Sensor (KS) signal.
IDLE AIR CONTROL - Range 0-255 - Displays the

commanded position of the idle air control pintle in
counts. The greater the number of counts, the greater
the idle air passages opened. Idle air control should
respond fairly quickly to changes in engine load to
maintain desired idle RPM.
LEARNED IAC - Range 0-255 counts - Learned IAC is
an internal PCM parameter. Each time the vehicle is
driven the IAC system learns how many counts is
required to produce a given desired idle.
EGR DUTY CYCLE - Range 0-100% - The PCM cycles
the EGR solenoid valve "ON" and "OFF." The "ON"
time (duty cycle) of the EGR solenoid valve, expressed
as a percent, determines how much the exhaust gas is
recirculated.
SYSTEM VOLTAGE Range 0.0-25.5 Volts - This
represents the system voltage measured by the PCM.

AIR CONTROL Tech 1 displays ON/OFF - When the
PCM enables the Secondary Air Injection System, the

Tech 1 will display Air Control "ON." When the PCM
determines that AIR Control is not required the Tech 1
will display "OFF."
FUEL EVAP PURGE Tech 1 range 0-100% - Used to
control EV AP canister purge function. 0% indicates
the valve is commanded fully closed while 100%
indicates that the valve is fully open.
INJECTOR FAULT - Tech 1 displays YES/NO - "YES"
KNOCK SIGNAL Tech 1 displays YES/NO - Indicates
whether or not a knock signal is being detected by the

PCM. Should display "NO" at idle.
LO RESOLUTION SIGNAL Range 0-1000 m/sec. - This
signal is generated by the ignition control module and

should display time between low resolution signal
reference pulses detected by the PCM.
indicates that the PCM does not detect voltage at the

injector driver. Injector faults should indicate "NO,"
when circuits are OK.
TCS/ASR ACTIVE Tech 1 displays NO/YES - When the
"ASR" system is active, the Tech 1 will display "YES."
FAN CONTROL PCM A10- Tech 1 displays OFF/ON -
HI RESOLUTION SIGNAL Tech 1 displays YES/NO -
This signal is generated by the ignition control module

and will switch from "NO" to "YES" when the PCM
detects a high resolution signal.
INJECTOR PULSE WIDTH -Tech 1 range 0.0-1000 m/sec
- Indicates the time the injectors remain "ON." When

engine load is increased, injector pulse width will
increase.
Early Production Vehicles: This will display

"ON" when the PCM enables the secondary
cooling fan.
Late Production Vehicles: This will display
"ON" when the PCM enables high speed fans.
FAN CONTROL PCM A 11 Tech 1 displays OFF/ON -
Early Production Vehicles: This will display

"ON" when the PCM enables the primary
cooling fan.
Late Production Vehicles: This will display
"ON" when the PCM enables low speed fans,
and when the PCM enables high speed fans.

A/C REQUEST Tech 1 displays YES/NO - Represents if
TCC SOLENOID - Displays OFF/ON - The Tech 1 only
the NC request from the control head is being received

by the PCM.
indicates when PCM has enabled the TCC Driver, but

this does not confirm that the TCC has engaged. To
determine if TCC is operating properly, engine RPM
should decrease when TCC is enable.
A/C CLUTCH - Tech 1 displays ON/OFF - Represents the

command state of the NC clutch control relay. Clutch
should be engaged when "ON" is displayed.
A/C STATUS -Tech 1 displays ON/OFF -The Tech 1 will
display "ON" if voltage has been applied to the NC
compressor clutch.
A/C REFRIG PRESSURE Range 0-459 psi I 0.00-5.0
Volts - The Tech 1 will display the NC refrigerant
pressure used by the PCM for cooling fan operation

and NC diagnostic trouble codes.
1 - 2 SHIFT SOL Tech 1 displays ON/OFF - When the

transmission in in first or fourth gear, the Tech 1
should display "ON." When the transmission is in
second or third gear, the Tech 1 should indicate
"OFF.".
2 3 SHIFT SOL Tech 1 displays ON/OFF - When the
automatic transmission is in first or second gear, the
Tech 1 should indicate "ON." When the transmission
is in third or forth gear, the Tech 1 should display
"OFF."
A/C EVAP TEMP - -7C to 32C, 19F to 90F - The Tech
1 will display the NC evaporator temperature and is

used by the PCM to cycle the A/C clutch. The
evaporator temperature sensor will also prevent
evaporator freeze-up.

inputs from the transmission range pressure switch

assembly. "ON" represents a B+ voltage signal,
"OFF" represents a Ovoltage signal.
SKIP SHIFT ACT - Tech 1 displays NO/YES - When the
PCM enables the skip shift system, the Tech 1 will

display "YES."
VEHICLE SPEED Range 0-255 km/h, mph - The vehicle
speed sensor signal is converted into km/h and mph for
display.
PERF MODE SWITCH Tech 1 Displays OPEN/CLOSED -
This parameter indicates the position of the

performance mode switch. The Tech 1 will display
"YES" when the switch is depressed and then "NO"
when the switch is released.
ENG/TRANS DTC DETECTED Tech 1 Displays YES/NO-
TRANS RANGE SWITCH Tech 1 displays Park/Neutral,

Reverse, Drive 4, Drive 3, Drive 2, Low and Invalid -
This will display "YES" if the PCM detects a fault in

an engine or transmission circuit that caused a OTC.
These values represent the decoded sequence of the

Transmission Range (TR) pressure switch assembly
circuits and are used to determine manual valve
position.
- The PCM monitors the KS circuit and can determine

if the sensor is open, grounded, or if the circuit is "OK."
PARK/NEUTRAL POS Tech 1 displays PN- or -R-DL -
P-N-- displayed indicates that the gear select lever is

in park or neutral.
rec BRAKE SWITCH Tech 1 displays OPEN/CLOSED When the brake pedal is applied, the switch sends a
signal to the PCM to disengage the TCC solenoid.
KNOCK SENSOR - Tech 1 displays OK/Open/Grounded
TIME FROM START - Range 0:00:00-18:12:15

HR/MIN/SEC - A measure of how long the engine has
been operating. When the ignition is cycled to "OFF"

the value is reset to zero.
TRANSMISSION DATA
ENGINE SPEED - Scan tool displays 0.9999 RPM -
Engine speed is computed by the PCM from the

distributor reference input (low resolution circuit). It
should remain close to desired idle under various
engine loads with engine idling.
represents the position of the transmission manual

valve.
COMMANDED GEAR - Scan tool displays a range of 1,
2, 3, or 4 - This parameter is the decoded commanded
state of the 1-2 and 2-3 Shift Solenoids. Gear 1 = ON,
TRANS OUTPUT SPEED Scan tool displays O RPM to

8191 RPM - This parameter indicates the rotational
ON. Gear 2 = OFF, ON. Gear 3

= ON,OFF.
speed of the transmission output shaft expressed as

revolutions per minute.
ADAPTABLE SHIFT -This value indicates if the current
ENG COOL TEMPERATU RE - Range -40C to 151 C, - 40

to 304F - The Engine Coolant Temperature (ECT)
sensor is mounted in the coolant pump and sends

engine temperature information to the PCM. The
PCM supplies 5 volts to the ECT sensor circuit. The
sensor is a thermistor which changes internal
resistance as temperature changes. When the sensor
is cold (internal resistance high), the PCM monitors a
high signal voltage and interprets it as a resistance
decreases), the voltage signal will decrease and the
PCM will interpret the lower voltage as a warm
engine.
TRANS FLUID TEMP - Scan tool displays a range of
-40C to 151C, 40F to 304F - This parameter is the
input signal of the transmission fluid temperature

sensor. Transmission fluid temperature is high
(151 C) when signal voltage is low (0 volt), and
transmission fluid temperature is low (-40C) when
signal voltage is high (5 volts).
THROTPOSITION Range of 0-5.00 Volts- Used by the
PCM to determine the amount of throttle demanded by

the driver. The display should read 0.36-0.96 volt at
idle to greater than 4 volts at wide open throttle.
= OFF, OFF.
Gear 4
shift will update the 1-2 adapt tables. The adapt tables
are used to modify line pressure. The following items
cause a shift not to be adaptable:
Braking pressure (manual gear ranges).
Long shift delay (shift delay is the time the
solenoid changes state until the shift starts).
Long shift time.
Throttle range
Significant throttle angle change.
Hotmode.
Transmission fluid temperature range.
Manual gear ranges (Dl, 02).
If shift starts too soon after the solenoid state
change.
Diagnostic failures - 21, 22, 24, 28, 53, 58, 59,
72, 73, 75, 79, 81, or 82.
Time since last shift.
Time since the last range change.
Significant vehicle speed change.
1 2 SOLENOID (SOL)/2-3 SOLENOID (SOL) - Scan tool
displays ON/OFF - These parameters are the
commanded status of the 1-2 and 2-3 shift solenoids.

"ON" represents a commanded energized state
(current flowing through solenoid). "OFF" represents
a commanded non-energized state (current not flowing
through solenoid).
THROTILE ANGLE - Range 0-100% - Computed by the
PCM from TP sensor voltage (throttle position) and

at idle.
status of the 1-2 and 2-3 shift solenoid driver control

circuits.

3 2 CONTROL SOLENOID (SOL) Scan tool displays a

range of 0% to 100% - This parameter is the
inputs from the Transmission Range Pressure Switch

Assembly. "ON" represents a B + voltage signal,
"OFF" represents a O voltage signal.
commanded percentage of"ON" time of the 3-2 Control

Solenoid. "0%" represents a completely "OFF" (nonenergized) commanded state. "100%" represents an
"ON" (energized) commanded state.
TRANS RANGE SWITCH (SW) - Scan tool displays a

range of Invalid, Park/Neutral, Reverse, Drive 4, Drive
3, Drive 2, and Low - This parameter is the decoded
status of the three A/B/C Range inputs from the

Transmission Range Pressure Switch Assembly and
CONTROL (CTR) FEEDBACK (FDBK) 1/2 2/3 - Scan tool

displays OK/FAULT - These parameters are the actual
3-2 CONTROL (CTR) FEEDBACK (FDBK) Scan Tool

displays ON/OFF." - This parameter is the actual state
of the 3-2 control solenoid driver control circuit.

HOT MODE - The scan tool will display this value
either "ON" or "OFF" When displayed "ON," the
transmission fluid temperature has become greater
than 135C and the following actions will occur:
1. The TCC will engage in fourth gear, except
when the brakes are applied, low TP signal, or
a DTC is stored.
2. When the fluid temperature obtains 150C but,
less than 154C for 15 minutes, DTC 79 will
set. When DTC 79 is set, TCC application will
still occur in the same criteria as when hot
mode started.
3. When fluid temperature increases from 150C
for 1 second, in a time period less than 15
minutes, DTC 79 will not set. DTC 58 will set
when transmission fluid temperature is
greater than 154C for 1 second.
4. When DTC 58 is set and in hot mode, the
vehicle will retain hot mode criteria until the
next ignition cycle.
5. If fluid temperature cools from 135C down to
less than 125C, hot mode criteria will
discontinue.
TCC SLIP SPEED - Scan tool displays a range of -4096
RPM to + 4095 RPM - This parameter is the difference
between transmission input speed derived (from the

engine speed) and transmission output speed (from the
vehicle speed sensor). A negative value indicates
input speed is less than output speed (deceleration). A
positive value indicates input speed is greater than
output speed (acceleration). A value of zero indicates
input speed is equal to output speed (TCC applied).
pressure. 1.10 amps (high current flow) indicates

actual lower line pressure.
PRESSURE CONTROL SOLENOID (PCS) DUTY CYCLE
Scan tool displays a range of 0% to 100% ~ This
parameter is the commanded state of the pressure

control solenoid expressed as a percent of energized of
on time. 0% indicates zero on time (non-energized) or
on current flow. 100% indicates maximum on time
(energized) or high current flow.
MPH/Km/h Range 0-255 km/h, mph - The vehicle
speed sensor signal is converted into km/h and mph for

display.
TCS/ASR ACTIVE Tech 1 Displays YES/NO - When the
"ASR" SYSTEM is active, the Tech 1 will display
"YES."
CRUISE ENGAGED Scan tool displays NO/YES - This
parameter is the signal state of the cruise control

ON/OFF switch. "NO" indicates a O voltage signal
(cruise control not requested). "YES" indicates a B +
voltage (cruise control requested).
TCC BRAKE SWITCH Scan tool displays
APPLIED/RELEASED - This parameter indicates the
state of the TCC Brake Switch circuit input.

"APPLIED" indicates a O voltage input (brake switch
open, brake pedal applied). "RELEASED" indicates a
B + voltage input (brake switch closed, brake pedal
released).
KICKDOWN ENABLED Scan tool displays NO/YES -
TCC SOLENOID Scan tool displays ON/OFF - This
parameter is the commanded state of the TCC

solenoid. "ON" indicates a commanded energized state
(current flowing through the solenoid). "OFF"
indicates a commended non-energized state (current
not flowing through the solenoid).
CONTROL (CTR) FEEDBACK (FDBK) TCC SOL Scan tool
displays OK/FAULT - This parameter is the actual state
of the TCC solenoid driver control circuit.

DESIRED PRESSURE CONTROL SOLENOID (PCS) Scan
This parameter indicates whether enabling conditions

exists for an acceleration mode downshift. "NO"
indicates enabling conditions (throttle position,
vehicle speed, input speed, etc.) do not exists for an
acceleration mode downshift. "YES" indicates
enabling conditions exists for an acceleration mode
downshift.
1 - 2 SHIFT TIME - Scan tool displays a range of 0.00
seconds to 6.38 seconds - This parameter is the actual
time of the last 1-2 shift. This parameter is not

accurate at less than 25% throttle position.
parameter is the commanded current of the Pressure

Control Solenoid circuit. 0.00 amps (no current flow)
indicates commended higher line pressure. 1.10 amps
(high current flow) indicates commanded lower line
pressure.
2 - 3 SHIFT TIME - Scan tool displays a range of 0.00

seconds to 6.38 seconds - This parameter is the actu.al
ACTUAL PRESSURE CONTROL SOLENOID (PCS) Scan

difference between the desired 1-2 shift time and the

actual 1-2 shift time. This parameter is not accurate
at less than 25% throttle position
parameter is the actual current of the Pressure

Control Solenoid circuit at the Control Module. 0.00
amps (no current flow) indicates actual higher line

1 - 2 SHIFT ERROR - Scan tool displays a range of 0.00
seconds to 6.38 seconds - This parameter is the

CURRENT (CURR) ADAPT CELL - Scan tool displays a
range of NOT USED, 25% TP Cell, 40% TP Cell and
70% TP Cell - This parameter indicates the current
throttle position cell used for fluid line pressure

modification (adaptation). "NOT USED" represents
0% - 25% throttle angle. "25% TP Cell" represents
25% - 39% throttle cell. "40% TP Cell" represents 40%
- 70% throttle angle. "70% TP Cell" represents 70% 100% throttle angle.
PERF MODE SWITCH - Tech 1 Displays OPEN/CLOSED -
This parameter indicates the position of the

performance mode switch. The Tech 1 will display
"CLOSED" when the switch is depressed and then
"OPEN" when the switch is released.
PERF LAMP FOBK - Tech 1 Displays OK/Fault - This
parameter is the actual state of the performance mode

indicator lamp circuit. The Tech 1 will display FAULT
when the lamp is "ON" while commanded "OFF" or
when the lamp is "OFF" while commanded "ON." The
Tech 1 will display OK w:tien the lamp is "ON" while
commanded "ON" or when the lamp is "OFF" while
commanded "OFF."
PERF MODE STATUS - Tech 1 Displays Normal/PERF -
This parameter is the actual state of the performance

mode control program (within the PCM). The Tech 1
will display "PERF" when the performance mode is
active (Performance Shift Calibration). The Tech 1
will display "Normal"when the performance mode is
not active (Normal Shift Calibration)
ENG/TRANS OTC DETECTED - Tech 1 Displays YES/NO -
This will display "YES" if the PCM detects a fault in

an engine or transmission circuit that caused a DTC.
PARK/NEUTRAL POS - Tech 1 displays - P-N-- or -R-DL -
P-N-- displayed indicates that the gear select lever is

in park or neutral.
SYSTEM VOLTAGE - Scan tool displays 0.00 volt to
25.5 volts - This parameter is the battery ignition
voltage input to the control module.
7-9-93
MS 12724
PCM
PCM BATTERY FEED
PCM BATTERY FEED
TO OTHER CIRCUITS._..-------,!
In\
#9 (1/P)
41(.-----,r'V-...i--
TO IGNITION ...
10 AMP
39 PNK - - - - - ~
MALFUNCTION
TO OTHER
INDICATOR
CIRCUITS
LAMP (MIL)
439 P"i'K
PCM IGNITION FEED
439 PNK
15AMP
\TO MASS AIR
C230
c FLOW SENSOR
r-----c:4K.---- 448 WHT/BLK
C230
PCM IGNITION FEED
#5 (1/P)
TO IGNITION--------- 3 PNK
(,(-- 419 BRN/WHT

C230

ENABLE
451BLK/WHT-=:..__
CHART A-1
NO MALFUNCTION INDICATOR LAMP (MIL)
5. 7L (VIN P) F" CARLINE (SFI)
11
There should always be a steady MIL when the ignition is "ON" and engine stopped. Ignition voltage is
supplied to the bulb on CKT 39. The Powertrain Control Module (PCM) will turn the light "ON" by providing the
ground path through CKT 419.

1. Fuse #4 and #5 feed several circuits in addition to
the PCM. Check thoroughly for a short to ground
or a shorted component that may cause either fuse
to open. Refer to SECTION 8A for detailed circuit
diagnosis.
2. Low voltage on "03" will cause a high idle and soft
landing to 3rd gear. If the voltage is extremely low,
the MIL may not operate and/or serial data may be
lost. If serial data appears to be functioning, cycle
the ignition "OFF/ON" and recheck.
Diagnostic Aids: An open circuit to "03" will cause

a high idle, no serial data and soft landing to 3rd gear.
An open circuit to "B30" will cause a no start and
no MIL. An open CKT 340 between the fuse and the
splice will cause a no start and no MIL. "Bl5" and
"B31" are connected internally within the PCM.
CHART A-1
NO MALFUNCTION INDICATOR LAMP (MIL)
5. 7'- (VIN P) "F" CARLINE (SFI)
DOES ENGINE START?
G) ARE FUSES FOR PCM IGNITION FEED AND PCM
G)
DOES TECH 1 DISPLAY SERIAL DATA?
BATTERY FEED CIRCUITS OK?
IGNITION "OFF."
DISCONNECT PCM ELECTRICAL
CONNECTORS.
IGNITION "ON."
PROBE BOTH IGNITION FEED
CIRCUITS AND BOTH PCM
BATTERY FEED CIRCUITS AT
PCM ELECTRICAL HARNESS
WITH A DVM (J 39200)
BATTERY VOLTAGE SHOULD BE
INDICATED.
ISIT?
FAULTY PCM GROUNDS

OR
OR
FAULTY PCM.
LOCATE AND CORRECT

SHORT TO GROUND IN
CIRCUIT THAT HAD AN
OPEN FUSE.
IGNITION "Off."
DISCONNECT PCM
CONNECTOR "D".
IGNITION "ON."
USING A DVM (J 39200)
MEASURE VOLTAGE AT
.PCM ELECTRICAL HARNESS
TERMINAL "03". BATTERY
VOLTAGE SHOULD BE
PRESENT.
IS IT?
------------,
: REFER TO OTC 11 FOR :

I MIL DIAGNOSIS.
1
L-------------_J

OR
FAULTY PCM.
5-25-93
PS 17787
6E3-A-28 5.7L (VIN P) DRIVEABILITYAND EMISSIONS
PCM
PCM BATTERY FEED
PCM BATTERY FEED
TO OTHER CIRCUITS,..-------.
#9 (1/P)
~----.AJ,----- 39 PNK
TO IGNITION ....
10 AMP
TO OTHER
CIRCUITS
(n\
_ _ _....,.)6(1""-----c(~ 419 BRN/WHT

MALFUNCTION C230
INDICATOR
LAMP (MIL)
439PNK
#5 (1/P)
TO IGNITION...------- 3 PNK
15AMP
C230
439PNK
\TO MASS AIR
FLOW SENSOR
448 WHT/BLK
r-------<!l.,K--C230
PCM IGNITION FEED

PCM IGNITION FEED

ENABLE
451BLK/WHT ~
CHART A-2
OUTPUT/FIELD SERVICE ENABLE CIRCUIT
5.7L (VIN P) .. F" CARLINE (SFI)
The PCM provides 5 volts on CKT 448 to Data Link Connector (DLC) terminal "B". Grounding terminal "B"
pulls the 5 volts low. With the key "ON" engine "OFF," most outputs will be enabled. With the engine running,
the field service mode is enabled.

circled number(s} on the diagnostic chart.
1. There should be 5 volts present at DLC terminal
2. This checks the continuity of CKT 448 from the
DLC to the PCM connector.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-Ai9
CHART A-2
OUTPUT/FIELD SERVICE ENABLE CIRCUIT
5. 7L (VIN P) "F" CARLINE (SFI)
G)
ENGINE IDLING.
IS MIL FLASHING?
PROBE OUTPUT/FIELD SERVICE ENABLE TERMINAL

AT THE DATA LINKCONNECTOR(DLC)WITH A DVM
IS 5 VOLTS PRESENT?
IGNITION "OFF."
DISCONNECT PCM CONNECTOR
"D".

OR
FAULTY PCM.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "D".
PROBE OUTPUT/FIELD SERVICE ENABLE TERMINAL AT
THE DATA LINKCONNECTOR(DLC)WITH A TEST
LIGHT CONNECTED TO B +.
DOES TEST LIGHT ILLUMINATE?
OUTPUT/FIELD SERVICE
ENABLE CIRCUIT
SHORTED TO GROUND.
'FAULTY PCM.
USING A JUMPER WIRE,

GROUND OUTPUT/FIELD
SERVICE ENABLE TERMINAL AT
DLC.
WITH A TEST LIGHT
CONNECTED TO B +, PROBE
TERMINAL "020" AT PCM
HARNESS CONNECTOR. TEST
LIGHT SHOULD ILLUMINATE.
DOESIT?

OR
FAULTY PCM.
OUTPUT/FIELD SERVICE
EN.ABLE CIRCUIT OPEN.
5-20-93
PS 17788
6E3-A-30 5.7L (VIN P) ORIVEABILITY AND EMISSION'S
PCM
IGNITION SYSTEM
TEST CONNECTOR
- - - - - - - - - 632 PNK/BLK
~ - - - - - - - - 632 PNK/BLK
1 - - - - - - - - - - - 631 RED
1---------- 430 PPL/WHT
. - - - - - - - - - - - - 631 RED
. - - - - - - - - 430 PPL/WHT
- - - - - - - 453 RED/BLK
1---------- 453 RED/BLK
,ii.--
ENGINE
GROUND
45 0BLK
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
CONNECTOR
--------\
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
IGNITION
COIL
MODULE
239 PNK
423WHT
IGNITION CONTROL
IGNITION
COIL
II
L---------/-..J
BLACK
CONNECTOR
(U/H)
6-25-93
MS 12328
= LOCATED IN UNDERHOOD ELECTRICAL CENTER
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
11
This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank.

1. Perform OBD system check to determine if the
PCM and the MIL (Malfunction Indicator Lamp)
are functioning, before proceeding with this chart.
2. An injector with a resistance value too low will
cause an injector fuse to open. If Injector #9 or
#10 fuse is open, 4 injectors will be disabled and a
no start may occur. The resistance of each injector
should be within one ohm of each other.
3. Use fuel pressure gage J 34730-1. Wrap a shop
towel around the fuel pressure tap to absorb any
small amount of fuel leakage that may occur when
ihstalling the gage.
4. CHART C-4 will address all problems related to
the causes of a no spark condition.
Diagnostic Aids:
An EGR valve sticking open can cause a low

air/fue 1 ratio during cranking.
Unless engine enters "Clear Flood" at the first
indication of a flooding condition, it can result
in a no start.
Check duct work between mass air flow sensor
and throttle body for air leaks.
A defective Mass Air Flow (MAF) sensor may
cause a no start or a stall after start.
Disconnect the MAF sensor. The PCM will
default to speed density (MAP, IAT, RPM) to
calculate load and air flow. If the condition is
corrected and the connections are OK, replace
the MAF sensor.
If above are all OK, refer to "Hard Start" in
"Symptoms," Section "6E3~B''.
DRIVEABILITYAND EMISSIONS 5. 7L (VIN P) 6E3-A-31
PERFORM ON-BOARD DIAGNOSTIC SYSTEM CHECK BEFORE

PROCEEDING WITH THIS CHART. ALSO CHECK THE
FOLLOWING:
IF PCM DTC{s) 16, 18,41,42,46 OR48 ARE STORED, USE
THOSE CHARTS FIRST.
ACTUAL ENGINE TEMPERATURE AND ECT TEMPERATURE
ON THE TECH 1 SHOULD BE CLOSE TO THE SAME, IF NOT,
REFER TO OTC 15.
TP SENSOR - IF OVER 2.5 VOL TS AT CLOSED THROTTLE, USE
THE OTC 21 CHART.
IS RPM INDICATED ON TECH 1 DURING CRANKING?
USING A ST-125 {SPARK CHECKER},

J 26792, CHECK FOR SPARK WHILE
CRANKING (CHECK TWO WIRES).
IS SPARK PRESENT?
0:
CHECK INJECTOR FUSES

FOR BEING OPEN.
ARE FUSE{s) OK?
CHART A-3
ENGINE CRANKS BUT WILL NOT
RUN
11
5.7L (VIN P) F" CARLINE (SFI)
IGNITION "OFF."
DISCONNECT DISTRIBUTOR ELECTRICAL CONNECTOR.
IGNITION "ON."
PROBE TERMINAL "C" WITH A TEST LIGHT TO GROUND.
IS IT?
CHECK FOR CONTINUITY BETWEEN

DISTRIBUTOR CONNECTOR
TERMINAL "D" AND GROUND.
CIRCUIT SHOULD HAVE
CONTINUITY.
DOES IT?
------,
BASIC
I IGNITION
: SYSTEM
: PROBLEM.
I REFERTO
: CHART C-4.
:
I
:
:
I
L--------J

OR
OPEN OR GROUNDED IGNITION
FEED CIRCUIT FROM
DISTRIBUTOR TO PCM
OR
FAULTY PCM.
YES
: CHECK
INJECTOR(s) OR
: INJECTOR :
: CIRCUITS FOR
I BEING SHORTED
: TO GROUND.
FAULTY DISTRIBUTOR CONNECTION

OR
FAULTY DISTRIBUTOR.
L-----------J

OR
OPEN GROUND CIRCUIT
FROM DISTRIBUTOR TO PCM
OR
FAULTY PCM.
USING TECH 1, ENABLE FUEL PUMP.

DOES FUEL PUMP OPERA TE?
-----,
: USE
:
I CHART A-5. 1
L-------J
fi\
V
IGNITION "OFF."
INSTALL FUEL PRESSURE GAGE AND NOTE
PRESSURE AFTER IGNITION "ON."
SHOULD BE (283-325 kPa}41-47 psi.
r-- ----,
REVIEW THE "DIAGNOSTIC AIDS" ON FACING PAGE FOR ADDITIONAL

ITEMS TO CHECK. IF ALL ARE OK, SFI SYSTEM IS OK.
REFER TO "HARD START" IN "SYMPTOMS," SECTION "B".
: USE
:
I CHART A-7. 1
L-------J
6-25-93
MS 12469
PCM
TO THEFT DETERRENT MODULE
TO
81
#5{1/P)
.
IGN ~(--3PNK
C200
15AMP
K
C230
SENSOR
~FLOW
AI
R
439 PNK
PCM IGNITION FEED
439PNK
PCM IGNITION FEED
~ 465 DK GRN/WHT
C220
451 BLK WHT
FUEL PUMP RELAY

CONTROL
---=:.._
FUEL PUMP (FP) RELAY

TO
A1
D
FUEL~120 GRY ~ - - - - - - 1 2 0 GRY - ( ~
PUMP
C405
C210 FUEL PUMP PRIME CONNECTOR
6-25-93
MS 12488
CHART A-5
FUEL PUMP RELAY CIRCUIT
fuel pump. It will remain "ON" as long as the PCM is receiving low resolution reference pulses from the
distributor ignition system.
If there are no reference pulses, the PCM will shut "OFF" the fuel pump about 2-3 seconds after key "ON," or
when engine stops. When sufficient oil pressure is present to close the oil pressure switch, the fuel pump will
remain "ON."
The pump will deliver fuel to the fuel rail and injectors, then to the pressure regulator, where the system
pressure is controlled to 284-325 kPa (41-47 psi). Excess fuel is then returned to the fuel tank.
When the engine is stopped, the fuel pump can be turned "ON" by using the Tech 1. Improper fuel system
pressure will result in one or all of the following symptoms:
Cranks but won't run.
DTC 44 and 64.
DTC 45 and 65.
Cuts out, may feel like ignition problem.
Poor fuel economy, loss of power.
Hesitation.
DTC55.
CHART A-5
FUEL PUMP RELAY CIRCUIT
5. 7L (VIN P) "F'' CARLINE (SFI)
,----------------,
FROM CHART A-3 (1 OF 2).
~-r--------------~
CHECK FUSE #5 I
.
I
NOTOKI
DISCONNECT FUEL PUMP RELAY .
IGNITION "OFF," FUSE REMOVED.

DISCONNECT HARNESS AT FUEL PUMP.
PROBE CKT 120 WITH A TEST LIGHT TO 12 VOLTS.
PROBE IGNITION FEED CIRCUIT OF FUEL PUMP

RELAY
HARNESS CONNECTOR WITH A TEST LIGHT
TO GROUND.
LIGHT"ON"
PROBE RELAY GROUND CIRCUIT AT FUEL

PUMP RELAY HARNESS WITH A TEST LIGHT
TO 12 VOLTS. LIGHT SHOULD LIGHT,
DOESIT?
L~GHT "Off"
OPEN IN
IGNITION
FEED
CIRCUIT.
]
TO GROUND.
USING TECH 1, ENABLE FUEL PUMP.
LIGHT SHOULD LIGHT.
DOES IT?
RECONNECT FUEL PUMP HARNESS.

REPLACE FUSE.
IGNITION "ON."
RECHECK FUSE
USING A FUSED JUMPER WIRE, JUMPER

TERMINALS "C1" AND" A2" OF RELAY
HARNESS.
FUEL PUMP SHOULD RUN.
DOESIT?
]
OPEN IN
RELAY
GROUND
CIRCUIT.
FAULTY FUSE
OR
INTERMITTENT SHORT
TO GROUND IN CKT 120.
CKT 120 SHORTED TO

GROUND.
.
NOT OK
FAULTY IN-TANK
FUEL PUMP
OR
PUMP HARNESS
SHORT TO GROUND.
]
OPEN OR GROUNDED CKT 465
OR
OR
FAULTY PCM.
WITH TERMINALS "C1" AND "A2" STILL JUMPERED

DISCONNECT FUEL PUMP HARNESS CONNECTOR.
PROBE CKT 120 OF FUEL PUMP HARNESS (RELAY SIDE)WITH A TEST LIGHT TO GROUND.
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
WITH TERMINALS "C1" AND" A2" STILL JUMPERED

USING A TEST LIGHT, PROBE CKT 120 TO FUEL PUMP GROUND CIRCUIT AT FUEL PUMP HARNESS.
CKT 120 OPEN FROM

FUEL PUMP TO FUEL
PUMP RELAY.
I
~
OPEN FUEL PUMP HARNESS

OR
FAULTY IN-TANK FUEL PUMP.
I OPEN FUEL PUMP GROUND CIRCUIT. I
7-9-93
NS 15558

CAUTION:


BLEED
HOSE
MANIFOLD VACUUM
HOSE CONNECTION
RETURN LINE
FUEL FILTER
NYLON
FUEL PUMP AND

RESERVOIR ASSEMBLY
CHART A-7
NS 16050
(Page 1 of 3)

fuel pump. It will remain "ON" as long as the engine is cranking or running, and the PCM is receiving reference
pulses. If there are no reference pulses, the PCM will shut "OFF" the fuel pump within 2 seconds after ignition
"ON" or engine stops.
,
Inside the fuel tank an electric fuel pump (within an integral reservoir), supplies fuel through an in-line filter
to the fuel rail assembly. The pump is designed to provide fuel at a pressure above the regulated pressure needed
by the injectors. A pressure regulator, attached to the fuel rail, keeps fuel available to the injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a separate line.
The fuel pump "Test" connector is located in the engine compartment near the passenger side shock tower.
Chart Test Description: N umber(s) below refer to
Leaking valve/seat within pressure regulator.
Leaking injector(s).
1. Connect fuel pressure gage as shown in
4. A leaking injector can best be determined by
illustration. Wrap a shop towel around the fuel
checking for a fouled or saturated spark plug(s). If
pressure connection to absorb any small amount of
a leaking injector can not be determined by a
fuel leakage that may occur when installing the
fouled or saturated spark plug, the following
gage. With ignition "ON" and fuel pump running,
procedure should be used.
pressure should be 284-325 kPa (41-47 psi). This
Remove fuel rail but leave fuel lines connected.
pressure is controlled by spring pressure within
Follow the procedures in "Fuel Metering
the regulator assembly.
System," Section "6E3-C2" of this manual.
2. When the engine is idling, manifold pressure is
Lift fuel rail out just enough to leave injector
low (high vacuum) and is applied to the pressure
nozzles in the ports.
regulator diaphragm. Vacuum will offset spring
pressure and result in lower fuel pressure. Fuel
pressure at idle will vary somewhat depending on
personal injury that may result from fuel
barometric pressure but, should be less than
spray .on the engine, n:ial<e sure fuel rail is
pressure noted in Step (1).
pqs1t1oned. qver .in1ect9r ports and
3. A system that does not hold pressure is caused by
m1ector retammg chps are intact.
one of the following:
Leaking fuel pump check ball.
Pressurize the fuel system and observe injector
Leaking fuel pump flex pipe.
nozzles.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P} 6E3-A-35
CHART A-7
G)
INSTALL FUEL PRESSURE GAGE AS SHOWN ON FACING PAGE.

IGNITION "OFF" FOR 10 SECONDS. A/C "OFF."
IGNITION "ON." FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
IT MAY BE NECESSARY TO CYCLE THE IGNITION "ON" MORE
THAN ONCE TO OBTAIN MAXIMUM PRESSURE.
NOTE FUEL PRESSURE WITH PUMP RUNNING, PRESSURE
SHOULD BE 284-325 kPa (41-47 psi). WHEN PUMP STOPS.
PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY.
IS PRESSURE CORRECT AND DOES IT HOLD?
(Page 1 of 3)

5.7L (VIN P) ''F" CARLINE (SFI)
r--------- .-,
FROM CHART A-3
L-----
-------------------------,
: IF FUEL PRESSURE IS WITHIN NORMAL

:
I RANGE BUT IS SUSPECTED OF DROPPING
I
: OFF DURING ACCELERATION, CRUISE OR
:
I HARD CORNERING, SEE CHART A-7 (2 OF 3). 1
~
G)
FUEL PRESSURE
WITHIN SPEC., BUT
DOES NOT HOLD.
-------------------------~
DISCONNECT VACUUM HOSE

FROM PRESSURE REGULATOR
ASSEMBLY.
WITH ENGINE IDLING, APPLY 1214 INCHES OF VACUUM TO
PRESSURE REGULATOR. FUEL
PRESSURE NOTED IN STEP (1)
SHOULD DROP APPROXIMATELY
21-69 kPa (3-10 psi).
DOES IT?
LOCATE AND
REPAIR LOSS
OF VACUUM
TO PRESSURE
REGULATOR.
FUEL
PRESSURE
OUT OF SPEC.
PRESSURE
REGULATOR
IS FAULTY.
NO FUEL PRESSURE
r- - - - - - - - - - - - - - ,
USE CHART A-5 TO
I
,-------, :DIAGNOSEFUELPUMP:
: SEE CHART A-7 : ELECTRICAL CIRCUIT.
1
1
. (2 OF 3 )
.,1 - - - - - - - - - - - - - - J
__________
STARTENGINE,ALLOWITTOIDLEAT
FUEL PRESSURE NOTED IN STEP (1)
SHOULD DROP APPROXIMATELY 21-69
kPa (3-10 psi).
DOESIT?
NO TROUBLE
FOUND,
REVIEW
"SYMPTOMS,"
SECTION "B".
-----...I
INSTALLJ 37287FUEL LINE

SHUT-OFF ADAPTORS, REFER TO
PAGES 3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVES ARE OPEN.
IGNITION "OFF."
USING A 10AMPFUSEDJUMPER
WIRE, CONNECT FUEL PUMP
"TE,ST" CONN ECTOR TO B +
AND WAIT FOR PRESSURE TO
BUILD.
CLOSE VALVE IN FUEL PRESSURE
LINE. PRESSURE SHOULD.HOLD.
DOES IT?
CHECK FOR:
PLUGGED IN-LINE
FILTER.
RESTRICTED FUEL
PRESSURE LINE.
PLUGGED FUEL
PUMP STRAINER.
LEAKING FUEL
PUMP FEED HOSE.
OPEN VALVE IN FUEL

PRESSURE LINE.
RECONNECT PUMP "TEST"
JUMPER AND WAIT FOR
PRESSURE TO BUILD.
CLOSE VALVE IN FUEL
RETURN LINE. PRESSURE
SHOULD HOLD.
DOES IT?
CHECK FOR:
LEAKING FUEL
PUMP FEED HOSE .
LOCATE AND CORRECT LEAKING

INJECTOR(S).
FUEL PUMP IS
FAULTY.
(LEAKING
CHECK BALL
INSIDE PUMP.)
PRESSURE
REGULATOR
IS FAULTY.
11-30-92
NS 16051-6E

CAUTION:

PLACE TOWEL.IN APPROVED CONTAINER.

RE SUL TING IN POSSIBLE FIRE OR PERSONAL INJURY.
BLEED
HOSE
MANIFOLD VACUUM
HOSE CONNECTION
RETURN LINE
FUEL FILTER
NYLON
FUEL PUMP AND

RESERVOIR ASSEMBLY
cHART A-7
(Page 2 of 3)

11
5. Fuel pressure that drops off during acceleration,
cruise or hard cornering may cause a lean
condition and result in a loss of power, surging or
misfire. This condition can be diagnosed using a
Tech 1 scan tool. If the fuel system is very lean,
one or both oxygen sensors will stop toggling and
output voltage will drop below 300 m V. Also,
injector pulse width will increase.
rn
6.
Important
Make sure system is not operating at "FuelCutoff'' which may cause false readings on the
scan tool.
Fuel pressure below 284 kPa (41 psi) may cause a

lean condition and may set a DTC 44/64.
cold, hesitation, poor driveability, lack of power,
surging or misfire.
7. Restricting the fuel return line causes fuel

pressure to build above regulated pressure. With
battery voltage applied to the pump "test"
connector, pressure should rise above 325 kPa (47
psi) as the valve in the return line is partially
closed.
NOTICE: Do not allow pressure to exceed 414

kPa (60 psi) as damage to the regulator may result.
8. Fuel pressure above 325 kPa (47 psi) may cause a
rich condition and may set a DTC 45/65.
(followed by black smoke) and a strong sulphur
smell in the exhaust.
9. This test determines if the high fuel pressure is
due to a restricted fuel return line or a faulty fuel
pressure regulator.
10. The pressure regulator filter screen is designed to
trap any contaminants introduced during engine
assembly. If dirty, it can be removed with a small
pick and discarded without potential harm to the
regulator.
DRIVEABIUTY AND EMISSIONS 5.7L (VIN P) 6E3-A-37
CHART A-7
(Page 2 of 3)

r--------,
:
FROM
:
CHARTA-7 1
:
(1 OF 3) :
I
L-r-----J
r--,.,..-'------------, ,::'\
~
0 FUEL PRESSURE DROPS OFF
FUEL PRESSURE LESS

THAN 284 kPa (41 psi).
DURING ACCELERATION, CRUISE

OR HARD CORNERING.
(v
FUEL PRESSURE ABOVE

325 kPa (47 psi).
CHECK FOR RESTRICTED IN-LINE

FUEL FILTER OR FUEL PRESSURE
LINE. IS THERE A RESTRICTION?
G)
SERVICE AS
REQUIRED
AND
RECHECK.
INSTALLJ 37287-2 FUEL

RETURN LINE SHUT-OFF
ADAPTER, REFER TO PAGES
3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVE IS OPEN.
IGNITION "OFF."
USING A 10AMPFUSED
JUMPER WIRE, CONNECT FUEL
PUMP "'TEST" CONNECTOR
TOB+.
SLOWLY CLOSE SHUT-OFF
VALVE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi).
DO NOT EXCEED414 kPa (60
psi).
DOES PRESSURE RISE ABOVE
325 kPa (47 psi)?
G)
DISCONNECT QUICK-CONNECT
FITTING AT ENGINE FUEL RETURN
PIPE, REFER TO PAGES 3 OF 3 AND
FACING PAGE ILLUSTRATION.
ATTACH A LENGTH OF FLEXIBLE
FUEL HOSE TO ENGINE FUEL
RETURN PIPE. PLACE OPEN END OF
HOSE INTO AN APPROVED
GASOLINE CONTAINER.
IGNITION "ON." NOTE FUEL
PRESSURE WITH PUMP RUNNING.
PRESSURE SHOULD BE 284-325 kPa
(41-47 psi).
ISIT?
CHECK FOR:
LEAKING FUEL PUMP FEED HOSE.
WRONG FUEL PUMP.
IFUELPUMPISFAULTY. I
PRESSURE
REGULATOR
IS FAULTY.
CHECK FOR
RESTRICTED ENGINE
FUEL RETURN PIPE.
IS THERE A
RESTRICTION?
REMOVE PRESSURE
REGULATOR AND
CHECK FOR
RESTRICTED FILTER
SCREEN (IF EQUIPPED).
LOCATE ANO
CORRECT
RESTRICTION IN
FUEL RETURN LINE
TO FUEL TANK.
SERVICE AS
REQUIRED AND
RECHECK.
$
PRESSURE
REGULATOR IS
FAULTY.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL(SERVICE ENGINE SOON).
11-30-92
NS 16052-6E
CHART A-7
(Page 3 of 3)
FUEL SYSTEM PRESSURE TEST

FUEL SYSTEM PRESSURE RELIEF PROCEDURE

Engines With Fuel Pressure Connection
(Must Be Performed Before Disconnecting Fuel Line Fittings)
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve fuel system
pressure before disconnecting fuel line fittings.
After relieving system pressure, a small amount of fuel may be released when
disconnecting fuel line fittings. In order to reduce the chance of personal injury,
cover fuel line fittings with a shop towel before disconnecting, to catch any fuel
that may leak out. Place the towel in an approved container when disconnect is
completed.
Tool Required: J 34730-1 Fuel Pressure Gage
1. Ignition "OFF."
2. Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to
start the engine.
3. Loosen fuel filler cap to relieve tank vapor pressure.
4. Connect gage J 34730-1 to fuel pressure connection. Wrap a shop towel around fitting while connecting
5. Install bleed hose into an approved container and open valve to bleed system pressure. Fuel line fittings
are now safe for servicing.
6. Drain any fuel remaining in gage into an approved gasoline container.
7. Perform service required.
9. Ignition "OFF."
10. Connect negative battery cable.
11. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks.
11-11-92
NS 14624
CHART A-7
SERVICING QUICK-CONNECT FITTINGS
rn
(Page 3 of 3)
FUEL SYSTEM PRESSURE TEST

5. 7L (VIN P) ''F" CARLINE (SFI)
Important
In order to install fuel system diagnostic equipment on vehicles equipped with plastic quick-connect
fittings, fuel line separator tools must be used to disconnect the fittings. Using the separator tools to
release the fittings will cause the plastic retainer to remain inside the female connector allowing
diagnostic equipment to be connected.
Tools required:
J 37088-A tool set, fuel line quick-connect separator;
J 39504 tool set, fuel line quick-connect separator (restricted access).

1. Relieve fuel system pressure (see "Fuel System Pressure Relief").
2. If equipped, slide dust cover back to access quick-connect fitting.
3. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt
5. Choose correct tool from J 37088-A or J 39504 tool set for size of fitting.
connector, then push/pull inward to release locking tabs.
Insert tool into female
NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring sealing surface.
Using a clean shop towel, wipe off male pipe end.

Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.

CAUTION: To Reduce the Risk of Fire and Personal Injury:
Before connecting fitting, always apply a few drops of clean engine oil to the
male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off
adapter. This will ensure proper reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.)
1. Apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or
fuel line shut-off adapter.
2. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make sure connection is secure.
4. If equipped, reposition dust cover over quick-connect fitting.
11-21-92
NS 14628
PCM
TO OTHER CIRCUITS
MALFUNCTION
INDICATOR LAMP (MIL)
r-----,
MIL CONTROL
10AMP
.... -
- - ....
REFER TO SECTION BA FOR

1/P CONNECTOR DETAILS.
(1/P)
= LOCATED IN INSTRUMENT PANEL FUSE BLOCK

629-93
PS 17013
OTC 11
MALFUNCTION INDICATOR LAMP (MIL) CIRCUIT
There should always be a steady MIL with the ignition "ON" and engine stopped. Ignition voltage is supplied
directly to the bulb on CKT 39. The Powertrain Control Module (PCM) controls the light by providing the ground
path through CKT 419.
OTC 11 Will Set When: The PCM detects the wrong voltage potential on CKT 419 for 26 seconds.
Action Taken (PCM will default to): None.
1. If CKT 419 is open or ignition feed circuit to the
bulb is open, the Malfunction Indicator Lamp
(MIL) will not illuminate.
2. Use J 35616-A tool kit to probe PCM harness
terminals, so that you do not damage them.
3. The MIL should go "OFF" after the engine starts.
Ifit does, the problem is not present at this time. If
not, CKT 419 is shorted to ground between the
PCM and MIL or the PCM is faulty.
4. If other DTCs are displayed along with DTC 11,
repair other DTCs first, then restart at the
beginning of this chart.
Diagnostic Aids: If ignition feed circuit is

suspected of being open, check and see if other bulbs on
that circuit illuminate.
The MIL will be "ON" if DTC 11 is stored and the
MIL circuit becomes operational.
DRIVEABtLITY AND EMISSIONS 5.7l (VIN P) 6E3-A-41
OTC 11
MALFUNCTION INDICATOR LAMP (MIL) CIRCUIT
11
'i'
~
G)

IS MIL "ON"?
START ENGINE.
DOES MIL STAY "ON"?
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "D" (BLUE).
PROBE CKT 419 WITH A FUSED TEST LEAD
TO GROUND.
IGNITION "ON."
IS MIL "ON"?
CHECK:
- FAUL TY BULB.
- OPEN CKT 419.
CKT 419 SHORTED TO
VOLTAGE.
- OPEN FEED CIRCUIT/FUSE
TO BULB.
......----~ 0
FA ILTY PCM
CONNECTION
OR
FAULTY PCM.
USING THE TECH 1 READ

DTC(s)....
ARE ANY DTC(s) OTHER
THAN DTC 11 DISPLAYED?
IF OTHER DTC(s) ARE

DISPLAYED, USE
THOSE CHARTS FIRST.
DTC 11 IS INTERMITTENT.
IF NO ADDITIONAL DTC(s)
WERE STORED, REFER TO
"DIAGNOSTICAIDS" ON
FACING PAGE.
MIL CONTROL CKT 419

SHORTED TO GROUND
OR
FAULTY PCM.
3-1-93
MS 9997-6E

PCM
BANK 1 (LEFT) HEATED OXYGEN SENSOR (H02S)
- - - - - - - - 1 6 5 3 TAN/WHT------1
H02SLOW
t - - - - - - - - - 1 6 6 5 PPL/WHT-------11
H02SHIGH
5-24-93
PS 17916
OTC 13
BANK 1 (LEFT) HEATED OXYGEN SENSOR (H02S) CIRCUIT
(OPEN CIRCUIT)

The PCM supplies a voltage of about 450 mV between terminals "C20" and "C19". (If measured with a 10
megohm digital voltmeter, this may display as low as 320 mV.) The oxygen sensor varies the voltage within
range of about 1000 m V if the exhaust is rich, down through about 10 mV if exhaust is lean.
circuit or cold ~~nsor causes "Open Loop" operation. Whenever the ignition is "ON," voltage is supplied to the
H02S heaters on CKT 541, Even with the engine not running, the H02S will reach operating temperature and
indicate the oxygen content of the exhaust gas at the sensor. Typically the signal voltage will be near 450 m V at
key-up. The signal voltage will then rise or drop as the sensor becomes active, depending on the oxygen content of
the air near the sensor.
OTC 13 Will Set When: Engine at normal operating temperature (70?C/158F), engine operating more than 2
minutes, oxygen signal voltage steady between 350 mV to 550 mV, throttle position angle above 5% and OTCs 21
and 22 not set. All conditions must be met for about 60 seconds.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate and the fuel
control system will go into "Open Loop."
Number(s) below
1. This test checks the oxygen sensor's heating
element. The heating element resistance should
be 3.5 ohms at 20C (68F) or 14 ohms at 350C
(622F). An inoperative H02S heater could cause
a OTC 13 to set.
2. This will determine if the oxygen sensor is at fault,
or if the cause of the OTC 13 is elsewhere in the
circuit.
3. For this test use only a high impedance digital volt
ohmmeter (J 39200). This test checks the
continuity of CKT 1665.
Diagnostic Aids: Normal Tech 1 voltage readings

vary between 10 m V to 1000 mV (.01 and 1.0 volt),
while in "Closed Loop." The system will go into "Open
Loop" operation when OTC 13 sets.
"6E3-B".
An oxygen supply inside the H02S is necessary for
proper H02S operation. This supply of oxygen is
supplied through the H02S wires. All H02S wires
and connections should be inspected for breaks or
contamination that could prevent reference oxygen
from reaching the H02S.
OTC 13
(ABOVE 80C/176F),
RUN ENGINE ABOVE 1200 RPM FOR TWO
MINUTES.
DOES TECH 1 INDICATE "CLOSED LOOP"?
8
(D
BANK 1 (LEFT) HEATED OXYGEN

SENSOR (H02S) CIRCUIT
(OPEN CIRCUIT)
5. 7L {VIN P) "F" CARLINE (SFI)
IGNITION "OFF."
DISCONNECT BANK 1 HEATED OXYGEN SENSOR (H02S) HARNESS
CONNECTOR.
CONNECT TEST LIGHT BETWEEN HARNESS TERMINALS "C" AND "D"
(PCM SIDE).
IGNITION '"ON."
IS TEST LIGHT "ON"?
ADDITIONAL DTC(s) WERE STORED,
MEASURE RESISTANCE BETWEEN H02S

TERMINALS "C" AND "D".
IS RESISTANCE BETWEEN 3.5 OHMS AND 14 OHMS?
JUMPER HARNESS CKTs 1665 AND 1653 (PCM

SIDE) TO GROUND.
TECH 1 SHOULD DISPLAY H02S VOLTAGE BELOW
.2 VOLT (200 mV).
DOESIT?
REMOVE JUMPER.
CHECK VOLTAGE ON CKT 1665 (PCM SIDE) AT H02S
HARNESS CONNECTOR USING A DVM.
VOLTAGE SHOUL_D BE OVER .3 VOLT (300 mV).
ISIT?
OPEN CKT 1653

OR
OR
FAULTY PCM.
FAULTY
HEATED
OXYGEN
SENSOR.
CONNECT TEST LIGHT TO HARNESS

IS TEST LIGHT "ON"?
FAULTY CONNECTION
OR
IGNITION FEED
CIRCUIT OPEN
OR
SHORTED.
FAULTY
CONNECTION
OR
FAULTY GROUND .
FAULTY H02S CONNECTION

OR
FAULTY H02S.
OPEN CKT 1665

OR
OR
FAULTY PCM.
6-29-93
PS 17254
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR
PCM
ECT SENSOR SIGNAL

SVOLTS
SENSOR
GROUND
TO ELECTRONIC TRANSMISSION AND
TPSENSOR
5-17-93
PS17917
DTC 14
ENGINE COOLANT TEMPERATURE {ECT) SENSOR CIRCUIT
{SIGNAL VOLTAGE LOW, HIGH TEMPERATURE INDICATED)
S.7L (VIN P) ,.F,, CARLINE (SFI)

The Engine Coolant Temperature (ECT) sensor uses a thermistor to control a signal vbltage to the PCM. The
PCM applies a voltage on CKT 410 to the sensor. When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore, the PCM signal voltage will be high. As the engine coolant warms, the sensor
resistance becomes less, and the PCM voltage drops. At normal engine operating temperature (85C-95C or
185F-203F) the voltage should measure about 1.5 to 2.0 volts.
DTC 14 Will Set When: The PCM indicates engine coolant temperature signal voltage above 140C (284F).
Action Taken {PCM will default to):
The 'Malfunction Indicator Lamp (MIL) will illuminate, and
transmission TCC will apply early.

1. Monitoring ECT will determine if the fault is a
hard failure or an intermittent condition.
2. This test will determine if CKT 410 is shorted to
ground, which will cause the condition for DTC 14.
Diagnostic Aids: Tech 1 displays engine

temperature in degrees celsius and fahrenheit. After
engine is started, the temperature should rise steadily,
reach normal operating temperature, and then
stabilize when thermostat opens.
"6E3-B".
DTC14
(SIGNAL VOLTAGE LOW, HIGH TEMPERATURE INDICATED)
DOES TECH.1 D\SPLAY ENGINE COOLAN.T

TEMPERATURE OF 14QCj(284F) OR HIGHER?
0 .
DISCONNECT ENGINECOOLANT
TEMPE~ATURESENSOR.
TECH 1 SHOULD DISPLAY ENGINE
COOLANT TEMPERATURE BELOW -30C
.(-22F). ,
DOESll?'.
'
'
REPJ-ACE ENGINE COOLANT
TEMPERATURE SENSOR..
TQ "DIAGNOSTIC AIDS" ON FACING PAGE.
CKT410 SHORTED TO GROUND

OR
CKT 410 SHORTED TO SENSOR GROUND CIRCUIT
OR
FAULTY PCM.
Dl~GNOSTIC AID
'

(APPROXIMATE)
c
100
90
.~o
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
Of
212
.194
176
158
'
140
112
ft3
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
OHMS
111
241
332
467
667 .
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
12-18-92
MS 8926-6E
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR
PCM
ECT SENSOR SIGNAL

~ - - - - - - - 410YEL
------?\------
470 BLK
C25
86
SVOLTS
SENSOR
GROUND
TO ELECTRONIC TRANSMISSION AND

TPSENSOR
5-17-93
PS 17917
DTC 15
(SIGNAL VOLTAGE HIGH, LOW TEMPERATURE INDICATED)

The Engine Coolant Temperature (ECT) sensor uses a thermistor to control the signal voltage to the PCM.
The PCM applies a voltage on CKT 410 to the sensor. When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the PCM signal voltage will be high. As the engine coolant warms, the sensor
resistance becomes less, and the PCM voltage drops. At normal engine operating temperature (85C-95C or
185F-203F), the voltage should measure about 1.5 to 2.0 volts at the PCM.
OTC 15 Will Set When: The PCM indicates engine coolant temperature signal -49C (-56F) or lower for 2
seconds.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate, and
transmission TCC will apply early.

1. Monitoring ECT will determine if the fault is a
hard failure or an intermittent condition.
recognizes the low signal voltage, (high
temperature) and the Tech 1 displays 130C
(266F) or above, the PCM and wiring are OK.
3. This test will determine if CKT 410 is open. There
should be 5 volts present at sensor connector, if
measured with a DVM.
Diagnostic Aids: A Tech 1 displays engine coolant

temperature in degrees celsius and fahrenheit. After
engine is started, the temperature should rise steadily,
reach normal operating temperature, and then
stabilize when the thermostat opens.
A faulty connection, or an open in CKT 410 or 470,
will result in a DTC 15.
If DTC 21 or 59 is also set, check CKT 470 for
faulty wiring or connections. Check terminals at
sensor for good contact.
"6E3-B".
DTC 15
ENGINE COOLANT TEMPERATURE {ECT) SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH, LOW TEMPERATURE II\IDICATED)
5.7L {VIN P) "F" CARLINE {SFI)
0 .
0
DOES TECH 1 DISPLAY ENGINE COOLANT TEMPERATURE OF -40C (-40F) OR LESS?
DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR.

JUMPER HARNESS TERMINALS TOGETHER.
TECH 1 SHOULD DISPLAY 130C (266F) OR MORE.
DOESIT?
JUMPERCKT410TOGROUND.
TECH 1 SHOULD DISPLAY OVER 130C (266F).
DOESIT?
FAUL TY CONNECTION OR ENGINE

COOLANT TEMPERATURE SENSOR.
OPEN ENGINE COOLANT TEMPERATURE SENSOR GROUND

CIRCUIT, FAULTY CONNECTION OR FAULTY PCM.
OPEN CKT 410, FAULTY

CONNECTION AT PCM, OR
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
OF
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
"AFTER REPAIRS.'' REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
5-1-93
MS 8829-6E
6E3-A-48 5.7L (VIN P) ORIVEABILITY AND EMISSIONS

PCM
IGNITION SYSTEM
TEST CONNECTOR
~ - - - - - - - - - 631 RED
1---------- 632 PNK/BLK

1 - - - - - - - - - - - 631 RED
~ - - - - - - 430 PPUWHT
. . . . . - - - - - - - - - 430 PPUWHT
. . . - - - - - - - - - - 632 PNK/BLK
. . . - - - - - - - - - 453 RED/BLK
t - - - - - - - - - - 453 RED/BLK
111----
ENGINE
GROUND
450 BLK
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
:~~~E_C!~~ \
IGNITION
COIL
MODULE
239 PNK
B
IGNITION
COIL
423WHT
"!~NG:~
II
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
IGNITION CONTROL
: YONNECTORS
1
.--r-<llf--T-'A-'--- 1847 WHT/BLK
L---------/-.J
BLACK
CONNECTOR
625-93
MS 12328
DTC 16
DISTRIBUTOR IGNITION SYSTEM
(LOW RESOLUTION PULSE)
5.7L (VIN P)
11
F" CARLINE (SFI)
The distributor ignition system supplies two timing inputs to the PCM, a high resolution signal (360 pulses
per one crankshaft revolution) and a low resolution signal (4 pulses per one crankshaft revolution). The PCM can
determine if one of the timing inputs is not being received by comparing the two inputs. If the PCM detects the
high resolution timing pulse without detecting the low resolution timing pulse, this OTC will set.
The reference signals toggle between O and 5 volts as the camshaft turns. Therefore, an open, a short to
voltage, a short to ground, or a defective sensor inside the distributor can prevent the voltage from pulsing at the
PCM.
OTC 16 Will Set When: The PCM detects 720 high resolution timing pulses before any low resolution pulses
are detected.
Action Taken (PCM will default to): OTC 16 will be stored in the PCM memory, but will not turn "ON" the
Malfunction Indicator Lamp (MIL). Fuel pump and injector operation will be disabled.

1. If the engine starts at this point, OTC 16 is
intermittent.
2. This test will determine if the PCM is sending out
a signal to the distributor for processing. If this
signal is not available or is shorted to ground or
voltage, the distributor cannot ground it to
produce reference pulses.
Diagnostic Aids: DTC 16 will set if the high and

low resolution signal circuits are shorted to each other.
Before replacing any components, make sure these
circuits are not shorted together. If OTC 16 does not
reset and the vehicle still does not start, refer to
CHART A-3 "Engine Cranks But Will Not Run."
If distributor components must be replaced, check
distributor vent system (if so equipped). Refer to
"Distributor Ignition (DI) System," Section "6E3-C4."
DRIVEABILITY AND EMISSIONS 5.7L .(VIN P) 6E3-A-49
OTC 16
(LOW RESOLUTION PULSE)
CLEAR DTC(s).
CRANK ENGINE FOR 1SSECONDS.
DOES DTC 16 SET?
IGNITION "OFF."
DISCONNECT IGNITION SYSTEM TEST CONNECTOR.
IGNITION "ON."
USING A DVM ON THE DC VOLTS SCALE.MEASURE VOLTAGE ON
TERMINAL "A" AT THE PCM SIDE OF THE IGNITION TEST
CONNECTOR.
OVER6VOLTS
LESS THAN .5 VOLTS
OPEN OR GROUNDED LOW

RESOLUTION SIGNAL
CIRCUIT FROM PCM TO
TEST CONN ECTOR
OR
OR
FAULTY PCM.
OTC 1615
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
RECONNECT IGNITION SYSTEM
TEST CONNECTOR.
DISCa'NNECT DISTRIBUTOR
CONNECTOR.
IGNITION "ON."
MEASURE VOLTAGE ON TERMINAL
"A".
LESS THAN .5 VOL TS
OPEN OR GROUNDED
LOW RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
SHORT TO VOLTAGE
ON LOW RESOLUTION
SIGNAL CIRCUIT
FROM PCM TO TEST
CONNECTOR.
OVER6VOLTS
FAULTY DISTRIBUTOR
CONNECTION
OR
FAUL TY DISTRIBUTOR.
SHORT TO VOLTAGE
ON LOW RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
6-25-93
MS 8828-6E
TO OTHER CIRCUITS
#5 (1/P)
81
TO""
IGNITION
((-3 PNK
15AMP
C200
#10(U/H)
7.SAMP
FUSE
BLOCK
JUNCTION
#9(U/H)
7.SAMP
439 PNK
C230
439PNK
A
r639PNK
C100
PCM
830
PCM IGNITION FEED

PCM IGNITION FEED
1744 BLK
INJECTOR #1 CONTROL
844 LT BLU/BLK
INJECTOR #4 CONTROL
846 YEL/BLK
INJECTOR #6 CONTROL
877 RED/BLK
INJECTOR #7 CONTROL
~(A
1745 LT GRN/BLK
INJECTOR #2 CONTROL
~(A
1746 PNK/BLK
INJECTOR #3 CONTROL
B~(A
845BLK/WHT
INJECTOR #5 CONTROL
B~(A
878 DK BLU/WHT
INJECTOR #8 CONTROL
K
~839PNK
C100
3PNK~TO
IGNITION
TO MASS AIR
O W SENSOR
INJ#2
B
B

78-93
PS 17918
OTC 18
INJECTOR CIRCUIT(S)
The PCM controls each individual injector by providing a ground. The PCM will enable each injector on the
intake stroke of each cylinder and is referred to as Sequential Multiport Fuel Injection (SFI).
The PCM continuously monitors the voltage of each injector driver circuit. When the PCM detects a voltage
that is out of range, (grounded circuit, open circuit, a circuit shorted to voltage, an injector that is shorted, open,
or has a low resistance), a DTC 18 will set and the driver will be disabled.
OTC 18 Will Set When: The PCM detects the wrong voltage potential on any of the injector driver circuits for
4 seconds or more.
Action Taken (PCM will default to): The PCM will disablethe injector driver on the particular injector
that had a fault. OTC 18 will be stored in the PCM memory but will not turn "ON" the Malfunction Indicator
Lamp(MIL).

1. The injector fuse(s) are located in the underhood
electrical center.
2. Performing an injector balance test is necessary to
locate what injector circuit is faulty.
3. Fuse #9 feeds injectors 2, 3, 5, 8, and fuse #10
feeds injectors 1, 4, 6, 7.
4. When checking injector resistance, engine coolant
temperature should be about 21 C (70F).
Diagnostic Aids: If an injector is disconnected and

then reconnected while the engine is operating, the
injector driver will be disabled for a predetermined
time and a DTC 18 will set. When the driver is
disabled, an engine miss will be apparent.
G)
DTC 18
ARE INJECTOR FUSES OK?
INJECTOR CIRCUIT(S)
CLEAR DTC{s).
START ENGINE.
DOES DTC 18 SET?
USING A TECH 1,
PERFORM INJECTOR
BALANCE TEST.
DTC 18 IS
INTERMITTENT. REFER
TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
DISCONNECT INJECTOR HARNESS THAT HAD NO
RPM DROP.
IGNITION "ON."
PROBE INJECTOR HARNESS IGNITION FEED CIRCUIT
USING A TEST LIGHT CONNECTED TO GROUND.
IGNITION "OFF."
DISCONNECT PCM
CONNECTOR "A".
USING A TEST LIGHT
CONNECTED TO B +,
PROBE INJECTOR DRIVER
CIRCUIT HARNESS THAT
HAS A FAULT.
DOES TEST LIGHT
ILLUMINATE?
OPEN IGNITION
FEED CIRCUIT.
Cv
RECONNECTPCM
CONNECTOR.
CONNECT INJECTOR TEST
LIGHT {J 34730-2C) TO
INJECTOR HARNESS THAT
HASA FAULT.
START ENGINE AND IDLE.
DOES TEST LIGHT BLINK?
REPLACE OPEN FUSE.

START ENGINE.
DOES FUSE OPEN?
IGNITION "OFF."
DISCONNECT ONE
INJECTOR HARNESS THAT
IS POWERED BY THE FUSE
THAT WAS OPEN.
USING A TEST LIGHT TO
B +, PROBE INJECTOR
HARNESS IGNITION FEED
CIRCUIT.
DOES TEST LIGHT
ILLUMINATE?
FAULTY FUSE OR
INTERMITTENT
SHORT TO GROUND
IN INJECTOR
CIRCUIT{S) THAT
PERTAIN TO THE
FUSE THAT WAS
OPEN.
USING DVM {J 39200)

MEASURE THE
RESISTANCE OF THE 4
INJECTORS THAT ARE
POWERED BY THE FUSE
THAT WAS OPEN.
DOES ANY INJECTOR
MEASURE LESS THAN
11.60HMS?
IGNITION FEED
CIRCUIT SHORTED
TO GROUND.
INTERMITTENT SHORT
TO GROUND IN
INJECTOR IGNITION
FEED CIRCUIT.
INJECTOR DRIVER CIRCUIT OPEN

OR
OR
FAULTY PCM.
3-25-93
PS 16657
PCM
TO ELECTRONIC TRANSMISSION
AND ECT SENSOR
1-------------------- 470 BLK

1----------------- 417 DK BLU
THROTTLE
POSITION (TP)
SENSOR
IDLE
t----------------~474GRY
TO MAP SENSOR, A/C
EVAPORATOR------- 416GRY
TEMPERATURE
SENSOR, AND A/C
REFRIGERANT
PRESSURE SENSOR.
SENSOR GROUND
....,,dH\.t-
5 VOLT
REFERENCE
6-10-93
MS 12320
DTC21
(SIGNAL VOLTAGE HIGH)

The Throttle Position (TP) sensor provides a voltage signal that changes, as throttle blade opens or closes.
Signal voltage should vary from about .6 volt at idle to about 5 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the PCM for fuel control and for most of the
PCM controlled outputs.
OTC 21 Will Set When: TP sensor signal is greater than 2.5 volts, engine idling (less than 10 grams per
second of air flow), all conditions met for 5 seconds or TP sensor signal voltage over 4.8 volts with ignition "ON."
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate, transmission
TCC will not apply, high transmission line pressure, fixed shift points, hard shifts and no fourth gear in hot mode.

1. With throttle closed, the TP sensor should display
between .3 and .9 volt. If it does not, check throttle
cable adjustment and throttle shaft.
2. With the TP sensor disconnected, the TP sensor
voltage should go low, if the PCM and wiring are
OK.
3. Probing CKT 452 with a test light to 12 volts
checks the sensor ground. A faulty sensor ground
will cause a DTC 21.
Diagnostic Aids: The Tech 1 displays throttle

position in voltage and percentage of throttle blade
opening. With ignition "ON" or at idle, TP sensor
signal voltage should display between .3 and .9 volt
with the throttle closed and increase at a steady rate
as throttle is moved toward Wide Open Throttle
(WOT).
IfDTC 15 or 59 is also set, check CKT470 for being
open or a faulty PCM connection.
Refer to "lntermittents" in "Symptoms," Section
"6E3-B".
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E] ..A .. 53
DTC21
{SIGNAL VOLTAGE HIGH)
5.7L (VIN P)
11
F" CARLINE (SFI)
THROTTLE CLOSED.
DOES TECH 1 DISPLAY THROTTLE POSITION (TP)
SENSOR OVER 2.5 VOLTS OR THROTTLE ANGLE
GREATER THAN 0%?
DISCONNECT THROTTLE POSITION SENSOR.

TECH 1 SHOULD DISPLAY THROTTLE
POSITION BELOW .2 VOLT (200 mV).
DOES IT?
REFER TO "DiAGNOSTIC AIDS" ON
FACING PAGE.
PROBE SENSOR GROUND CIRCUIT

WITH A TEST LIGHT CONNECTED TO
B+.
TP SENSOR SIGNAL CIRCUIT

SHORTED TO VOLTAGE
OR
FAULTY PCM.
LIGHT"ON"
FAULTY CONNECTION
OR
THROTTLE POSITION SENSOR.
OPEN SENSOR GROUND CIRCUIT

OR
FAULTY PCM.
REFER TO SECTION "5E2" TO CLEAR ANY EBTCM DTC(s) THAT MAY HAVE SET.
6-29-93
PS 17920
PCM
TO ELECTRONIC TRANSMISSION
AND ECT SENSOR
THROTTLE
POSITION {TP)
SENSOR
SENSOR GROUND
- - - - - - - - - - - - - - - 417 DK BLU
1----------------~474GRY
TO MAP SENSOR, A/C
EVAPORATOR----- 416GRY
TEMPERATURE
SENSOR, AND A/C
REFRIGERANT
PRESSURE SENSOR.
....,..,,,u,.,- 5 VOLT
REFERENCE
6-10-93
MS 12320
DTC22

The Throttle Position (TP) sensor provides a voltage signal that changes, relative to the throttle blade
position. Signal voltage should vary from about .6 volt at idle to about 5 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the PCM for fuel control and for most of the
PCM controlled outputs.
OTC 22 Will Set When: TP sensor signal voltage is less than about .23 volt.
TCC will not apply, high transmission line pressure, harsh shifts, fixed shift points and no fourth gear in hot
mode.

1. The TP sensor has an auto zeroing feature. If the
voltage reading is within the range of about .3 to .9
volt, the PCM will use that value as closed
throttle. If the voltage reading is out of the auto
zero range at closed throttle, check for a binding
throttle cable and throttle shaft operation.
2. Simulates DTC 21: (high voltage) If the PCM
recognizes the high signal voltage, the PCM and
wiring are OK.
an open in CKT 417.
Diagnostic Aids: The Tech 1 displays throttle

position in voltage and percentage of throttle blade
opening. With ignition "ON" or at idle, TP sensor
signal voltage should display between .3 and .9 volt
with the throttle closed and increase at a steady rate
as throttle is moved toward Wide Open Throttle
(WOT).
An open or short to ground in CKT 474 or CKT 417
will result in a DTC 22.
"6E3-B".
DTC22
THROTTLE CLOSED.
DOES "TECH 1" DISPLAY TP SENSOR .2 VOL TS
(200 mv) OR BELOW?
DISCONNECT TP SENSOR.
JUMPER CKTS474 &417 TOGETHER.
"TECH 1" SHOULD DISPLAY TP SENSOR OVER
4.0 VOLTS (4000 mv).
DOES IT?

CONNECTED TO BATTERY VOLTAGE.
"TECH 1" SHOULD DISPLAY TP SENSOR
OVER 4.0 VOLTS (4000 mv).
DOES IT?
FAUL TY SENSOR CONNECTION

OR
FAUL TY SENSOR.
CKT 474 OPEN OR SHORTED TO GROUND

OR
FAULTY CONNECTION
OR
FAULTY PCM.
IF NO ADDITIONAL DTCs WERE STORED, REFER TO
CKT 417 OPEN OR SHORTED TO GROUND, OR

SHORTED TO SENSOR GROUND CIRCUIT
OR
OR
FAULTY PCM.
REFER TO SECTION "SE2" TO CLEAR ANY EBTCM DTC(s) THAT MAY HAVE SET.
6-29-93
95 7843-6E
PCM
INTAKE AIR
TEMPERATURE
SENSOR
IAT SENSOR SIGNAL
- - - - - - - - - - - 472TAN
' - - - - - - - - - - - - - - 452 BLK
TOMAP,A/C
REFRIGERANT PRESSURE,
AND A/C EVAPORATOR
TEMPERATURE SENSORS
5-17-93
MS 12321
DTC23
(SIGNAL VOLTAGE HIGH, LOW TEMPERATURE INDICATED)

PCM applies a voltage (about 5 volts) on CKT 472 to the sensor. When the intake air is cold, the sensor
(thermistor) resistance is high, therefore, the PCM will sense a high signal voltage. If the intake airis warm, the
sensor (thermistor) resistance is low, therefore, the PCM will sense a low voltage.
OTC 23 Will Set When: IAT signal voltage indicates an intake air temperature below -35C (-31F), ECT
above 85C (185F), engine idling, no VSS and all conditions met for 60 seconds or IAT signal voltage indicates an
intake air temperature below -35C (-31F), DTC 14 or 15 present, engine idling, no VSS and all conditions met
for 7 minutes.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate.
1. Monitoring IAT with a Tech l will determine if the
fault is a hard failure or an intermittent condition.
2. A DTC 23 will set, due to an open sensor, wire, or
connection. This test will determine if the wiring
and PCM are OK.
3. This will determine if the IAT sensor signal (CKT
472) or the IAT sensor ground (CKT 452) is open.
Diagnostic Aids: The scan tool displays

temperature of the air entering the engine and should
display close to ambient air temperature when engine
is cold, and rise as underhood temperature increases.
Carefully check harness and connections for
possible open.
If DTC 33, 66 or 71 are also set, check CKT 452 for
being open or faulty PCM connection.
"6E3-B".
If the engine has been allowed to sit overnight, the
intake air temperature and engine coolant
temperature values should display within a few
degrees of each other.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-A-57
DTC23
{SIGNAL VOLTAGE HIGH, LOW TEMPERATURE INDICATED)
0 .
0
DOES TECH 1 DISPLAY IAT -40C (-40F) OR COLDER?
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS
TOGETHER.
ADDITIONAL DTC(S) WERE
TECH 1 SHOULD DISPLAY

TEMPERATURE OVER 130(
(266F).
DOES IT?

TECH 1 SHOULD DISPLAY
TEMPERATURE OVER 130(
(266F).
DOESIT?
DIAGNOSTIC AID
(APPROXIMATE)
OF
OHMS
100
90
80
70
60
212
194
176
158
140
122
113
104
95
86
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
so
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
77
68
59
so
41
32
23
14
5
-4
-22
-40
OPEN SENSOR
GROUND CIRCUIT,
OPEN CKT 472,

FAULTY CONNECTION
FAULTY CONNECTION
OR FAULTY PCM.
OR FAUL TY PCM.
5-1-93
MS8427-6E
PCM
VEHICLE SPEED SENSOR (VSS)
I<0 ~ ffi-----:: : ~
SVOLT
REFERENCE
VSSGROUND
PERMANENT MAGNET GENERATOR

(MOUNTED IN TRANSMISSION)
CRUISE CONTROL
MODULE
INSTRUMENT
PANEL
VSS OUTPUT
C220
7-8-93
PS16656
DTC24
5.7L (VIN P) F CARLINE (SFI)
11
11
Vehicle speed information is provided to the PCM by the Vehicle Speed Sensor (VSS), which is a Permanent
Magnet (PM) generator located in the transmission. The PM generator produces a pulsing AC voltage. The AC
voltage level and the number of pulses increases as the speed of the vehicle increases. The PCM then converts the
pulsing voltage to vehicle speed which is used for calculations. The vehicle speed can be displayed with a Tech 1.
The PCM supplies a signal, on CKT 817, to the instrument cluster for operating the speedometer and
odometer and to the cruise control module.
OTC 24 Will Set When:
(Automatic transmission) - Transmission output speed is less than 250 RPM when engine speed is greater
than 3000 RPM, not in park or neutral, and DTCs 21, 22, 28, 33 and 34 not set and MAP greater than 20
kPa but less than 99 kPa. All conditions met for 3 seconds.
(Manual transmission) - Transmission output speed is less than 3 RPM when engine RPM is greater than
1250 RPM, TP angle less than 1%, MAP between 11 kPa and 21 kPa, DTCs 21, 22, 33 and 34 not set. All
conditions met for 6 seconds.
will default to third gear, high transmission line pressure.

1. The ASR system must be disabled when
performing this step. Whenever the ignition key is
cycled to the "OFF" position and then cycled back
"ON" the ASR system will default "ON."
2. If software/calibration is correct and DTC 24 sets,
replace PCM.
3. Be sure harness is routed away from hot exhaust
components.
Diagnostic Aids: The Tech 1 should indicate a

vehicle speed whenever the drive wheels are turning.
Check CKTs 400 and 401 for proper connections to
be sure they're clean and tight and the harness is
routed correctly.
DTC24
Cv
IGNITION "OFF."
RAISE DRIVE WHEELS.
START ENGINE.
DISABLE "TCS/ASR" SYSTEM (IF SO EQUIPPED).
WITH ENGINE IDLING IN GEAR, TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOES IT?
FACING PAGE.
G)
IGNITION "OFF."
DISCONNECT VSS HARNESS CONNECTOR AT TRANSMISSION.
CONNECT SIGNAL GENERATOR TESTER J 33431-B TO VSS HARNESS
CONNECTOR.
IGNITION "ON," TESTER "ON" AND SET TO GENERATE A VSS SIGNAL.
THE TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOESIT?
CHECK CALIBRATION 1.D. FOR MOST

CURRENT AND/OR INCORRECT SOFTWARE.
CKT 400 OR 401 OPEN,

SHORTED TO GROUND,
SHORTED TOGETHER,
OR
FAULTY PCM.
6-29-93
PS 17922
6E3-.A-60 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
PCM
INTAKE AIR
TEMPERATURE
SENSOR
IAT SENSOR SIGNAL

....__ _ _ _ _ _ _ _ _ _ 472 TAN
'-------------.1----- 452 BLK

TO MAP,A/C
REFRIGERANT PRESSURE,
AND A/C EVAPORATOR
TEMPERATURE SENSORS
5-17-93
MS 12321
DTC25
5.7L (VIN P)
11
F" CARLINE (SFI)
PCM applies a voltage (about 5 volts) on CKT 472 to the sensor. When intake air is cold, the sensor (thermistor)
resistance is high, therefore, the PCM will sense a high signal voltage. If the intake air is warm, the sensor
(thermistor) resistance is low, therefore, the PCM will sense a low signal voltage.
OTC 25 Will Set When: !AT.signal is greater than 145C (293F) for 12 seconds and vehicle speed is greate~
than 5 mph or IAT signal is greater than 145C (29,3F), no vehicle speed and all above conditions met for 60
seconds.
1. Monitoring IAT with a Tech 1 will determine if the
fault is a hard failure or an intermittent condition.
Diagnostic Aids: The Tech 1 displays temperatur!=l

of the air entering the engine and should display close
to ambient air temperature, when engine is cold, and
rise as underhood temperature increases.
Check harness routing for possible short to ground
inCKT472.
'
"6E3-B".
DTC25
5.7L (VIN P)
11
11
F CARLINE (SFI)
DOES TECH 1 DISPLAY IAT OF 145C

(293F) OR HOTTER?
DISCONNECT SENSOR.
TECH 1 SHOULD DISPLAY TEMPERATURE
BELOW -30C (-22F).
DOESIT?


OR
TO SENSOR GROUND
OR
PCM IS FAULTY.
DIAGNOSTIC AID
(APPROXIMATE)
"F
OHMS
100
90
80
70
60
212
194
176
158
140
122
113
104
95
86
77
68
59
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
so
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
so
41
32
23
14
5
-4
22
-40
1-5-93
MS8367-6E

TO EGR VACUUM CONTROL
SIGNAL SOLENOID VAL VE,
REVERSE INHIBIT SOLENOID,
SKIP SHIFT SOLENOID AND H02S
HEATERS
PCM
541 BRN
EVAP CANISTER
PURGE SOLENOID
VALVE CONTROL
EVAPORATIVE EMISSIONS
(EVAP) CANISTER PURGE SOLENOID VALVE
428 DK GRN/WHT
C100
- - - - - - T O OTHER CIRCUITS
300 ORN
TO
IGNITION
6-29-93
PS 17924
DTC26
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE CIRCUIT
Ignition voltage is supplied directly to the EVAP canister purge solenoid valve on CKT 541. The Powertrain
Control Module (PCM) controls the solenoid valve by providing the ground path through CKT 428.
When the PCM is commanding a component "ON," the voltage of the control circuit should be "low" (near O
volts). When the PCM is commanding the control circuit to a component "OFF," the voltage potential of the
circuit should be "high" (near battery voltage). The primary function of the driver is to supply the ground for the
component being controlled.
Each driver has a fault line which is monitored by the PCM. The PCM will monitor the voltage at the driver.
If the fault detection circuit senses a voltage other than what is expected, the fault line status will change and the
DTC will set.
DTC 26 Will Set When: The PCM detects the wrong voltage potential for 26 seconds on CKT 428.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate and the PCM
disables the driver for this circuit to prevent internal PCM damage.
DTC 26 Will Clear When: The fault condition(s) no longer exist, and the ignition switch cycled "OFF" then
"ON."
1. This test determines if the device can be controlled
by the PCM.
2. This check can detect a partially shorted coil which
would cause excessive current flow. If excessive
current flow is detected, a circuit check will be
performed to isolate the device from the wiring.
Leave the circuit energized for 2 minutes to allow
the coil to warm up. The coil may open (amps drop
to "O") when warm.
3. The remaining circuit checks will identify a circuit
problem that has caused an excessive current flow
or inoperative solenoid.
Diagnostic Aids: Inspect the harness and all

related connectors including connections at the PCM.
These may cause an intermittent. Check for damaged
or pushed out terminals.
DTC26
EVAPORATIVE EMISSION (EVAP) CANISTER
PURGE SOLENOID VALVE CIRCUIT
,."'\
~
IF OTC 50 IS SET, USE THAT CHART FIRST.

USING TECH 1 "MISC TEST," ACTIVATE THE
EVAP CANISTER PURGE SOLENOID VALVE.
DOES THE EVAP CANISTER PURGE
SOLENOID VALVE OPERATE?
KEY "OFF."
KEY "ON."
USING DVM J 39200 ON 10 AMP SCALE,
MEASURE CURRENT FROM HARNESS TERMINAL,
no1 O" TO GROUND FOR 2 MINUTES.
CURRENT DRAW SHOULD MEASURE LESS THAN
.75 AMPS (BUT NOT "O").
DOESIT?

IGNITION "OFF."
DISCONNECT THE EVAP CANISTER PURGE
SOLENOID VALVE CONNECTOR.
CONNECT TEST LIGHT BETWEEN THE SOLENOID
COIL HARNESS CONNECTOR TERMINALS.
IGNITION "ON."
LIGHT SHOULD BE "OFF."
ISIT?
USING TECH 1 "MISC TEST"

ACTIVATE THE EVAPCANISTER
PURGE SOLENOID VALVE.
LIGHTSHOULDBE"ON."
ISIT?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF
SOLENOID
VALVE
CONNECTOR TO
GROUND.
LIGHT SHOULD
BE "ON.'"
ISIT?
DISCONNECT PCM
CONNECTOR "D".
IS LIGHT OFF?
FAULTY
SOLENOID
VALVE
CONNECTION
OR
FAULTY
SOLENOID
VALVE.
CONNECT TEST LIGHT FROM CONTROL CIRCUIT

OF SOLENOID VALVE CONNECTOR TO GROUND.
ISIT?

OR
OPEN SOLENOID VALVE
CONTROL CIRCUIT
OR
FAULTY PCM.
OPEN
SOLENOID
VALVE
IGNITION
FEED
CIRCUIT.
SOLENOID VALVE
CONTROL CIRCUIT
SHORTED TO B +.
6-11-93
MS9731

PCM
TO EVAP CANISTER PURGE
SOLENOID VALVE, REVERSE
INHIBIT SOLENOID SKIP SHIFT
SOLENOID AND H02S HEATERS.
EGRVACUUM
CONTROL SIGNAL
SOLENOID VALVE
CONTROL
EXHAUST GAS RECIRCULATION

(EGR}VACUUM CONTROL SIGNAL
SOLENOID VALVE
541BRN ~ - - - - 4 3 5 G R V - - - - s
F ~TOOTHERCIRCUITS
#6 ~10AMP
300 ORN
TO
IGNITION
(U/H}
6-29-93
p~ 17925
DTC27
EXHAUST GAS RECIRCULATION {EGR) VACUUM CONTROL SIGNAL SOLENOID
VALVE CfRCUIT
11
5. 7L {VIN P) F" CARLINE {SFI)
Ignition voltage is supplied directly to the Exhaust Gas Recirculation (EGR) vacuum control signal solenoid
valve on CKT 541 . The Powertrain Control Module (PCM) controls the solenoid valve by providing the ground
path through CKT 435. When the PCM is commanding a component "ON," the voltage of the,.control circuit
should be "low" (near O volts). When the PCM is commanding the control circuit to a component "OFE'," the
voltage potential of the circuit should be "high" (near battery voltage). The primary function of the driver is to
supply the ground for the component being controlled.
Each driver has a fault line which is monitored by the PCM. The PCM will monit9r the voltage at the driver.
OTC will set.
DTC 27 Will Set When: The PCM detects the wrong voltage potential on CKT 435 for 26 seconds.
disables the driver for this circuit to prevent internal PCM damage.
Number(s) below
by the PCM.
to "0") when warm.
3. The remaining checks will identify a circuit
Diagnostic Aids: [nspect the harness and all

DRIVEASILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-65
DTC27
EXHAUST GAS RECIRCULATION (EGR) VACUUM
CONTROL SIGNAL SOLENOID VALVE CIRCUIT

EGR SOLENOID VALVE.
DOES THE EGR SOLENOID VALVE OPERA TE?
it
KEY"OFF."
DISCONNECT PCM CONNECTOR" A".
KEY "ON."
.
USING DVM J 39200 ON 10 AMP SCALE, MEASURE
CURRENT FROM HARNESS TERMINAL," A9" TO
GROUND FOR 2 MINUTES.
CURRENT DRAW SHOULD MEASURE LESS THAN .75
AMPS (BUT NOT "O").
DOESIT?
DTC 2715 INTERMITTENT. REFER TO

IGNITION "OFF."
DISCONNECT THE EGR SOLENOID VALVE
CONNECTOR.
COIL HARNESS CONNECTOR TERMINALS.
IGNITION "ON."
ISIT?
USING TECH 1 "MISC

TEST" ACTIVATE THE
EGR SOLENOID
VALVE.
LIGHT SHOULD BE
"ON."
ISIT?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF
SOLENOID VALVE
CONNECTOR TO
GROUND.
LIGHT SHOULD BE
"ON."
ISIT?
DISCONNECT
PCM
CONNECTOR
"A.'
IS LIGHT OFF?
FAULTY
SOLENOID
VALVE
CONNECTION
OR
FAULTY
SOLENOID
VALVE.
OPEN
SOLENOID
VALVE
IGNITION
FEED
CIRCUIT.

CONTROL CIRCUIT OF SOLENOID
VALVE CONNECTOR TO GROUND.
ISIT?

OR
OPEN SOLENOID VALVE
CONTROL CIRCUIT
OR
FAULTY PCM.
SOLENOID VALVE
CONTROL CIRCUIT
SHORTED TO B +.
6-12-93
PS 16536
6E3-A-66 S.7L (VIN P) DRIVEABILITY AND EMISSIONS

PCM
TRANSMISSION RANGE
B+
- - - - - - - - - 1224PNK
B+
- - - - - - - - 1225 DK BLU
B+
1226 RED
TRANSMISSION
......_ CONNECTOR
1
...,__ _ _ _ _ _ _ 1221 BLK/YEL

TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
sv
---------.4708.LK
6-7-93
PS 18401
DTC28
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY FAULT
11
5. 7L {VIN P) F" CARLINE (SFI)
.
. ..
The TR pressure switch assembly consists of five pressure switche:, (2 normally closedand 3 normally open),
and a TFT sensor combined into one unit and mounted on the valve body. The PCM sup.plies batt~ry voltage to
each range signal. By grounding one or more of these.circuits through various combinations 6f the pressure
switches, the PCM detects which manual valve position has been sele.cted by the vehicle operator. With ignition
"ON" and engine "OFF," PIN will be indicated.
OTC. 28 Will Set When: Range signals "A" and "C" are both Ovolt ("ON"), for two seconds.
Action. Taken (PCM will default to): Drive Range 4 for shift pattern contrbl, harsh.shifts. TCC will be
inhibited, and if in hot mode, no fourth gear will occur. OTC 28 will be stored in the PCM memory but will not
turn "ON" the Malfunction Indicator Lamp (MIL) .
OTC 28 Will Clear When: The fault condition(s) no longer exist, and the ignition switch cycled "OFF" then
"ON."

valve position signal actually selected.
"ON"
= Zero Volt/"OFF" = B +
Range Signal
ar
Rev
Neutral
04
03
02
01
I ega
Ille al
A
F
ON
OFF
OFF
OFF
OFF
ON
B
N
ON
ON
ON
OFF
OFF
OFF
ON
ON
Expected Readings
c
FF
OFF
OFF
ON
ON
OFF
OFF
ON
2.
3.
This test checks for correct voltage from the PCM

This test checks a short to ground in any one of the
three valve position circuits.
Diagnostic Aids: OTC 28 will set if the PCM

detects one of two "illegal" combinations.
Refer to accompanying chart for various
combinations.
Check all connectors for good contact.
7 A14A of the appropriate service manual for further
information.
DTC28
TRANSMISSION RANGE (TR) PRESSURE
SWITCH ASSEMBLY FAULT

SCAN TOOL STILL INST ALL ED.

DOES EACH SELECTED TRANSMISSION RANGE MATCH THE SCAN TOOL "TRANS RANGE SW .. DISPLAY?
IGNITION "OFF ...

IGNITION "ON,.. ENGINE "OFF."
CONNECTOR TERMINALS "N", "R" AND "P ...
ON CIRCUIT(S) THAT DID NOT INDICATE B +, CHECK FOR AN

VERIFY THAT CKT(s) 1224, 1225, OR 1226 ARE NOT

CHECK .. SECTION 7A14A (4L60E) OR 7A17A
"AFTER REPAIRS, .. REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
4-27-93
PS 17065
6E3-A-68 5.7L (VIN P) DRIVEABILIT:Y AND EMISSIONS

PCM

(AIR) PUMP RELAY
, - - - - - - - - 7 8 RED - - - - , 1
1-----4~K---436 BRN
C100
~----78RED
AIR PUMP RELAY

CONTROL
B+~502RED
#7 (U/H)
82
...L...._L_ _c;:;-----, sO BLK ---'-44_1_,BRN ~ 300 ORN

..
_j_
20AMP
II
)>---,
l
C200
TO
IGNITION
SECONDARY AIR
INJECTION (AIR)
PUMP
5-21-93
PS 17944
INTEGRAL STOP
VALVE SOLENOID
DTC29
SECONDARY AIR INJECT~ON (AIR) PUMP CIRCUIT
Ignition voltage is supplied directly to the air pump relay coil on CKT 441. The Powertrain Control Module
(PCM) controls the relay by providing the ground path through CKT 436. When the PCM is commanding a
component "ON," the voltage of the control circuit should be "low" (near O volts). When the PCM is commanding
the control circuit to a component "OFF," the voltage potential of the circuit should be "high" (near battery
voltage). The primary function of the driver is to supply the ground for the component being controlled.
OTC will set.
OTC 29 Will Set When: The PCM detects the wrong voltage potential for 26 seconds on CKT 436.
disables the driver for this circuit.to prevent internal PCM damage.

by the PCM.
to "0") when warm.
or inoperative relay. If a circuit check is done on a
relay, it is important to identify and test the relay
coil terminals ("E2" and "E5") to avoid improper
diagnosis.
Diagnostic Aids:
Inspect the harness and all

related connectors including the PCM. These may
cause an intermittent. Check for damaged or pushed
out terminals.
DTC29
SECONDARY AIR INJECTION (AIR) PUMP CIRCUIT

AIR PUMP RELAY.
DOES THE AIR PUMP RELAY OPERATE?
KEY"OFF."
KEY "ON."
MEASURE CURRENT FROM HARNESS
TERMINAL," A 14" TO GROUND FOR 2 MINUTES
CURRENT DRAW SHOULD MEASURE LESS
THAN .75 AMPS (BUT NOT "O").
DOES IT?

IGNITION "OFF."
DISCONNECT THE AIR PUMP RELAY CONNECTOR.
CONNECT TEST LIGHT BETWEEN THE RELAY COIL
HARNESS CONNECTOR TERMINALS.
IGNITION "ON."
IS IT?
USING TECH 1 "MISC

TEST" ACTIVATE THE AIR
PUMP RELAY.
ISIT?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF RELAY
CONNECTOR TO
GROUND.
LIGHT SHOULD BE
"ON."
ISIT?
DISCONNECT PCM
CONNECTOR "A."
IS LIGHT OFF?
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
OPEN
RELAY
IGNITION
FEED
CIRCUIT.

CONTROL CIRCUIT OF RELAY
CONNECTOR TO GROUND.
ISIT?

OR
OPEN RELAY CONTROL CIRCUIT
OR
FAULTY PCM.
RELAY CONTROL
CIRCUIT SHORTED
TOB+.
5-28-93
PS 16537
EXHAUST GAS
RECIRCULATION
(EGR) VACUUM
CONTROL SIGNAL
SOLENOID VALVE
TO
IGNITION
PCM
~
fl .~
~TO
INTAKE
EGRVACUUM
CONTROL SIGNAL
SOLENOID VALVE
CONTROL
541 BRN
-"4--
C100
CIRCUITS
(U/H)
TO REVERSE INHIBIT SOLENOID, EVAP CANISTER PURGE SOLENOID

VALVE, SKIP SHIFT SOLENOID AND H02S HEATERS
6-29-93
17926
PS
OTC 32 (Page 1 of 2)
5.7L (VIN P) ,.,, CARLINE (SFI)
Vacuum to the Exhaust Gas Recirculation (EGR) valve is controlled by the EGR vacuum control signal
solenoid valve. Ignition voltage is supplied directly to the solenoid valve on CKT 541. The PCM controls the
solenoid valve by providing the ground path through CKT 435. The vacuum signal to the EGR valve is regulated
by varying the duty cycle ("on-time") of the solenoid valve. The duty cycle is calculated by the PCM based on data
from the Engine Coolant Temgerature (ECT) sensor, Mass Air Flow (MAF) sensor and RPM. If Intake Air
Temperature (IAT) is below 15 C (59F) when the vehicle is started, EGR will not be enabled until ECT is above
82C (180F). If IAT is above 15C (59F) at start up, EGR will not be enabled until ECT is above 32C (90F).
There should also be no EGR when in park/neutral or when Throttle Position (TP) sensor is below a specified
value or at Wide Open Throttle (WOT). During specific driving conditions the PCM will test the EGR system.
OTC 32 Will Set When: Vehicle speed between 16-50 for Automatic Transmission (NT) or 25-65 for Manual
Transmission (M/T), vehicle coasting NT, throttle angle 0% NT or throttle angle between 8% and 20% M/T,
transmission in 3rd gear or higher, MAP within range as shown in table (depends on altitude), no change in NC
status, DTCs 21, 22, 24, 33, 34 not set, BARO greater than 80 kPa (depends on altitude), all conditions met for 2.5
seconds, and the PCM does not detect at least 1.0 kPa change in MAP when it commands EGR "ON" NT or when
the .fCM commands the E9-R "OFF" M/T within the 1.5 second period of the test.

1. Intake Passage: Shut "OFF" engine and
remove the EGR valve from the manifold. Plug
the exhaust side hole with a suitable stopper.
With the intake side hole open, attempt to start
the engine. If the engine runs at a very high idle
(up to 3000 RPM is possible) or starts and stalls,
the EGR passages are not restricted. If the engine
starts and idles normally, the EGR intake side
Q_assage in the intake manifold is restricted.
Exhaust Passage: With EGR valve still
removed, plug the intake side hole with a suitable
stopper. With the exhaust side hole open, check for
the presence of exhaust gas. If no exhaust gas is
present, the EGR exhaust side passage in the
intake manifold is restricted.
2. The Tech 1 actuates the EGR vacuum control
signal solenoid valve when in the "Field Service"
mode. The system should hold vacuum which
should be indicated at the vacuum pump gage and
at the vacuum gage installed in place of the EGR
valve.
3. Exiting "Field Service" will de-energize the EGR
solenoid valve.
BARO
MAP
RANGE
FOR
TEST
100
30
95
25
90 85
20
15
80
10
50
45
40
35
30
43
38
33
28
23
65
60
55
50
45
(A/T)
(MIT)
kPa
The vacuum gage should bleed off through a vent in

the solenoid valve. The pump gage may or may not
bl~ed offbu_t thi~ does not indicate a problem.
D1agnost1c Aids: Suction from shop exhaust hoses
can alter backpressure and may affect the operation of
the EGR valve during in stall testing. A DTC 32 can
be caused by a leaking exhaust system. An exhaust
leak will alter backpressure. Thoroughly check
exhaust system for leaks.
Vacuum lines should be thoroughly checked for
proper routing. Vacuum source goes to orifice side of
the solenoid valve. Refer to "Vehicle Emissions
Control Information" label.
When TCC is enabled, EGR will be operating at a
reduced duty cycle.
DTC32
(Page 1 of 2)

BEFORE USING THIS CHART, CHECK FOR MANIFOLD VACUUM TO
EGR SOLENOID VALVE, ALSO CHECK HOSES FOR LEAKS OR
RESTRICTIONS. SHOULD BE AT LEAST 7" Hg VACUUM AT 2000 RPM.
IF DTC 27 IS SET, USE THAT CHART FIRST.

WITH ENGINE AT IDLE AND AT NORMAL OPERATING
TEMPERATURE, MANUALLY LIFT EGRVALVE DIAPHRAGM.
RPM SHOULD DECREASE OR ENGINE SHOULD STALL. DOES IT?
DISCONNECT EGR VACUUM HARNESS AT SOLENOID VALVE. INSTALL A

VACUUM GAGE TO MANIFOLD SIDE OF HARNESS AND CHECK FOR
VACUUM SUPPLY TO SOLENOID VALVE.
VACUUM SHOULD BE AT LEAST 25 kPa (7" Hg) OF VACUUM AT 2000 RPM.
ISIT?
ROTATE VACUUM HARNESS AND REINSTALL ONLY THE EGR VALVE SIDE, TO THE
SOLENOID VALVE.
INSTALL A VACUUM GAGE IN PLACE OF EGRVALVE.
INSTALL A HAND HELD VACUUM PUMP TO M/\NIFOLD SIDE OF EGR SOLENOID VALVE.
IGNITION "ON," ENGINE STOPPED.
USING TECH 1 SELECT "FIELD SERVICE" MODE.
APPLY 34 kPa (10" Hg) VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP. DOES IT?
USING TECH 1, EXIT "FIELD SERVICE" MODE.

VACUUM SHOULD BLEED OFF COMPLETELY
AT GAGE.
DOESIT?
r
--------,
: REFER TO EGR
:
I CHART (2 OF 2). 1
L----------.J
DISCONNECT SOLENOID VALVE

ELECTRICAL CONNECTOR.
DOES VACUUM BLEED OFF
RAPIDLY AT GAGE?
PCM DRIVER
CIRCUIT OPEN
OR
FAULTY PCM.
CHECK FOR PLUGGED

EGR PASSAGES.
PLUGGED VACUUM PORT

AT INTAKE MANIFOLD.
LEAKING OR RESTRICTED
VACUUM SUPPLY LINE
TO EGR SOLENOID
VALVE.
CONNECT VACUUM PUMP TO EGR VALVE SIDE OF HARNESS.

APPLY VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP.
DOESIT?
FAULTY SOLENOID
VALVE
CONNECTION
OR
FAULTY SOLENOID
VALVE.
FAULTY
VACUUM
SUPPLY LINE
TO EGR VALVE.
REPLACE
SOLENOID
VALVE.
1-28-93
MS9329-6E
6E3-A-72 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS
TO
IGNITION
EXHAUST GAS
RECIRCULATION
(EGR) VACUUM
CONTROL SIGNAL
SOLENOID VALVE
PCM
EGRVACUUM
CONTROL SIGNAL
SOLENOID VALVE
CONTROL
F
541BRN ~ - - C100
CIRCUITS
(U/H)

6-29-93
PS 17926
OTC 32 (Page2of2)
Vacuum to the Exhaust Gas Recirculation (EGR) valve is controlled by the EGR vacuum control signal
solenoid valve. Ignition voltage is supplied directly to the solenoid valve on CKT 541. The PCM controls the
solenoid valve by providing the ground path through CKT 435. The vacuum signal to the EGR valve is regulated
by varying the duty cycle ("on-time") of the solenoid valve. The duty cycle is calculated by the PCM based on data
from the Engine Coolant Temperature (ECT) sensor, Mass Air Flow (MAF) sensor and RPM. If Intake Air
Temperature (IAT) is below 15C (59F) when the vehicle is started, EGR will not be enabled until ECT is above
82C (180F). If IAT is above 15C (59F) at startup, EGR will not be enabled until ECT is above 32C (90F).
There should aiso be no EGR when in park/neutral or when Throttle Position (TP) sensor is below a specified
value or at Wide Open Throttle (WOT). During specific driving conditions the PCM will test the EGR system.
OTC 32 Will Set When: Vehicle speed between 16-50 for Automatic Transmission (A/T) or 25-65 for Manual
Transmission (MIT), vehicle coasting NT, throttle angle 0% A/Tor throttle angle between 8% and 20% MIT,
transmission in 3rd gear or higher, MAP within range as shown in table {depends on altitude), no change in NC
status, DTCs 21, 22, 24, 33, 34 not set, BARO greater than 80 kPa (depends on altitude), all conditions met for 2.5
seconds, and the PCM does not detect at least 1.0 kPa change in MAP when it commands EGR "ON" A/Tor when
the PCM commands the EGR "OFF" MIT within the 1.5 second period of the test.

1. The remaining test checks the ability of the EGR
valve to interact with the exhaust system. This
system uses a negative backpressure EGR valve
which should hold vacuum with engine "OFF."
2. When engine is started, exhaust backpressure at
the base of the EGR valve should open the valve's
internal bleed and vent the applied vacuum
allowing the valve to seat.
Diagnostic Aids: The EGR circuit can be
inoperative if the Park/Neutral Position (PNP) switch
is misadjusted or faulty. The EGR is disabled when in
park or neutral. To check the PNP switch, refer to
CHARTC-lA.
During normal EGR valve operation, the
movement of the EGR valve pintle is small.
BARO
MAP
~~:r
RANGE
100
30
95
25
90
20
85
15
80
10
50
45
40
35
30
43
38
33
28
23
65
60
55
50
45
(AIT)
(MIT)
kPa
It is important to determine whether or not the valve

pintle moves and not how much it moves.
Suction from shop exhaust hoses can alter
backpressure and may affect the functional check of
the EGR valve. A OTC 32 can be caused by a leaking
exhaust system. An exhaust leak will alter
backpressure. Thoroughly check exhaust system for
leaks.
When TCC is enabled, EGR will be operating at a
reduced duty cycle.
DTC32
(Page 2 of 2)

11
.-------------,
: CONTINUED FROM :
I EGRCHART
: (1 OF 2).
L-
----------..J
IGNITION "OFF."
CONNECT A VACUUM PUMP TO EGRVALVE.
OBSERVE EGR DIAPHRAGM WHILE APPLYING VACUUM.
DIAPHRAGM SHOULD MOVE FREELY AND HOLD VACUUM
FOR AT LEAST 20 SECONDS.
DOESIT?
APPLY34kPa(10"Hg)VACUUMTOEGRVALVE.
START ENGINE AND IMMEDIATELY OBSERVE GAGE ON VACUUM PUMP.
EGR VALVE DIAPHRAGM SHOULD MOVE TO SEATED POSITION AND
VACUUM SHOULD DROP FROM PUMP GAGE WHILE STARTING ENGINE.
DOESIT?
REPLACE EGR VALVE ..
REMOVE EGR VALVE.

CHECK FOR PLUGGED OR RESTRICTED EXHAUST PASSAGES.
EGR CIRCUIT IS OPERATING PROPERLY. REFER

TO SYMPTOMS (SECTION 6E3-B).
PASSAGES NOT OK
REPLACE EGR VALVE.
CLEAN PASSAGES.
RE-CHECK EGR VALVE.
10-9-90
MS 10854
MANIFOLD ABSOLUTE PRESSURE

(MAP) SENSOR
PCM
TO A/C EVAPORATOR TEMPERATURE AND
A/C REFRIGERANT PRESSURE SENSORS
MANIFOLD
ABSOLUTE
PRESSURE
(VACUUM)
TO TP SENSOR..- 474 GRV

...__---a-----~416GRY
5VOLT
REFERENCE
...__----------432LTGRN
~ - - - - - - - - - - - - 452 BLK
TO IAT, A/C REFRIGERANT PRESSURE, AND
A/C EVAPORATOR TEMPERATURE SENSORS
6-5-93
MS 12081
DTC33
{SIGNAL VOLTAGE HIGH- LOW VACUUM)

The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The PCM
receives this information as a signal voltage that will vary from about 1 - 1.5 volts at idle to 4.0 - 4.8 volts at Wide
Open Throttle (WOT).
The Tech 1 displays manifold pressure in kPa of pressure and voltage. Low pressure (high vacuum) indicates
a low voltage while a high pressure (low vacuum) indicates a high voltage.
OTC 33 Will Set When: Less than 3% throttle angle, MAP greater than 80 kPa, MAP greater than 90 kPa
with A/C "ON," RPM greater than 500 RPM, and DTCs 21 and 22 not set. All conditions met for 1 second.
Action Taken {PCM will default to): If the MAP sensor fails, the PCM will calculate a MAP value based on
throttle position and engine speed (RPM). The Malfunction Indicator Lamp (MIL) will illuminate.

1. Engine misfire or a low unstable idle may set DTC
33. Disconnect MAP sensor and system will go
into backup mode. If the misfire or idle condition
remains, refer to "Symptoms," Section "6E3-B".
2. If the PCM recognizes the low MAP signal, the
PCM and wiring are OK.
3. An open in CKT 452 will result in a DTC 33.
Diagnostic Aids: If the idle is rough or unstable,
refer to "Symptoms," Section "6E3-B" for items which
can cause an unstable idle.
With the ignition "ON," and the engine "OFF," the

is used by the PCM as an indication of vehicle altitude
and is referred to as BARO. Comparison of this BARO
reading with a known good vehicle with the same
sensor is a good way to check accuracy of a "suspect"
sensor. Reading should be the same, .4 volt.
Also, CHART C-1 D can be used to test the MAP
sensor.
If DTC 23, 66 or 71 is also set, check CKT 452 for
faulty wiring or connections.
"6E3-B".
DTC33
(SIGNAL VOLTAGE HIGH - LOW VACUUM)
5.7L (VIN P)
11
F" CARLINE (SFI)
IF ENGINE IDLE IS ROUGH, UNSTABLE, OR INCORRECT, CORRECT CONDITION

BEFORE USING CHART. SEE "SYMPTOMS" IN SECTION ''B".
ENGINE IDLING.
DOES TECH 1 DISPLAY A MAP VOLTAGE OF4.0 VOLTS OR OVER?
IGNITION "OFF."
IGNITION "ON."
TECH 1 SHOULD DISPLAY A VOLTAGE OF 1 VOLT OR LESS.
DOESIT?
PROBE SENSOR GROUND CIRCUIT WITH

TEST LIGHT SHOULD LIGHT.
DOES IT?
MAP SIGNAL CIRCUIT SHORTED TO

VOLTAGE, SHORTED TO 5 VOLT
REFERENCE CIRCUIT
OR
FAULTY PCM.
VACUUM LEAK AT MAP SENSOR SEAL

OR
FAUL TY MAP SENSOR.
5-8-93
MS 9327-6E

(MAP) SENSOR
MANIFOLD
ABSOLUTE _ .
PRESSURE
(VACUUM)
PCM
TO TP SENSOR..,_ 474 GRY
,______ _ _ _ _ _ _ _ _ 416 GRY
,_____ _ _ _ _ _ _ _ _ _ 432 LTGRN
' - - - - - - - - . . . . . - - - - - - 452 BLK
6-5-93
MS 12081
OTC 34
(SIGNAL VOLTAGE LOW HIGH VACUUM)

The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The PCM
receives this information as a signal voltage that will vary from about 1 - 1.5 volts at idle to 4.0 - 4.8 volts at Wide
Open Throttle (WOT).
The scan tool displays manifold pressure in kPa of pressure and voltage. Low pressure (high vacuum)
indicates a low voltage while a high pressure (low vacuum) indicates a high voltage.
OTC 34 Will Set When: MAP is less than 16 kPa, and RPM is less than 700 RPM, OTC 21 not set or MAP less
than 16 kPa, RPM greater than 700 RPM, TP sensor angle greater than 26% and DTC 21 not set and all
conditions met for 1 second.
Action Taken (PCM will default to): If the MAP sensor fails, the PCM will calculate a MAP value based on
throttle position and engine speed (RPM). The Malfunction Indicator Lamp (MIL) will illuminate.

1. If the PCM recognizes the high MAP signal, the
PCM and wiring are OK.
2. The Tech 1 will not display 12 volts. The
important thing is that the PCM recognizes the
voltage as more than 4 volts, indicating that the
PCM and CKT 432 are OK.
3. An intermittent open in CKT 432 or CKT 416 will
result in a DTC 34.
Diagnostic Aids: With the ignition "ON" and

engine "OFF," the manifold pressure is equal to
atmospheric pressure and the signal voltage will be
high. This information is used by the PCM as an
indication of vehicle altitude and is referred to as
BARO. Comparison of this BARO reading with a
known good vehicle with the same sensor is a good way
to check accuracy of a "suspect" sensor. Reading
should be the same, .4 volt.
Also, CHART C-lD can be used to test the MAP
sensor.
"6E3-B".
DTC34
{SIGNAL VOLTAGE LOW- HIGH VACUUM)
ENGINE IDLING.
DOES TECH 1 DISPLAY MAP VOLTAGE BELOW .25 VOLT?
IGNITION "OFF."
DISCONNECT SENSOR ELECTRICAL CONNECTOR,
JUMPER HARNESS TERMINALS "B" TO "C".
IGNITION "ON."
MAP VOLTAGE SHOULD READ OVER 4.7 VOL TS.
DOESIT?
DTC 34 IS INTERMITTENT. IF NO ADDITIONAL

IGNITION "OFF."
FAULTY CONNECTION
OR
SENSOR.
REMOVE JUMPER WIRE.

.. .
,,
PROBE TERMINAL "B" (CKT 432) WITH A TEST
LIGHT TO B +.
IGNITION "ON."
TECH 1 SHOULD DISPLAY OVER 4 VOLTS.
DOESIT?
5 VOLT ~EFERENCE CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY PCM.
CKT432 OPEN
OR
OR
CKT 432 SHORTED TO SENSOR GROUND
OR
FAULTY PCM.
5-8-93
MS9298-6E

PCM
IGNITION SYSTEM
TEST CONNECTOR
. - - - - - - , , - - - - - - - 632 PNK/BLK
r---------
632 PNK/BLK
. . . . . - - - - - - - - - - 631 RED
- - - - - - - - - - 631 RED
. . . - - - - - - - - - 430 PPLJWHT
1--------- 430 PPLJWHT
. . - - - - - - - - 453 RED/BLK
- - - - - - - - - 453 RED/BLK
,ii.--
45 0BLK
ENGINE
GROUND
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
CONNECTOR
--------\
IGNITION
COIL
I
I
I
I
I
I
II
IGNITION
COIL
MODULE
239 PNK
423WHT
B
>-~
1846PNK/BLK
B
1
I
I
I
I
I
I
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
I
I
I
I
I
IGNITION CONTROL
GRAY
CONNECTORS
A
1847 WHT/BLK
---------/.J A
BLACK
CONNECTOR
6-25-93
MS 12328
DTC36
(FAULTY HIGH RESOLUTION PULSE OR EXTRA LOW RESOLUTION PULSE DETECTED)

The distributor ignition system supplies two timing inputs to the PCM, a high resolution signal (360 pulses
per one crankshaft revolution) and a low resolution signal (4 pulses per one crankshaft revolution). The PCM can
determine if one of the timing inputs is not being received by comparing the two inputs. If the PCM detects the
low resolution timing pulse without detecting the high resolution timing pulse, this DTC will set.
The reference signals toggle between O and 5 volts as the camshaft turns. Therefore, an open, a short to
voltage, a short to ground, or a defective sensor inside the distributor can prevent the voltage from pulsing at the
PCM.
OTC 36 Will Set When: 40 low resolution pulses occur before any high resolution pulses are detected.
1. This determines if the DTC 36 is intermittent.
2. This test will determine if the PCM is sending out
a signal to the distributor for processing. If this
signal is not available, or is shorted to ground or
voltage, the distributor cannot ground it to
produce reference pulses.
Diagnostic Aids: The engine does not need the

high resolution pulse to operate. If a DTC 36 is present
and the vehicle will not start, check for DTC 16 and
use that chart first. If the engine will still not run,
refer to CHART A-3 "Engine Cranks But Will Not
Run."
If distributor components must be replaced, check
distributor vent system (if so equipped). Refer to
"Distributor Ignition (DI) System," Section "6E3-C4".
DTC36
(FAULTY HIGH RESOLUTION PULSE OR EXTRA LOW
RESOLUTION PULSE DETECTED)
CLEAR DTC(s).
RUN ENGINE FOR 30 SECONDS.
DOES DTC 36 SET?
DTC361S
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
DISCONNECT IGNITION "TEST" CONNECTOR.
IGNITION "ON."
USING A DVM ON THE DC VOLTS SCALE, MEASURE VOLTAGE
ON TERMINAL "B" AT THE PCM SIDE OF THE IGNITION TEST
CONNECTOR.
LESS THAN .5 VOL TS
OPEN OR GROUNDED HIGH

RESOLUTION SIGNAL
CIRCUIT FROM PCM TO TEST
CONNECTOR
OR
OR
FAULTY PCM.
IGNITION "OFF."
RECONNECT IGNITION SYSTEM
TEST CONNECTOR.
DISCONNECT DISTRIBUTOR
CONNECTOR.
IGNITION "ON."
MEASURE VOLTAGE ON
TERMINAL "B".
SHORT TO VOLTAGE
ON HIGH
RESOLUTION SIGNAL
CIRCUIT FROM PCM
TO TEST CONNECTOR.
LESS THAN .5 VOLTS
OPEN OR GROUNDED
HIGH RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
FAUL TV DISTRIBUTOR
CONNECTION
OR
FAUL TV DISTRIBUTOR.
SHORT TO VOLTAGE
ON HIGH RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
2-24-93
MS 9026-6E
6E.3-A-80 5. 7L {VIN P) DRIVEABILITY AND EMISSIONS
ml
LJ-4)
#9(U/H}
TO ~ 3 9 P N K
IGNITION
10 AMP
SWITCH
BRAKE SWITCH
(NORMALLY CLOSED}
PCM
____.'l'T
00---
583 LT BLUIBLK
--!!:
BRAKE SIGNAL
BRAKE TRANSMISSION
SHIFT INTERLOCK
(U/H} = UNDERHOOD ELECTRICAL CENTER
6-8-93
PS18402
DTC37
BRAKE SWITCH STUCK "ON"
The TCC brake switch is used to indicate brake pedal status. The normally closed brake switch supplies a
this signal to de-energize the TCC solenoid when the brakes are applied.
DTC 37 Will Set When:
CKT 420 is open.

Vehicle speed is less than 5 mph.
Then vehicle speed is between 5 mph.
Then vehicle speed is greater than 30 mph for greater than .6 seconds.
For a complete total of seven times.
Action Taken {PCM will default to): An incorrect brake signal can affect TCC scheduling. Also, an
incorrect brake signal can inhibit fourth gear operation, if in hot mode. OTC 37 will be stored in PCM memory,

Diagnostic Aids:

traffic).
INSTALL SCAN TOOL.

DTC37
BRAKE SWITCH STUCK "ON"

IS TEST LIGHT "ON"?

"DIAGNOSTIC AIDS."

IS TEST LIGHT "ON"?

VOLTAGE FEE.D FUSE IS OPEN, A.LSO CHECK
CKT 420 FOR A SHORT TO GROUND.
APPLY BRAKE PEDAL.


OR
IGNITION "OFF."
WITH A TEST LIGHT CONNECTED TO GROUND, PROBE
CONTROL MODULE CKT 420 HARNESS. CONNECTOR.
IS TEST LIGHT "ON"?

IGNITION "OFF."
IGNITION "ON."
WHEN RELEASED?

SWITCH TO PCM.

MAY HAVE BE EN CORRECTED DURING THIS
5-3-93
PS 17053
6E3-A-82 5.7L (VIN P) DRIVEABll.dTYAND EMISSIONS
ml
LUJ
#9 (U/H}
TO
~39PNK
IGNITION
10 AMP
SWITCH
(U/H)
BRAKE SWITCH
(NORMALLY CLOSED}
PCM
___......,ff
8fJ---
583LTBLU/8LK
-@!:
BRAKE SIGNAL
BRAKE TRANSMISSION
SHIFT INTERLOCK
6-8-93
PS18402
DTC38
BRAKE SWITCH STUCK "OFF"
5.7L (ViN P) F" CARLINE (SFI)
11
The TCC brake switch is used to indicate brake pedal status. The normally clos~d brake switch supplies a
this signal to de-energize the TCC solenoid when the brakes are applied.
CKT 420 has constant voltage.

Vehicle speed is less than 5 mph.
Then vehicle speed is greater than 20 mph for greater than 6 seconds.
Then vehicle speed is between 5 mph and 20 mph for greater than 6 seconds.
For a complete total of seven times.
Action Taken (PCM will default to): An incorrect brake signal can affect TCC scheduling. Also, an
incorrect brake signal can inhibit fourth gear operation, ifin hot mode. OTC 38 will be stored in PCM memory,

Diagnostic Aids:

traffic).
DRIVEABILITYAND EMISSIONS 5.7L (VIN P) 6E3-A-83
G)
INSTALL SCAN TOOL.

DTC38
BRAKE SWITCH STUCK "OFF"
5.7L {VIN P) F" CARLINE {SFI)
11

IS TEST LIGHT "ON"?

"DIAGNOSTIC AIDS."

IS TEST LIGHT "ON"?

VOLTAGE FEED FUSE IS OPEN, ALSO CHECK
CKT 420 FOR A SHORT TO GROUND.
APPLY BRAKE PEDAL.


OR
IGNITION "OFF."
WITH A TEST LIGHT CONNECTED TO GROUND, PROBE
CONTROL MODULE CKT 420 HARNESS CONNECTOR.
IS TEST LIGHT "ON"?

IGNITION "OFF."
IGNITION "ON."
WHEN RELEASED?

SWITCH TO PCM.

MAY HAVE BEEN CORRECTED DURING THIS
5-3-93
PS 17053
6E3-A-84 5.7L (VIN P) DRIVEABttlTY AND EMISSIONS

PCM
IGNITION SYSTEM
TEST CONNECTOR
. . . . - - - - - - - - - - 632 PNK/BLK
1---------- 632 PNK/BLK
. . - - - - - - - - - - - - 631 RED
- - - - - - - - - - - 631 RED
. . - - - - - - - - - 430 PPL/WHT
1 - - - - - - - - - 430 PPL/WHT
~ - - - - - - 453 RED/BLK
- - - - - - - - - - 453 RED/BLK
111----
ENGINE
GROUND
450 BLK
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
CONNECTOR
--------\
DISTRIBUTOR
REFERENCE LOW
. SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
IGNITION
COIL
MODULE
239 PNK
423WHT
IGNITION CONTROL
IGNITION
COIL
l>,!"
:::~~;:.,
II
I
I
e---,r-<ll'--T'-A-'--- 1847 WHT/BLK
---------/.J A
BLACK
CONNECTOR
(U/H)
6-25-93
MS12328
DTC41
IGNITION CONTROL (IC) CIRCUIT
(OPEN CIRCUIT)

The distributor ignition system provides two timing inputs to the PCM, high resolution signal (360 pulses per
crankshaft revolution) and low resolution signal (4 pulses per crankshaft revolution). The PCM uses these two
reference pulses to determine individual ignition spark timing for each cylinder.
Once the PCM calculates ignition timing, the timing signal will be sent to the ignition coil module on the IC
circuit. Each timing pulse received by the ignition coil module, on the IC circuit, will trigger the coil module to
operate the ignition coil. Secondary ignition voltage is induced and is then sent to the distributor for distribution
to each spark plug.
The IC signal voltage ranges from abput .5 volt to 4.5 volts.
DTC 41 Will Set When: Voltage on CKT 423 exceeds 4.6 volts and engine speed is less than 1500 RPM.
Action Taken {PCM will default to): If a DTC 41 is detected, the PCM will disable the fuel injectors to
prevent flooding of the engine. DTC 41 will be stored in the PCM memory but will not turn "ON"the Malfunction
Indicator Lamp (MIL).

1. This determines if the DTC 41 is intermittent.
2. This check determines if the IC signal from the
PCM is available at the ignition coil driver. The
IC circuit voltage should be between about .5 and
4.5 volts.
3. The remaining tests begin to check that the coil
driver circuitry is OK.
4.
If all wiring and connections are OK, check the

ignition coil or the ignition coil voltage supply.
Check coil fuse for being open.
Diagnostic Aids: Since the coil driver gets its

power from the coil, check the ignition feed circuit to
the ignition coil for opens.
DTC 41 will set only during cranking.
DTC41
IGNITION CONTROL (IC)-CIRCUIT
(OPEN CIRCUIT)
5.7L (VIN P)
(D
11
F" CARLINE (SFI)
CLEAR DTC(s).
CRANK ENGINE FOR 15 SECONDS.
DOES DTC41 SET?
WITH VOLTMETER ON AC SCALE, CRANK ENGINE

AND OBSERVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4 VOLTS?
DTC 4115 l!IITERMITTENT. REFER TO

IGNITION "OFF."
WITH TEST LIGHT TO B +, PROBE IGNITION COIL
MODULE HARNESS CONNECTOR TERMINAL "C".
LIGHT SHOULD BE ON,
ISIT?
OPEN IGNITION
COIL MODULE
.GROUND CIRCUIT.
IGNITION "ON."
WITH TEST LIGHT TO GROUND,
PROBE IGNITION COIL MODULE
HARNESS CONNECTOR
TERMINALS uD" AND" A".
LIGHT SHOULD BE ON BOTH,
ISIT?
FAULTY IGNITION COIL

MODULE CONNECTION
OR
FAULTY IGNITION COIL MODULE.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "B".
CHECK FOR CONTINUITY BETWEEN PCM
CONNECTOR TERMINAL "85" AND IGNITION
COIL MODULE CONNECTOR TERMINAL "B".
IS CIRCUIT OPEN?

OR
FAULTY PCM.
OPEN IC CIRCUIT
BETWEEN PCM AND
IGNITION COIL
MODULE.
FAUL TY CIRCUIT FROM IGNITION

COIL TO IGNITION COIL MODULE
ON CIRCUIT THAT DID NOT LIGHT.
4-19-93
95 5271-6E
6E3-A-86 5. 7L {VIN P) DRIVEABILITY AND EMISSIONS

PCM
IGNITION SYSTEM
TEST CONNECTOR
. - - - - - - - - - - 632 PNK/BLK
1---------- 632 PNK/BLK
. - - - - - - - - - - - 631 RED
t---------~631RED
. - - - - - - - - 430 PPL/WHT
t - - - - - - - - - 430 PPL/WHT
~ - - - - - - 453 RED/BLK
A - - - - - - - - - 453 RED/BLK
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
111---- 450BLK
ENGINE
GROUND
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
CONNECTOR
r
I
I
I
I
I
I
IGNITION I
COIL
:
I
I
I
I
I
IGNITION
COIL
MODULE
2 39 PNK
--------\ B
423WHT
IGNITION CONTROL
~ ~ > -1846PNK/BLK
~B
I
II
P : :
R I I
I I I
GRAY
CONNECTORS
I
I
1847 WHT/BLK
~---------/-.J A
BLACK
CONNECTOR
(U/H)
6-25-93
MS 12328
DTC42
{SHORTED OR GROUNDED CIRCUIT)

The distributor ignition system provides two timing inputs to the PCM, high resolution signal (360 pulses per
crankshaft revolution) and low resolution signal (4 pulses per crankshaft revolution). The PCM uses these two
reference pulses to determine individual ignition spark timing for each cylinder.
Once the PCM calculates ignition timing, the timing signal will be sent to the ignition coil module on the IC
circuit. Each timing pulse received by the ignition coil module on the IC circuit will trigger the ignition coil
module to operate the ignition coil. Secondary ignition voltage is induced and is then sent to the distributor for
distribution to each spark plug.
The IC signal voltage ranges from about .5 volt to 4.5 volts.
DTC 42 Will Set When: PCM detects 84 crankshaft revolutions without any IC activity.
Action Taken {PCM will default to): If DTC 42 is detected, the PCM will disable the fuel injectors to
prevent flooding of the engine. DTC 42 will be stored in the PCM memory but will not turn "ON" the Malfunction
Indicator Lamp (MIL).

1. If the engine starts at this point, DTC 42 is
intermittent.
2. This check determines if the IC signal from the
PCM is available at the ignition coil module.
3. The remaining tests begin to check that the
ignition coil module circuitry is OK. If the ignition
coil module loses its voltage source, secondary

voltage will not be produced and a DTC 42 will set.
4. Since the ignition coil module gets its power from
the coil, check the ignition feed circuit to the
ignition coil for opens.
Diagnostic Aids:
cranking.
DTC 42 will set only during
DTC42
(SHORTED OR GROUNDED CIRCUIT)
5. 7L (VIN P) "F" CARLINE (Sf I)
CLEAR DTC{s).
CRANK ENGINE FOR 15 SECONDS.
DOES DTC42 SET?
IGNITION "OFF."
DISCONNECT IGNITION COIL MODULE CONNECTOR.
WITH A VOLTMETER ON AC SCALE, PROBE IGNITION COIL
MODULE CONNECTOR TERMINAL "B" TO GROUND.
CRANK ENGINE AND OBSERVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4 VOLTS?

IGNITION "OFF."
WITH TEST LIGHT TO B +, PROBE IGNITION COIL
MODULE HARNESS CONNECTOR TERMINAL"(".
IS IT?
IGNITION "OFF."
WITH TEST LIGHT TO B +, PROBE
PCM HARNESS TERMINAL "BS".
IS TEST LIGHT ON?
IGNITION "ON."
WITH TEST LIGHT TO GROUND,
PROBE IGNITION COIL MODULE
HARNESS CONNECTOR
TERMINALS "D" AND "A".
LIGHT SHOULD BE "ON" BOTH.
ISIT?
WITH TEST LIGHT TO

GROUND,
PROBE PCM HARNESS
TERMINAL "BS".
IS TEST LIGHT "ON"?
FAULTY IGNITION COIL

MODULE CONNECTION
OR
FAUL TY IGNITION COIL MODULE.
OPEN IGNITION
COIL MODULE
GROUND CIRCUIT.
FAUL TY CIRCUIT
FROM COIL TO
IGNITION COIL
MODULE ON
CIRCUIT THAT
DID NOT LIGHT.
GROUNDED IC CIRCUIT
BETWEEN PCM AND
IGNITION COIL MODULE.
IC CIRCUIT SHORTED TO
B + BETWEEN PCM AND
IGNITION COIL MODULE.
5-1-93
MS 8943-6E
PCM
KS
SIGNAL
r------- 496 DK BLU
SVOLTS
KNOCK
SENSOR
(KS)
6-26-93
NS 15347
DTC43

The knock sensor system is used to detect engine detonation. The PCM will retard the spark timing based on
signals from the KS module. The knock sensor produces an AC voltage which is sent to the KS module. The
amount of AC voltage produced by the sensor is determined by the amount of knock. The circuitry within the
knock sensor causes the PCM's 5 volts to be pulled down so that under a no knock condition, CKT 496 would
measure about 2.5 volts.
The internal PCM test run on the Knock Sensor (KS) circuit will determine if it is operating correctly.
DTC 43 Will Set When: If the PCM detects that any of the following voltage conditions have been met for 5
seconds, DTC 43 will be set: Sensor open - voltage greater than 4.1 volts, or sensor grounded - voltage less than
.78 volt.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate. The PCM
will retard timing to a predetermined maximum based on current RPM and MAP. Some loss of performance will
result.

1. If an audible knock is heard from the engine,
repair the internal engine problem, as normally no
knock should be detected at idle.
The PCM supplies 5 volts on CKT 496 which
should be. present at the knock sensor terminal
when the sensor is disconnected.
2. This test determines if the knock sensor is faulty
or if the KS module is faulty.
3. CKT 496 shorted to voltage will set DTC 43 and
indicate on Tech 1 as sensor open. With the sensor
and the PCM disconnected, no voltage should be
present on CKT 496.
4. An improperly installed knock sensor can prevent
the knock sensor from grounding to the block.
Diagnostic Aids: The PCM has the ability to

diagnose opens and shorts in the KS circuit. The
Tech 1 will display if the sensor is open or if it is
grounded when the PCM detects these conditions.
Check CKT 496 for a potential open or short to
ground.
Also, check for proper installation of the KS
module.
KS sensor wire is routed too close to secondary
ignition components may be susceptible to EMI
interference.
"6E3-B".
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-:89
DTC43
G)
IGNITION "ON."
USING A DVM, MEASURE VOLTAGE BETWEEN
SENSOR CONNECTOR AND GROUND.
VOLTAGE SHOULD BE APPROXIMATELY SVOLTS.
MEASURE RESISTANCE
BETWEEN KNOCK SENSOR
TERMINAL AND GROUND.
RESISTANCE SHOULD BE
BETWEEN 3300-45000.
IS IT?
OPEN OR GROUNDED CIRCUIT

OR
FAULTY PCM.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "D."
IGNITION "ON."
USING A DVM MEASURE VOLTAGE ON CKT 496.
IS ANY VOLTAGE PRESENT?
CKT 496 SHORTED TO B +.
( . \ FAULTY KNOCK SENSOR INSTALLATION

OR
\V
FAUL TY KNOCK SENSOR.
FAUL TY KNOCK
SENSOR CONNECTION
OR
FAUL TY KS MODULE
OR
FAULTY PCM.
5-24-93
PS 17927
6E3-A-90 5.7l (VIN P) DRIVEABILITY AND EMISSIONS

PCM
t - - - - - - - - 1 6 5 3 TAN/WHT--------11
H02SLOW
J . - - - - - - - - - 1 6 6 5 PPL/WHT-------1
H02S HIGH
5-24-93
PS17916
DTC44

The PCM supplies a voltage of about 450 mV between terminals "C20" and "C19". (If measured with a 10
megohm digital voltmeter, this may display as low as 320 mV.) The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1000 m V if the exhaust is rich, down through about 10 m V if exhaust is lean.
circuit or cold sensor causes "Open Loop" operation. Whenever the ignition is "ON" voltage is supplied to the
H02S heaters on CKT 541. Even with the engine not running, the H02S will reach operating temperature and
indicate the oxygen content of the exhaust gas at the sensor. Typically the signal voltage will be near 450 m Vat
OTC 44 Will Set When: System is operating in "Closed Loop," n.ot in power enrichment, and signal voltage
remains below 200 m V for 50 seconds.
.OTC Chart Test Description:
Number(s) below
1. Engine must be at normal operating temperature
before performing this test.
Diagnostic Aids: Using the Tech 1, observe the

long term fuel trim values at different RPM and air
flow conditions. The Tech 1 also displays the fuel trim
cells, so the long term fuel trim values can be checked
in each of the cells to determine when the DTC 44 may
have been set. If the conditions for DTC 44 exist, the
long term fuel trim values will be near 160.
Heated Oxygen Sensor (H02S) wires. Sensor
pigtail may be mispositioned and contacting the
exhaust manifold.
Check for intermittent ground in signal wire
between connector and sensor.
contamination that could prevent reference
oxygen from reaching the H02S.
Lean injector(s). Perform "Injector Balance Test,"

using Tech 1 or CHART C-2A.
exhaust and can set a DTC 44.
speeds and/or loads to confirm. Refer to "Fuel
System Diagnosis," CHART A-7.
Exhaust leaks. If there is an exhaust leak, above
the oxygen sensor, the engine can cause outside air
to be pulled into the exhaust stream and flow past
the sensor causing lean condition. Vacuum or
AIR system. Make sure the secondary air pump is
not operating in "Closed Loop." While monitoring
long term fuel trim, squeeze the air hose going to
the exhaust ports (left bank). If long term fuel
trim values go down, refer to CHART C-6.
If the above are OK, the oxygen sensor may be at
fault.
DTC44
5.7L (VIN P)
11
F" CARLINE (SFI)
IF DTC 50 IS SET, USE THAT CHART FIRST.

RUN WARM ENGINE (75(/167F TO 95C/203F) AT 12.00 RPM.
DOES TECH 1 INDICATE BANK 1 (LEFT) H02S VOLTAGE FIXED BELOW .20 VOLT (200 mV)?
DISCONNECT H02S AND JUMPER CKT 1653

(PCM SIDE) TO GROUND.
IGNIT.ION ''ON" ENGINE "OFF", TECH 1 SHOULD
DISPLAY H02S VOLTAGE BETWEEN .35 VOLT
AND .55 VOLT (350 mV AND 550 mV).
DOESIT?

OR
FAULTY PCM.
6-11-93
MS8311

PCM
HEATING
BLK
ELEMENT~--+--
- - - - - - - 1 6 5 3 TAN/WHT-------11
H02SLOW
- - - - - - - - 1 6 6 5 PPL/WHT------1
H02S HIGH
1-.
450 B L K - - - - - ~ENGINE
~ROUND
541 BRN
#11(U/H)
~TO ..111;0---------~-------1111-~ TO BANK 2 (RIGHT) H02S
IGNITION
10 AMP
TO OTHER CIRCUITS
5-24-93
PS 17916
DTC45

The PCM supplies a voltage of about 450 mV between terminals "C20" 'and "C19". (If riieasured with a 10
megohm digital voltmeter, this may read as low as 320 m V.) The Heated Oxygen Sensor (H02S) varies the
voltage within a range of about 1000 m V if the exhaust is rich down through about 10 m V if exhaust is lean.
H02S heaters on CKT 541. Even with the engine not running, the H02S will reath operating temperature and
key-up. The signal voltage will then rise or drop as the sensor becorn~s active, dependingdn the oxygen content of
DTC 45 Will Set When: System is operating in "Closed Loop," not in power enrichi:nent, signal voltage
remaining above 700 mV for 50 seconds and throttle angle is greater than 4%.
Action Taken (PCM will default to): The Malfunction Indic!),tor Lamp (MIL) will illuminate and the fuel

1. Engine must be at normal operating temperature
before performing this test.
long term fuel trim values at different RPM and load
conditions. The Tech 1 also displays the fuel trim cells,
so the long term fuel trim values can be checked in
each of the cells to determine when the OTC 45 may
have been set. If the conditions for OTC 45 exist, the
increase. However, if it gets too high, a OTC 45
CHARTA-7.
Rich injector. Perform "Injector Balance Test,"
Leaking injector. Refer to "Fuel System
Check for fuel contaminated oil.
Evaporative Emission (EVAP) canister purge.
Check for fuel saturation. If full of fuel, check
canister control and hoses. Refer to "Evaporative
Emission (EVAP) Control System," Section
"6E3-C3".
.
MAF sensor. Disconnect the MAF sensor and see

if rich condition is corrected. If so, check for proper
installation. If installed OK, replace MAF sensor.
If the MAF sensor is installed backwards, the
system will go rich. The plastic portion of the
sensor has arrows cast into it indicating proper air
flow direction. The arrows must point toward the
engine.
for fuel.
TP sensor. An intermittent TP sensor output will
cause the system to go rich, due to a false
indication of the engine accelerating.
EGR. An EGR valve staying open (especially at
idle) will cause the oxygen sensor to indicate a rich
exhaust, and this could result in a OTC 45.
Heated oxygen sensor. An oxygen supply inside
the H02S is necessary for proper H02S operation.
This supply of oxygen is supplied through the
H02S wires. All H02S wires and connectiorts
should be inspected for breaks or contamination
that could prevent reference oxygen from reaching
the H02S.
DTC45
BANK 1 (LEFT) HEATED OXYGEN
RUN WARM ENGINE (75C/167FTO 95C/203F)AT 1200 RPM.

DOES TECH 1 DISPLAY BANK 1 (LEFT) H02S VOLTAGE FIXED ABOVE .70 VOLT (700 mV)?
DISCONNECT H02S AND JUMPER CKTs 1653

AND 1665 (PCM SIDE) TO GROUND.
TECH 1 SCAN TOOL SHOULD DISPLAY H02S
VOLTAGE BELOW .35 VOLT (350 mV).
DOES IT?
OTC 4515 INTERMITTENT.

5-1-93
95 7773
PCM
#4(1/P)
TOB+
10AMP
PCM BATTERY FEED
c
A1
THEFT
DETERRENT
MODULE
(1/P)
3400RN
KE
C230
229DKBLU
PCM BATTERY FEED
C210
A3
FUEL ENABLE SIGNAL
6-28-93
PS16717
DTC46
PASS-KEYII CIRCUIT
The PASS-KeyII system is designed to disable vehicle operation if the incorrect key or starting procedure is
used. The theft deterrent module enables the crank circuit to the starter and sends a signal to the PCM if the
correct key is being used. If the proper signal does not reach the PCM on CKT 229, the PCM will not pulse the
injectors "ON" and thus not allow the vehicle to continue to run, even if the crank circuit is bypassed.
DTC 46 Will Set When: DTC 46 will set and the engine will stall if the proper signal is not being received on
CKT 229 by the PCM after 1. 7 seconds.
Action Taken (PCM will default to): DTC 46 will be stored in the PCM memory but will not turn "ON" the

1. If the engine starts and then stalls, it indicates
that the portion of the theft deterrent module,
which generates the signal to the PCM is not
operating or CKT 229 is open or shorted to ground.
If theft deterrent module is found to be OK, as
determined from SECTION 8A or 8D, the PCM
may be at fault, but this is not a likely condition.
2. If DTC 46 is stored, and the engine will not crank,
it indicates that there is a PASS-KeyII problem or
an incorrect key or starting procedure is being
used.
Diagnostic Aids: If the proper signal is not received

on CKT 229 by the PCM, the engine will start then
stall. The proper signal is between 40 - 60 Hz and
must be measured using the AC scale on the DVM.
DTC46
PASS-KeyII CIRCUIT
S.7L (VIN P) "F" CARLINE (SFI)
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "A".
IGNITION "ON."
USING A DVM CONNECTED TO GROUND ON AC
VOLTS AND HERTZ (Hz) SCALE PROBE TERMINAL
"A25". 40-60 Hz SHOULD BE PRESENT.
ISIT?
DTC 46 IS INTERMITTENT, REFER

TO "INTERMITTENTS" IN
DOES ENGINE CRANK?
G)
CHECK FOR OPEN OR SHORT TO GROUND IN CKT 229

OR
FAUL TY THEFT DETERRENT MODULE CONNECTIONS
OR
FAULTY THEFT DETERRENT MODULE.
FAUL TV PCM CONNECTION

OR
FAULTY PCM.
G)
f>ASSKeyII SYSTEM PROBLEM. REFER TO

PASS-Keyil DIAGNOSIS" IN SECTION SA.
6-26-93
NS15561
6E3-A-96 5. 7L (VIN P) DRtVEABILITY AND EMISSIONS
ACCESS COVER
KNOCK SENSOR
(KS)MODULE
PS 17347
DRIVEABILITY ANO EMISSIONS 5.7L (VIN P) 6E3-A-97
DTC47
, OR MODULE MISSING
OTC 47 WILL SET IF THE KNOCK SENSOR (KS)

MODULE IS MISSING. BE SURE KS MODULE IS
FULLY SEA TED IN THE CONNECTOR IN THE PCM.
USING TECH 1, CLEAR DTCs.
START ENGINE.
DOES DTC47 REAPPEAR?
IGNITION"OFF."
REPLACE KS MODULE.
IGNITION"ON." USINGTECH1,CLEARDTCs.
START ENGINE.
DOES DTC47 REAPPEAR?
FAULTY PCM. REINSTALL

ORIGINAL KS MODULE IN.
NEW PCM.
DTC47 IS INTERMITTENT.
SYSTEM OK.
4-19-93
PS 16662
6E3-A-98 5.7l (VIN P) DRIVEABILITYAND EMISSIONS

PCM
MAFSENSOR
SIGNAL
MASS AIR
FLOW
{MAF)
SENSOR
451 BLKJWHT-i
439 PNK
81
#5(1/P)
TO--oc--c(~3PNK~
IGNITION
C200
15 AMP
C230
TO OTHER CIRCUITS
(1/P)
6-29-93
PS 17930
= LOCATED IN INSTRUMENT PANEL FUSE BLOCK.
DTC48
MASS AIR FLOW (MAF) SENSOR CIRCUIT
The Mass Air Flow (MAF) sensor measures the amount of air that is ingested by a vehicles' engine. This
information is required by the engine's Powertrain Control Module (PCM) to schedule fuel and maintain the
desired air/fuel ratio.
The MAF sensor used on this vehicle is a hot wire type and is used to measure air flow rate. The Mass Air
Flow (MAF) output frequency is a function of the power required to keep the air flow sensing elements (hot wires)
at a fixed temperature above ambient temperature. As air flows through the MAF sensor, the "hot wires" are
'Cooled. The amount of cooling is proportional to the rate of air flow. As air flow increases, a greater amount of
current is required to maintain the "hot wires" at a constant temperature. The MAF sensor converts the changes
in current draw to a frequency signal read by the PCM. The PCM calculates air flow (grams per second) based on
this signal.
'
OTC 48 Will Set When: The PCM detects engine reference pulses without detecting a frequency signal from
the Mass Air Flow (MAF) sensor.
Action Taken (PCM will default to): The Malfunction Indicator Lamp (MIL) will illuminate and speed
density will be used for fuel management.

1. This step will determine if the fault is a hard
failure or an intermittent condition.
2. This step checks for a 5 volt reference from the
PCM.
3. Verifies that both ignition voltage and a good
ground circuit are available.

by a poor connection, mis-routed harness, rubbed
through wire insulation, or a broken wire inside the
insulation.
A DTC 48 could be caused by a vacuum leak.
Check short and long term fuel trim for being in the
optimal range (both banks).
DTC48
MASS AIR FLOW (MAF) SENSOR CIRCUIT
11
CD
CLEAR DTC{s).
START AND IDLE ENGINE FOR ATLEAST 1 MINUTE OR
UNTIL OTC 48 SETS.
DOES OTC SET?
IGNITION "OFF."
DISCONNECT MAF SENSOR ELECTRICAL
CONNECTOR.
IGNITION "ON." ENGINE STOPPED.
CONNECT VOLTMETER BETWEEN HARNESS
CONNECTOR TERMINAL" A" AND GROUND.
SHOULD READ 4-6 VOLTS.
DOESIT?
MEASURE VOLTAGE BETWEEN HARNESS

CONNECTOR TERMINALS "B".AND "C".
SHOULD BE B +.
ISIT?
MEASURE VOLTAGE BETWEEN HARNESS

CONNECTOR TERMINAL "C" AND CHASSIS
GROUND.
SHOULD BE B +.
IS IT?
OTC 48 IS INTERMITTENT, REFER TO

CKT 492 OPEN,

SHORTED TO GROUND,
OR FAULTY PCM.
CKT 492 SHORTED TO

VOLTAGE OR FAULTY
PCM.
FAULTY MAF SENSOR CONNECTION OR SENSOR.
2-3-93
PS 16534
~ - - - - - - T O THEFT DETERRENT MODULE

AND FUEL PUMP RELAY
#5 (1/P)
TO - - - - - - ~ ~ " " ' ~ ~ ~ _ . , _ _ ~ - ~ - ~ ~ - - - e : : - - - 4 3 9 P N K
IGNITION
15 AMP
439 PNK
PCM
PCM IGNITION FEED

PCM IGNITION FEED

5-24-93
PS 17929
DTCSO
SYSTEM VOLTAGE LOW
CKT 439 is the ignition feed to the PCM on terminals "B30" and "03". The PCM monitors the voltage at
terminal "03". When voltage on "03" drops below 8.0 volts, OTC 50 will set and the Malfunction Indicator Lamp
(MIL) will be illuminated.
OTC 50 Will Set When: The engine is running and the PCM senses a voltage of less than 8.0 volts on PCM
terminal "03".
Action Taken (PCM will default to): High idle, and
3rd
gear starts. The Malfunction Indicator Lamp
(MIL) will illuminate.

1. Normal battery output is between 9.6 - 16.0 volts.
2. Checks to see if the low voltage reading is due to
the generator. With engine running, check
voltage at the battery.
3. Checks to see if generator is faulty under load
condition. If the voltage is below 8.0 volts, refer to
SECTION 60.
Diagnostic Aids: An open circuit, or extremely low

voltage (below 5.5 volts) to "03" may cause loss of
serial data and the MIL may not function. Additional
DTCs may be set. An '.>pen circuit to "B30" will cause a
no start and the MIL will not illuminate.
DTCSO
SYSTEM VOLTAGE LOW

NOTE BATTERY VOLTAGE ON TECH 1.
BELOW 8.0 VOL TS
ABOVE 8.0 VOL TS
CHECKBATTERYVOLTAGEATBATTERY.

HEADLAMPS AND HIGH BLOWER "ON."
NOTE BATTERY VOLTAGE VALUE.
ABOVE 8.0 VOLTS
BELOW 8.0 VOLTS
ABOVE 8.0 VOL TS
BELOW 8.0 VOL TS
IGNITION "OFF."
DISCONNECT PCM
CONNECTOR "D".
IGNITION "ON,"
CHECK VOLTAGE AT
TERMINAL "D3"
USINGADVM.
REMOVE GENERATOR
FOR REPAIR.
SEE SECTION 6D.
FAULT IS NOT PRESENT

SEE "INTERMITTENTS" IN
ABOVE 8.0 VOLTS
BELOW 8.0 VOLTS
FAULTY PCM
CONNECTION
OR
FAULTY PCM.
IGNITION FEED CIRCUIT OPEN OR GROUNDED

OR
OPEN IGNITION FEED CIRCUIT FUSE
OR
HIGH RESISTANCE IN IGNITION FEED CIRCUIT.
REMOVE GENERATOR
FOR REPAIR.
SEE SECTION 60.
2-3-93
PS 16547
BLANK
DTC51
EEPROM PROGRAMMING
ERROR
PCM CALIBRATIONS ARE STORED IN THE. EEPROM (ELECTRONiCALLY ERASABLE PROGRAMMABLE

READ ONLY MEMORY). THE EEPROM IS NOT REMOVABLE FROM THE PCM. OTC 51 WILL SET IF NO
CALIBRATION WAS PROGRAMMED IN THE PCM, OR WHEN THE PCM DETECTS AN INTERNAL
PROGRAM FAULT (CHECKSUM ERROR). IF OTC .51 SETS DURING NORMAL VEHICLE OPERATION,
REPLACE THE PCM. THE REPLACEMENT PCM MUST BE PROGRAMMED USING TECH 1 (T1) OR CAMS
(T100)
USE THE FOLLOWING PROCEDURE TO REPROGRAM THE PCM:
CAUTION: THE SOFTWARE/CALIBRATION USED FOR PCM REPROGRAMMING MUST MATCH

THE VEHICLE APPLICATION, OR IMPROPER OPERATION AND/OR VEHICLE DAMAGE MAY
OCCUR.
BATTERY 1scAARGED.
IGNITION IS "ON."
CONNECTIOl'<IS TO THE DLC AND BATTERY/CIG. LIGHTER SECURE.
FOLLOW THE MOST CURRENT TECH LINE TERMINAUEQUIPMENT INSTRUCTIONS.
IF THE PCM FAILS TO PROGRAM, OR IF OTC 51 SETS DURING PROGRAMMING:
CHECK ALL PCM CONNECTIONS.

CHECK TECHLINE TERMINAL/EQUIPMENT FOR LATEST SOFTWARE VERSION.
REPEAT REPROGRAMMING PROCEDURE. IF IT FAILS AGAIN, REPLACE THE PCM. THE
REPLACEMENT PCM MUST BE PROGRAMMED.
5-3-93
PS 16658
6E3-A-104 5.7L {VIN P) DRIVEABIUTY AND EMISSIONS
_ _ _ _ _ _TO THEFT DETERRENT MODULE

AND FUEL PUMP RELAY
#5 (1/P)
ro------1GN1110N
PCM
J - - -. . .------4f~----<9:----439PNK
15AMP
439PNK
PCM IGNITION FEED

PCM IGNITION FEED
5-24-93
PS17929
DTC53
SYSTEM VOLTAGE HIGH
1
5. 7L (VIN P) 'F" CARLINE (SFI)
CKT 439 is the ignition feed to the PCM ori terminals "B30" and "03". The PGM monitors the voltage at
terminal "D3".
OTC 53 Will Set When: DTC 53 will set when the engine is running and the PCM senses a voltage of more
than 17.1 volts on PCM terminal "D3".
Action Taken {PCM will defau'lt to): During the time the fault is present, all PCM outputs will be
disengaged and the Malfunction Indicator Lamp (MIL) will illuminate.
During the time the failure is present, the pressure control solenoid is turned "OFF," causing maximum line
pressure, the 3-2 control solenoid is turned "OFF," transmission shifts immediately to third gear, and TCC
operation is inhibited. (The setting of additional diagnostictrouble codes may result,)
.1. Normal battery output is between 9.6 - 16.0 volts.
2. Checks to see if the high voltage reading is due to
the generator or PCM. With engine running,
check voltage at the battery.
If the voltage is above 17.1 volts, the PCM is OK.
Diagnostic Aids: During the time the failure is

present, all PCM outputs will be disengaged to protect
the hardware. The setting of additional DTCs may
result.
DTC53
SYSTEM VOLTAGE HIGH

NOTE BATTERY VOLTAG.E ON TECH 1.
ABOVE 17.1 VOLTS
CHECKBATTERYVOLTAGEATB~TTERY.
BELOW17.1 VOLTS

SEE "INTERMITTENTS" IN
"SYMPTOMS" (SECTION B).
ABOVE 17.1 VOLTS
REMOVE GENERATOR
FOR REPAIR.
SEE SECTION "6D."
1-15-93
PS 16548
/'

CAUTION:


MANIFOLD VACUUM
HOSE CONNECTION
RETURN LINE
FUEl FILTER
NYLON
FUEL PUMP AND

RESERVOIR ASSEMBLY
NS 16050
FUEL LEAN MONITOR

The PCM's internal circuitry can identify if the vehicle fuel system is capable of supplying adequate amounts
of fuel during heavy acceleration (power enrichment). When a power enrichment mode of operation is requested
during "Closed Loop" operation (by heavy acceleration), the PCM will provide more fuel to the engine. Under
these conditions, the PCM should detect a "rich" condition .
.DTC 55 Will Set When: Engine operating in "Closed Loop," not in fuel cutoff, no DTCs 44, 45, 64, 65 set. If
the PCM detects lean oxygen sensor voltage for 3 seconds during power enrichment modes of operation, DTC 55
will set.
Action Taken (PCM will default to}: The Malfunction Indicator Lamp (MIL) will illuminate.
1. Wrap a shop towel around the fuel pressure
connector to absorb any small amount of fuel
leakage that may occur when installing the gage.
Ignition "ON," pump pressure should be 284-325
kPa (41-47 psi). This pressure is controlled by
spring pressure within the regular assembly.
Pressure below 284 kPa (41 psi) may cause a lean
condition and may set a DTC 44 or 64. It could also
cause hard starting cold and poor driveability.
Low enough pressure will cause the engine not to
run at all. Restricted flow may allow the engine to
run at idle, or low speeds, but may cause a surge
and stall when more fuel is required, as when
accelerating or driving at high speeds. Low fuel

pressure under heavy acceleration conditions may
set a DTC 55.
2. Restricting the fuel return line allows the fuel
pressure to build above regulated pressure. With a
Tech 1 enable the fuel pump, pressure should rise
above 325 kPa (47 psi) as the valve in the return
line is partially closed.
Diagnostic Aids: A restricted fuel filter can supply

adequate amounts of fuel at idle but may not be able to
supply enough fuel during heavy acceleration. A
vapor lock condition can cause a DTC 55.
If a DTC 55 can not be duplicated, it may have
been caused by the customer running the vehicle out of
fuel.
DTCSS
FUEL LEAN MONITOR
8 .
IF DTC(s) 44 OR 64 ARE SET, REFER TO THOSE DTCs BEFORE

PROCEEDING WITH THIS CHART.
INSTALL FUEL PRESSURE GAGE, J 34730-1 .
START AND IDLE ENGINE AT NORMAL OPERATING TEMPERATURE.
DISCONNECT VACUUM LINE GOING TO FUEL PRESSURE REGULATOR.
NOTE FUEL PRESSURE WITH ENGINE RUNNING SHOULD BE 284-325 kPa
(41-47 psi).
CHECK FOR RESTRICTED FUEL LINES

OR
IN-LINE FILTER
IGNITION "OFF."
INSTALLJ 37287-2 FUEL LINE ADAPTOR IN FUEL RETURN LINE.
REFER TO FUEL SYSTEM PRESSURE TEST CHART A-7, PAGE 3 OF
3 FOR FUEL PRESSURE RELIEF PROCEDURE AND FOR SERVICING
QUICK-CONNECT FITTINGS.
USING A TECH 1, ENABLE THE FUEL PUMP."
SLOWLY CLOSE VALVE IN RETURN LINE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi). DO NOT EXCEED414 kPa (60 psi).
NO TROUBLE FOUND. IF NO ADDITIONAL

DTCs WERE STORED, REVIEW CIRCUIT
DESCRIPTION ON FACING PAGE.
REPLACE FILTER
OR
REPAIR FUEL LINE AND RECHECK.
PRESSUREBUTLESSTHAN
284 kPa (41 psi)
CHECK FOR:
LEAKING FUEL PUMP FEED HOSE.
FAUL TY FUEL PUMP.
INCORRECT FUEL PUMP.
11-16-92
MS 12893
6E3-A-108 5.7l (VIN P) DRIVEABIUTY AND EMISSIONS
PCM
TRANSMISSION RANGE
B+
- - - - - - - - - 1224PNK
B+
- - - - - - - - 1225 DK BLU
B+
...,.__ _ _ _ _ _ _ 1226RED
TRANSMISSION
1
I
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
~ CONNECTOR
. . , ' - - - - - - - 12.27 BLK(YEL
- - - - - - - - - 470 BLK
67-93
PS 18401
DTC58
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT LOW

The TFT sensor is a thermistor within the TR pressure switch assembly, that controls the signal voltage to
cold, the sensor resistance is high and the PCM will sense high signal voltage on terminal "D28".
the sensor resistance becomes less and the voltage decreases to approximately 1.5 to 2.0 volts. With a DTC 79
also set, check the transmission cooling system.
DTC 58 Will Set When: Signal voltage indicates TFT greater than 151C (306F) for at least 1 second.
Action Taken (PCM will default to): When DTC 58 is set, the trarismissiori will use a warm value for
operation, but the scan tool will display the actual fluid temperature. DTC 58 will be sfored in the PCM memory
DTC 58 Will Clear When: The fault condition(s) no longer exist.

DTC Chart Test Description:. Number(s) below
1. This test checks for a short to ground or a skewed
sensor.
2. This test checks for an internal fault within the
transmission by creating an open.

about 100C (212F) then stabilize.
SECTION 7Al4A may be used to test the transmission
the possibility of a "skewed" sensor. A "skewed"
enabled complaints.
DTC58
(TFT) SENSOR CIRCUIT LOW
{HIGH TEMPERATURE INDICATED)

BEEN PERFORMED?

TEMPERATURE OF 151C(306F)?
IGNITION"OFF."

SECTION 7 A 14A (4L60E) OR 7 A 17 A (4L80E) OF
DTC IS INTERMITTENT.

FAUL TY CONTROL MODULE OR
CONNECTIONS.
4-29-93
MS 13671
PCM
TRANSMISSION RANGE
B+
- - - - - - - - - 1224PNK
B+
- - - - - - - - 1225 DK BLU
B+
..., - - - - - - - - 1226RED
I
TRANSMISSION
:...__ CONNECTOR
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
I
1
1-T-------1227BLK/YEL
it+---------
sv
470 BLK
6-7-93
PS 18401
DTC59
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT HIGH
{LOW TEMPERATURE INDICATED)
5. 7L {VIN P) .. F.. CARLINE {SFI)

The TFT sensor is a thermistor within the fluid pressure switch assembly, that controls the signal voltage to
cold, the sensor resistance is high and the PCM will sense high signal voltage on terminal "028".
OTC 59 Will Set When: Signal voltage indicates TFT less than-40C (-40F), for 1 second.
Action Taken {PCM will default to): When DTC 59 is set, the transmission will use a warm value for
operation, but, the scan tool will display the actual fluid temperature.
When DTC is set, the TCC may not apply properly. DTC 59 will be stored in the PCM memory but will not
turn "ON" the Malfunction Indicator Lamp (MIL).
1. This test checks for a skewed sensor.
temperature), and the scan displays 151C (306F),
the PCM and wiring are OK.
3. This test checks ifCKT 1227 is open. There should
be 5 volts present at the sensor connector if
measured with J 39200.
Diagnostic Aids: Scan tool displays fluid

transmission temperature in degrees. After
transmission is operating, the temperature should rise
steadily to about 100C (212F) then stabilize.
A faulty connection or an open in CKT 455 or CKT
1227 can result in a DTC 59.
The "Temperature to Resistance Value" scale in
SECTION 7A14A may be used to check the TFT sensor
at various temperature levels to evaluate the
possibility of a "skewed" (mis-scaled) sensor. A
"skewed" sensor can result in firm shifts, or TCC
enabled.
DTC59
TRANSMISSION FLUID TEMPERATURE (TFT)
SENSOR CIRCUIT HIGH
1
5. 7L (VIN P) 'F" CARLINE (Sf I)

BEEN PERFORMED?
CHECKING PROCEDURE."
IGNITION "OFF."
DISCONNECT TRANSMISSION WIRING CONNECTOR.
INSTALLJ 39775 ON THE EXTERNAL WIRING CONNECTOR.
INSTALL TEST LIGHT BETWEEN TERMINALS "L" AND "M".
IGNITION "ON" SCAN TOOL SHOULD DISPLAY
TEMPERATURE OF 151C (306F).
IF NO ADDITIONAL DTC(s) WERE STORED,
JUMPER CKT 1227 TO KNOWN GOOD GROUND.

SCAN TOOL SHOULD DISPLAY TEMPERATURE
OF 151C(306F).

CHECK" SECTION 7A14A OR 7A17A IN
OPEN CKT 1227, FAULTY CONNECTION

AT CONTROL MODULE OR FAULTY
CONTROL MODULE.
OPEN SENSOR GROUND CIRCUIT OR

FAULTY CONNECTION.
4-26-93
MS 13451

#12 (U/H)
. - - - - - - 1 3 9 P N K ~ 3PNK __..TO IGNITION
, - - -......._..TO OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
139
PNK
HVAC
CONTROL
ASSEMBLY
F
762 DK GRN/WHT ~
I
I
230
I ~BI
1----~~~~~,,------------~459DKGRN/WHT
C100
59 DK GRN
CI
-+((--':---------7-----
DK GRN - - - - - - - - - - - 450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
TO OTHER
452 CIRCUITS
l-----.-=:---452 BLK
380 RED/BLK
416GRY
416GRY
- - - - - 7 3 2 DK BLU

{1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK
A/C REQUEST SIGNAL
'l'OOTHER
452.CIRCUITS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29,93
PS 16541
DTC61
11
The PCM monitors AJC refrigerant pressure and A/C evaporator temperature to determine if the AJC system
has adequate refrigerant (Rl34a) charge. The PCM will disable the AJC clutch whenever A/C refrigerant charge
drops below a predetermined value, to reduce the chance of compressor damage. The PCM will cycle the
compressor more frequently if the charge is only slightly low.
The PCM determines A/C charge based on A/C refrigerant pressure and A/C evaporator temperature. The
PCM uses these two inputs to calculate A/C reirigerant charge.
DTC 61 Will Set When: The PCM calculates refrigerant charge to be below a predetermined level.
Action Taken (PCM will default to): If the PCM determines A/C refrigerant charge to be low, the A/C
clutch will be disabled and DTC 61 will be set; DTC 61 will be stored in the PCM memory, but will not turn "ON"
the Malfunction Indicator Lamp (MIL).

I. DTC 61 could be caused by other DTCs, so refer to
those charts before proceeding with this diagnostic
chart.
2. If the A/C refrigerant pressure sensor is "slewed"
or "shifted" in value, the PCM could be detecting a
lower than normal pressure. Therefore, the PCM
would be sensing a low refrigerant change and
DTC 61 could result.
3. The conditions to set a DTC 67 could cause DTC 61
to set. DTC 67 will set if the PCM does not detect
an A/C refrigerant pressure change of more than 4
psi when the AJC clutch is cycled from "OFF" to
"ON."
4.
The A/C performance test (refer to SECTION lBl)

must be performed, because A/C system hardware
(A/C compressor, thermal expansion valve etc.)
could cause a OTC 61.
Diagnostic Aids: An A/C evaporator temperature

sensor and/or an A/C refrigerant pressure sensor that
is "slewed" (shifted in value) could cause a DTC 61.
DTC61
11
IF ANY PCM A/C DTCs ARE STORED REFER TO THOSE CHARTS FIRST.
AMBIENT TEMPERATURE GREATER THAN 16C {60F).
INSTALL A/C MANIFOLD GAGE SET {REFER TO SECTION 1B).
IS A/C REFRIGERANT PRESSURE {LOW SIDE) GREATER THAN 45 psi?
------------,
REFER TO SECTION 181 I
: FOR FURTHERA/C
:
I SYSTEM DIAGNOSIS.
I
USING A TECH 1, COMPARE A/C

REFRIGERANT PRESSURE TO TECH 1
A/C REFRIGERANT PRESSURE.
IS TECH 1 PRESSURE WITHIN 20 psi
OF HIGH SIDE PRESSURE?
G)
L--------------~
ENGINE IDLING, A/C "OFF" FOR 10

SECONDS.
TURN A/C "ON" FOR 10 SECONDS.
DOES DTC 67 SET?
DIDA/C
COMPRESSOR
CLUTCH
ENGAGE?
r-
'-----------~
IGNITION "OFF."
JUMPER PRESSURE SENSOR CONNECTOR TERMINALS "B" AND "C".
IGNITION "ON."
DOES TECH 1 INDICATE PRESSURE SENSOR VOLTAGE ABOVE 4.8 VOLTS?
USING DVM MEASURE VOLTAGE

FROM PRESSURE SENSOR
CONNECTOR "B" TO GROUND.
DOES DVM MEASURE ABOUT 5
VOLTS?
---------,
REFER TO
I
: DIAGNOSTIC
:
I TROUBLE CODE
I
: {DTC) CHART 67. :
I
L-----------~
----------, G)f REFER TO SECTION

181 AND PERFORM
: REFER TO
:
I CHARTC-10FOR I
: A/C ELECTRICAL :
I DIAGNOSIS.
I
FAULTY PCMS
VOLT REFERENCE
: A/C PERFORMANCE : CONNECTION OR
I TEST.
I OPEN OR
L-------------.J GROUNDEDS
VOLT REFERENCE
CIRCUIT OR
FAULTY PCM.
1
FAULTY PCM
SIGNAL CIRCUIT
CONNECTION OR
OPEN OR
GROUNDED
PRESSURE SENSOR
SIGNAL WIRE OR
FAULTY PCM.
WITH A TEST LIGHT TO B +,

PROBE A/C REFRIGERANT
PRESSURE SENSOR
CONNECTOR TERMINAL "A".
IS TEST LIGHT "ON"?
OPEN
PRESSURE
SENSOR
GROUND
CIRCUIT.
FAULTY
SENSOR
CONNECTION
OR FAULTY
SENSOR.
6-4-93
NS 16296
PCM
(U/H)
o--------1667TAN---------t
H02SLOW
--------1666 PPL---------1
H02S HIGH
5-22-93
PS17937
DTC63
BANK 2 (RIGHT) HEATED OXYGEN SENSOR (H02S) CIRCUIT
(OPEN CIRCUIT)

The PCM supplies a voltage of about 450 m V between terminals "CS" and "C7''. (If measured with a 10
megohm digital voltmeter, this may read as low as 320 m V.) The oxygen sensor varies the voltage within a range
of about 1000 m V if the exhaust is rich, down through about 10 mV if exhaust is lean.
H02S heaters on CKT 541. Even with the engine not running, the H02S will reach operating temperature an~
DTC 63 Will Set When: Engine is at normal operating temperature (above 70C/158F), engine operating
more than 2 minutes, oxygen signal voltage steady between 350 mV to 550 mV, throttle position angle above 5%
and DTCs 21 and 22 not set. All conditions met for about 60 seconds.
1. This test checks the oxygen sensor's heating
element. The heating element resistance should
be 3.5 ohms at 20C (68F) or 14 ohms at 350C
(622F). An inoperative H02S heater could cause
a DTC 13 to set.
2. This will determine if the oxygen sensor is at fault,
or if the cause of the DTC 63 is elsewhere in the
circuit.
3. For this test use only a high impedance digital volt
ohmmeter (J 39200). This test checks the
continuity ofCKT 1666.
Diagnostic Aids: Normal Tech 1 voltage readings

vary between 10 mV to 1000 mV (.01 and 1.0 volt),
while in "Closed Loop." The system will go into "Open
Loop" operation when DTC 63 sets.
"6E3-B".
DTC63
BANK 2 (RIGHT) HEATED OXYGEN
(ABOVE 80C/176F).
DOES TECH 1 INDICATE "CLOSED LOOP"?
(OPEN CIRCUIT)
IGNITION "OFF."
DISCONNECT BANK 1 HEATED OXYGEN SENSOR (H02S) HARNESS
CONNECTOR.
CONNECT TEST LIGHT BETWEEN HARNESS TERMINALS "C" AND "D".
IGNITION "ON."
IS TEST LIGHT "ON"?
REFER TO "DIAGNOSTIC AIDS.
MEASURE RESISTANCE BETWEEN H02S

TERMINALS "C" AND "D".
IS RESISTANCE BETWEEN 3.5 OHMS AND 14 .OHMS?
JUMPERHARNESSCKT1666ANDCKT1667(PCM
SIDE) TO GROUND.
TECH 1 SHOULD DISPLAY H02S VOLTAGE BELOW
.2 VOLT (200 mV).
DOESIT?
REMOVE JUMPER.
CHECK VOLTAGE ON CKT 1666(PCM SIDE)AT H02S
HARNESS CONNECTOR USING A DVM.
VOLTAGE SHOULD BE OVER .3 VOLT(300 mV).
ISIT?
OPEN CKT 1667

OR
OR
FAULTY PCM.
FAULTY
HEATED
OXYGEN
SENSOR.
CONNECT TEST LIGHT TO HARNESS

IS TEST LIGHT "ON"?
FAULTY CONNECTION
OR
IGNITION FEED
CIRCUIT OPEN
OR
SHORTED.
FAULTY
CONNECTION
OR
FAUL TY GROUND .
FAULTY H02S CONNECTION

OR
FAULTY H02S.
OPEN CKT 1666

OR
OR
FAULTY PCM.
5-27-93
PS 17255

PCM
(U/H)
1--------1667 TAN---------1
H02SLOW
1-------~-1666 PPL--------1
H02S HIGH
. 5-22-93
PS17937
DTC64

The PCM supplies a voltage of about 450 mV between terminals "CS" and "C7''. (If measured with a 10
megohm digital voltmeter, this may read as low as 320 mV.) The Heated Oxygen Sens.or (H02S) varies the
voltage within a range of about 1000 m V if the exhaust is rich, down through about 10 m V if exhaust is lean.
OTC 64 Will Set When: System is operating in "Closed Loop," not in power enrichment, and signal voltage
remains below 200 m V for 50 seconds.
Number(s) below
1. Engine must be at normal operating temperature.

long term fuel trim values at different RPM and air
flow conditions. The Tech I also displays the fuel trim
cells so the long term fuel trim values can be checked
in each of the cells to determine when DTC 64 may
Jong term fuel trim values will be near 160.
Low system voltage can cause a DTC 64 to set. If
DTC 50 is set, proceed to that chart first.
Heated Oxygen Sensor (H02S) wire. Sensor
pigtail may be mispositioned and contacting the
exhaust manifold.
Check for intermittent ground in signal wire
between connector and sensor
contamination that could prevent reference
oxygen from reaching the H02S.
Lean injector(s). Perform "Injector Balance Test,"

using Tech I or CHART C-2A.
exhaust and can set a DTC 64.
speeds and/or loads to confirm. Refer to "Fuel
System Diagnosis," CHART A-7.
Exhaust leaks. If there is an exhaust leak, above
the oxygen sensor, the engine can cause outside air
to be pulled into the exhaust stream and flow past
the sensor causing lean condition. Vacuum or
Air system. Make sure the secondary air pump is
not operating in "Closed Loop." While monitoring
long term fuel trim, squeeze the air hose going to
the exhaust ports (right bank). If long term fu~l
trim values go down, refer to CHART C-6.
If the above are OK, the oxygen sensor may be at
fault.
DRIVEABIUTY AND EMISSIONS 5.7l (VIN P) 6E3-A-117
DTC64
.
G)
RUN WARM ENGINE (75C/167F TO 95C/203F)AT 1200 RPM.

DOES TECH 1 INDICATE BANK 2(RIGHT) H02S VOLTAGE FIXED BELOW .20 VOLT (200 mV)?
DISCONNECT H02S AND JUMPER CKT 1667

(PCM SIDE)TO GROUND.
.
TECH 1 SHOULD DISPLAY H02S VOLTAGE
BETWEEN .35 VOLT AND .55 VOLT (350 mV
AND5~0mV).
DOES IT?
OTC 6415 INTERMITTENT.

IF NO ADDITIONAL DTC(s) WE RE
STORED: REFER TO "DIAGNOSTIC

OR
FAULTY PCM.
6-5-93
95 7382-6E

PCM
-------1667TAN--------t
t---------1666 PPL---------1
H02SLOW
H02SHIGH
5-22-93
PS17937
DTC65

The PCM supplies a voltage of about 450 mV between terminals "CS" and ''C7". (If measured with a 10
megohm digital voltmeter, this may read as low as 320 mV.) The Heated Oxygen Sensor (H02S) varies the.
voltage within a range of about 1000 mV if the exhaust is rich down through about 10 mV if exhaust is lean.
indicate the oxygen content of the exhaust gas at the sensor. Typically the signal voltage wiil be near 450 m Vat
key-up. The signal voltage will thenrise or drop as the sensor becomes active, depending on the oxygen content of
OTC 65 Will Set When: System is operating in "Closed Loop," not in power enrichment, signal voltage
remaining above 700 m V for 50 seconds and throttle angle is greater than 4%.

1. Engine must be at normal operating temperature.
long term fuel trim values at different RPM and load
conditions. The Tech 1 also displays the fuel trim cells,
so the long term fuel trim values can be checked in
each of the cells to determine when the DTC 65 may
increase. However, if it gets too high, a OTC 65
CHARTA-7.
Rich injector. Perform "Injector Balance Test,"
Leaking injector. Refer to "Fuel System
Check for fuel contaminated oil.
Evaporative Emission (EVAP) canister purge.
Check for fuel saturation. If full of fuel, check
canister control and hoses. Refer to "Evaporative
Emission (EV AP) Control System," Section "6E3C3".
MAF sensor. Disconnect the MAF sensor and see

if rich condition is corrected. If so, check for proper
installation. If installation is correct, replace MAF
sensor. If the MAF sensor is installed backwards,
the system will go rich. The plastic portion of the
sensor has arrows cast into it indicating proper air
flow direction. The arrows must point toward the
engine.
for fuel.
TP sensor. An intermittent TP sensor output will
cause the system to go rich, due to a false
indication of the eqgine accelerating.
EGR. An EGR v~lve staying open (especially at
idle) will cause the oxygen sensor to indicate a rich
exhaust, and this could result in a OTC 65.
proper H02S operation.. This supply of oxygen is
DTC65
S.7L (VIN P) .. F" CARLINE (SFI)
G)
RUN WARM ENGINE (75C/167F TO 95C/203F)AT 1200 RPM.

DOES TECH 1 DISPLAY BANK 2 (RIGHT) H02S VOLTAGE FIXED ABOVE .70 VOLT (700 mV)?
DISCONNECT H02S AND JUMPER CKTs 1667

AN[) 1666 (PCM SIDE) TO GROUND.
TECH 1 SHOULD DISPLAY H02S VOLTAGE
BELOW .35 VOLT (350 mV).
DOESIT?

6-4-93
9S6746-6E
6E3-A-120 5.7L (VIN P) DRIVEABlllTYAND EMISSIONS

#12 (U/H)
. - - - - - - 1 3 9 PNK ~ 3PNK ~ TO IGNITION
,--------To OTHER CIRCUITS
A/C
RELAY
139
PNK
PCM
20 AMP
___,...
_ TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
F
762 DK GRN/WHT ~
I
B1
230
I I'
I
,__---..~~r-~,---------~459DKGRN/WHT
C100
59 DK GRN
450 BLK
-+((f---!:---------7------
l
-
BLK
A/CCLUTCH
STATUS
TOOTHER
452 CIRCUITS
l - - - - f - - - 4 5 2 BLK
A/C
REFRIGERANT
PRESSURE
SENSO.R
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
A/CCLUTCH
CONTROL
CI
DK GRN - - - - - - - - - - - ~
A/C
COMPRESSOR
A/C REQUEST SIGNAL
SENSOR GROUND
A/CREFRIGERANT PRESS.
SENSOR SIGNAL .
+ 5 VOLT REFERENCE
380 RED/BLK
416 GRY
416GRY
A/C
EVAPORATOR
EMPERATURE
SENSOR
- - - - - 7 3 2 DK BLU
86
(U/H) = LOCATED INUNDERHOOD ELECTRICAL CENTER

TO OTHER
452 CIRCUITS
A/CEVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29-93
PS 16541
DTC66
(OPEN OR SHORTED)
5.7L (VIN P)
11
F" CARLINE (SFI)
The NC system uses an NC refrigerant pressure sensor mounted in the high side of the AJC system to
monitor NC pressure for use by the PCM.
The PCM can use this information to turn "ON" the engine cooling fans when NC refrigerant pressure is
high. The PCM can prevent compressor damage by disabling the compressor clutch if head pressure gets too
high.
The NC refrigerant pressure sensor operates much like other 3-wire sensors. A 5 volt reference is supplied to
the sensor and returned to the PCM on the signal line. As the NC refrigerant pressure increases or decreases,
the resistance of the sensor changes and varies the amount of signal returning to the PCM. The amount of signal
returned to the PCM is then converted to a pressure value which can be displayed on the Tech 1.
DTC 66 Will Set When: NC refrigerant pressure sensor indicates NC refrigerant pressure is below -8 psi (.12
volt) for 10 seconds or NC refrigerant pressure sensor indicates NC refrigerant pressure is above 448 psi (4.86
volts) for 10 seconds.
Action Taken (PCM will default to): OTC 66 will be stored in the PCM memory but will not turn "ON" the
Malfunction Indicator Lamp (MIL), NC operation will be disabled.

1. Normal voltage is between .1 and 1.8 volt.
2. Checks to see if the high voltage signal is from a
shorted sensor or a short to voltage in the circuit.
Normally, disconnecting the sensor would make a
normal circuit go to near zero volt.
3. Checks to see if low voltage signal is from the
sensor or the circuit. Jumpering the sensor signal
CKT 380 to 5 volts checks the circuit, com:iecti9ns
and PCM.
4. This step checks to see if the low voltage signal

was due to an open in the sensor circuit or the 5
volts reference circuit since the prior step
eliminated the pressure sensor.
Diagnostic Aids: OTC 66 sets when signal voltage

falls outside the normal range of the sensor and is not
due to a refrigerant system problem. If problem is
intermittent, check for opens or shorts in the harness,
or pQor connections.
'
DRIVEABILITY AND EMISSIONS 5.7l {VIN P) 6E3-A-121
DTC66
{OPEN OR SHORTED)
KEY "ON," ENGINE NOT RUNNING.
USING TECH 1, SCAN VOLTAGE

FOR A/C REFRIGERANT PRESSURE.
BELOW .1 VOLT

PRESSURE SENSOR.
DOES.TECH 1 SCAN DISPLAY
LESS THAN 1 VOLT?
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL CIRCUIT SHORTED
TO VOLTAGE
OR
FAULTY PCM.
FAULTY A/C
REFRIGERANT
PRESSURE SENSOR
CONNECTION
OR
OPENA/C
REFRIGERANT
PRESSURE SENSOR
GROUNDCKT
OR
FAULTY SENSOR.
G)

PRESSURE SENSOR CONNECTOR.
. JUMPER TERMINALS "B" AND "C".
DOES JECH 1 DISPLAY ABOVE 4.6
VOLTS?
BETWEEN .1 VOLTS
AND 1.8 VOL TS
DTC661S
INTERMITTENT. SEE
"DIAGNOSTIC AIDS"
OF FACING PAGE.
REMOVE JUMPER.
CONNECT VOLTMETER FROM
TERMINAL "A'' TO "B".
IS VOLTAGE ABOUTS VOLTS?
FAULTY A/C
REFRIGERANT
PRESSURE SENSOR
CONNECTION
OR
FAULTY SENSOR.
WITH TEST LIGHT TO B +,

PROBE SENSOR HARNESS
CONNECTOR TERMINAL" A".
IS LIGHT "ON"?
FAUL TY 380 CKT PCM

CONNECTION
OR
OPEN OR GROUNDED
CKT380
OR
FAULTY PCM.
OPEN A/C REFRIGERANT

PRESSURE SENSOR GROUND
CIRCUIT.
5-27-93
9S 5595-6E

#12 (U/H)
. - - - - - - 1 3 9 P N K ~ 3PNK ___. TO IGNITION
r - - -......._.To
OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
139
PNK
HVAC
CONTROL
ASSEMBLY
F
762 DK GRN/WHT ~
I
I
230
I ~BI
,__----,-~~1:--~,---------~459DKGRN/WHT
C100
59 DK GRN
CI
-f<(1:---!:---------7-....---
DK GRN - - - - - - - - - - - ~
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLJ<
A/C
EVAPORATOR
EIIIIPERATURE
SENSOR
A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
TO OTHER
452 CIRCUITS
t - - - - f - - 4 5 2 BLK
380 RED/BLK
416 GRY
416GRY
11------732 DK BLU

A/C REQUEST SIGNAL
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER
452 CIRCUITS
6-29-93
PS 16541
DTC67
A/C REFRIGERANTPRESSURE SENSOR CIRCUIT
(PRESSURE SENSOR OR A/C CLUTCH CIRCUIT PROBLEM)
The PCM can determine if the A/C compressor clutch is engaged or not engaged through the A/C clutch status
line. If the PCM has grounded the A/C relay, current can flow through the A/C relay to the A/C compressor clutch
and back to the PCM on the A/C status circuit.
When voltage is present at the PCM A/C clutch status terminal, A/C status "ON" will be displayed on the
Tech 1. As the PCM detects that the A/C clutch has cycled "OFF," the PCM will record A/C refrigerant pressure
from the A/C refrigerant pressure sensor. If the A/C refrigerant pressure does not increase more than 4 psi when
the A/C clutch is turned back "ON," a DTC 67 will set. This condition can occur if the A/C refrigerant pressure
sensor is fixed at one value.
OTC 67 Will Set When: The PCM does not detect an A/C refrigerant pressure change of more than 4 psi when
the NC clutch has been cycled "OFF" for 10 seconds, then "ON" for 10 seconds.
Action Taken {PCM will default to): DTC 67 will be stored in the PCM memory but will not turn "ON" the
Malfunction Indicator Lamp (MIL), A/C operation will be disabled.

1. If the A/C compressor clutch is disconnected or if
CKT 59 is open: between the splice and the clutch,
the A/C compressor clutch will not engage, but the
PCM will detect voltage on the A/C status line
which will indicate the clutch is "ON." If the A/C
controls are cycled from "OFF" to "ON" at this
point, a DTC 67 will set since the clutch did not
engage and therefore no pressure change was
detected.
2. If the relay power feed CKT 139 is intermittent,
the A/C clutch status terminal may not detect
voltage when A/C is commanded "ON."
3.
Visually check A/C compressor electrical harness

for problems that may prevent it from engaging.
4. If the A/C clutch status line becomes
intermittently open or shorted while the
compressor is "ON," the PCM will be wrongly
detecting the A/C clutch going "ON" and "OFF."
When the PCM falsely detects the clutch cycling
from "ON" to "OFF" and the clutch is remaining
"ON," a DTC 67 will set since no refrigerant
pressure change was detected.
Diagnostic Aids:
Inspect the harness and all

related connectors including the PCM connections.
DRIVEAB.ILITY AND EMISSIONS 5.7L (VIN P} 6E3-A-123
DTC67
(PRESSURE SENSOR OR A/C CLUTCH CIRCUIT PROBLEM}
5.7L (VIN P)
11
11
F CARLINE (SFI)
IF DTC(s} 66, 69 OR 70 ARE PRESENT

USE THOSE CHARTS FIRST.
CLEAR DTC(s}.
START ENGINE.
TURN A/C "ON."
DID CLUTCH ENGAGE?
USING TECH 1, OBSERVE A/C REFRIGERANT PRESSURE. A/C

CLUTCH "OFF" FOR 10 SECONDS, THEN "ON" FOR 10
SECONDS.
DID A/C REFRIGERANT PRESSURE INCREASE MORE THAN 5 psi
WHEN A/C CONTROLS WERE TURNED "ON"?
IGNITION "OFF."
DISCONNECT A/C
COMPRESSOR CLUTCH
CONNECTOR.
BETWEEN A/C CLUTCH
HARNESS CONNECTOR
TERMINALS.
START ENGINE.
A/C"ON."
IS TEST LIGHT "ON"?
INTERMITTENT
A/CCLUTCH
CIRCUIT FROM
A/CRELAYTO
SPLICE. SEE
FACING PAGE.
PROBE BATTERY FEED TO

A/C CLUTCH COIL WITH A
IS TEST LIGHT "ON"?
FAUL TV A/C CLUTCH CONNECTION

OR
OPEN A/C CLUTCH COIL.
FAULTY SENSOR CONNECTION

OR
FAULTY SENSOR.
SEE "DIAGNOSTIC AIDS"
ON FACING PAGE.
OPEN OR SHORTED A/C

CLUTCH CIRCUIT FROM
CLUTCH TO SPLICE.
6-7-93
PS 17337
6E3-A-124 5;7L (VIN P) DRIVEABILITY AND EMISSIONS

#12 (U/H)
. . - - - - - - 1 3 9 P N K ~ 3PNK - T O IGNITION
- - - - - - - T O OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
----;~ TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
139
PNK
C100
I
I
BI
~
I
CI
C
F
762 DK GRN/WHT ~
230
A -----
450BLKl
A/C
COMPRESSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
TO OTHER
452 CIRCUITS
l-----e<=---452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
_
-
1 - - - - - - 380 RED/BLK
1------.,---415 GRY
416GRY
A/C
EVAPORATOR
TEMPERATURE
SENSOR
1 - - - - - - 7 3 2 OK BLU
452 BLK - - - - - - - .
(U/H) = LOCA TEO IN UNOERHOOD ELECTRICAL CENTER

(1/P) = LOCATED IN INSTRUMENT PANEL fUSE BLOCK
A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
5 9 D K G R N - f < ( - - ~ : - - - - - - - - ~.. -- - ~
DKGRN~------~--~~
A/C REQUEST SIGNAL
TO OTHER
452 CIRCUITS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29-93
PS 16541
DTC68
A/C RELAY CIRCUIT
(SHORTED CIRCUIT)
5.7L {VIN P)
11
11
F CARLINE {SFI}
When the PCM detects that A/Chas been requested, the PCM will activate the AJC clutch relay. When the
relay is activated, voltage should be present at both the A/C compressor clutch and the A/C clutch status terminal
at the PCM.
If the PCM detects voltage on the A/C clutch status terminal when the AJC has not been requested a DTC 68
will set.
A short to voltage at any point in CKT 59, a grounded relay control circuit or stuck A/C relay contacts can set
a OTC 68.
DTC 68 Will Set When: Voltage is detected on the NC status line for more than 25 seconds after the PCM has
disengaged the A/C relay.
DTC Chart Test Description: Number(sl below

1. A/C must be "OFF" while performing test.
2. This will isolate the ignition feed portion of the
circuit from the clutch circuit.
3. If DTC 68 reappears at this step the PCM is
internally shorted to voltage.

related connectors including the PCM connectors.
DTC68
A/C RELAY CIRCUIT
(SHORTED CIRCUIT)
G)
IGNITION "OFF."
A/C "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH.
IGNITION "ON."
PROBE CKT 59 WITH TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
G)
DISCONNECTA/CRELAY.
IS TEST LIGHT "ON"?
FAUL TY A/C RELAY

OR
CKT 459 SHORTED TO
GROUND
OR
FAULTY PCM.
IGNITION "OFF."
DISCONNECT A/C RELAY.
IGNITION "ON."
CLEAR DTC(s).
START ENGINE AND RUN FOR 30
SECONDS.
DOES DTC 68 REAPPEAR?
FAULTY PCM.
2-4-93
95 5514-6E

#12 (U/H)
- - - - - 1 3 9 P N K ~ 3 P N K ~TOIGNITION
.-------TO OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
HVAC
CONTROL
ASSEMBLY
139
PNK
C100
I
I
KB I
CI
A/C REQUEST SIGNAL
I
I
A/CCLUTCH
CONTROL
59DKGRN--t((E--~:---~~-~-------1.--
~59DKGRN
~450BLKl
A/C
COMPRESSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
TO OTHER
452 CIRCUITS
452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/CCLUTCH
STATUS
380 RED/BLK
416GRY
416GRY
732 DKBLU
452 BLK

SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER
452 CIRCUITS
6-29-93
PS 16541
DTC69
A/C CLUTCH CIRCUIT
When the PCM detects that A/Chas been requested, the PCM will activate the A/C clutch relay. When the
relay has been activated, voltage should be present at both the AJC compressor clutch and the A/C clutch status
line terminal of the PCM.
An open or short to ground at any point in CKT 59 will cause DTC 69 to set.
OTC 69 Will Set When: The PCM has commanded A/C "ON" and no voltage is detected on the A/C status line
for more than 25 seconds.
Action Taken {PCM will default to): DTC 69 will be stored in the PCM memory but will not turn "ON" the

1. A problem that may prevent the compressor from
engaging may or may not cause DTC 69 to set.
2. Tech 1 will enable clutch circuit for 5 seconds.
3. If the A/C clutch operates properly and the Tech 1
shows A/C clutch status "OFF," then an open
exists between the PCM and the splice to the
compressor.

DTC69
G)
A/C CLUTCH CIRCUIT

CLEAR DTC(s).
START ENGINE.
CYCLE A/C CLUTCH CONTROLS TO "ON"
AND "OFF" WITHIN 20 SECONDS.
DOES A/C CLUTCH OPERATE PROPERLY?
IGNITION "OFF."
DISCONNECT A/C CLUTCH RELAY.
IGNITION "ON."
PROBE RELAY HARNESS TERMINALS
"81" AND "82" WITH A TEST LIGHT TO
.GROUND.
G)
DID SCAN TOOL INDICATE A/CCLUTCH STATUS "ON"?

OR
OPEN CKT 59 FROM SPLICE TO PCM
OR
FAULTY PCM.
DTC69
IS INTERMITTENT.
LIGHT "OFF" ONE OR BOTH
G)
USING TECH 1 "MISC TEST," ACTIVATE

THE A/CCLUTCH RELAY.
PROBE RELAY HARNESS TERMINAL "BS"
WITH TEST LIGHT TO B + .
OPEN IN CKT 139 THAT DID NOT LIGHT.
JUMPER RELAY HARNESS TERMINALS

"B2"TO"B4".
DOES A/C CLUTCH ENGAGE?
OPEN A/C CLUTCH RELAY

CONTROL CIRCUIT
OR
OR
FAULTY PCM.
FAULTY A/C CLUTCH RELAY CONNECTION

OR
FAUL TY A/C CLUTCH RELAY.
OPEN IN CKT 59 FROM RELAY TO SPLICE.
6-29-93
PS 17938

#12 (U/H)
~ - - - - 1 3 9 P N K ~ 3 P N K -TOIGNITION
, - - - - - - - T o OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
139
PNK
HVAC
CONTROL
ASSEMBLY
762 DK GRN/WHT ~
I
I
230
I ~BI
........~~--.-~~~~1.---~----~-~~459DKGRN/WHT
C100
59DKGRN
CI
--t<(F--~:~~-~~~~-~--11,--~
~59DKGRN
~450BLKl
COMPRESSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
TO OTHER
452 CIRCUITS
380 RED/BLK
416GRY
416GRY
732 DKBLU
452 BLK

(VP) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK
A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C
A/C REQUEST SIGNAL
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER
452 CIRCUITS
6-29-93
PS 16541
DTC70
A/C CLUTCH RELAY DRIVER CIRCUIT
Ignition voltage is supplied directly to the A/C clutch relay coil on CKT 139. The Powertrain Control Module
(PCM) controls the relay by providing the ground path through CKT 459.
When the PCM is commanding a component "ON," the voltage of the control circuit should be "low" (near O
volts). When the PCM is commanding the control circuit to a component "OFF," the voltage potential of the
If the fault detection circuit senses a voltage other than what is expected, the fault line status will change and the'
OTC will set.
DTC 70 Will Set When: The PCM detects the wrong voltage potential for 26 seconds on CKT 459.

1. The Tech 1 will enable the circuit for 5 seconds.
current flow is detected a circuit check will be
to "O") when warm.

coil terminals ("B2" and "B5") to avoid improper
diagnosis.

DRIVEABILITY AND EMISSIONS .5.7L (VIN P) 6E3-A-129
DTC70
A/C CLUTCH RELAY DRIVER CIRCUIT

A/CCLUTCH RELAY.
DOES THE A/C CLUTCH RELAY OPERATE?
KEY"OFF."
KEY oN.
USING DVMJ 39200 ON 10 AMP SCALE,
MEASU~E CURRENT FROM HARNESS
TERMINAL, "08" TO GROUND FOR 2 MINUTES.
CURRENT.DRAW SHOULD MEASURE LESS THAN
DOESIT?

IGP4ITION "OFF."
DISCONNECT THE A/C CLUTCH RELAY
CONNECTOR.
CONNECT TEST LIGHT BETWEEN THE REL~ Y COIL
IGNITION "ON."
ISIT?
USING TECH 1 "MISC

TEST" ACTIVATE THE
.A/C CLUTCl-t RELAY.
LIGHT SHOULD BE
"ON."
ISIT?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF RELAY
CONNECTOR TO
GROUND.
LIGHT SHOULD BE
"ON."
ISIT?
DISCONNECT PCM
CONNECTOR "D:"
IS LIGHT OFF?
FAUL TY RELAY
CONNECTION
OR
FAUL TY RELAY.
OPEN
RELAY
IGNITION
FEED
CIRCUIT.

ISIT?

OR
OR
FAULTY PCM.
RELAY CONTROL
CIRCUIT SHORTED
TOB+.
6-29-93
PS 16538
6E3:-A-130 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

#12 (U/H)
~ - - - - 1 3 9 P N K ~ 3PNK __..TOIGNITION
. - - - - - - '...TO OTHER CIRCUITS
PCM
20 AMP
A/C
RELAY
139
PNK
HVAC
CONTROL
ASSEMBLY
762 DK GRN/WHT ~
I
B1
230
I~
,I
,__----r~~lk--~1r------------459DKGRN/WHT
C100
59 DK GRN
CI
~(--':------------1--
~59DKGRN
~450BLKl
A/C
COMPRESSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
TO OTHER
452 CIRCUITS
380 RED/BLK
416GRY
416GRY
732 DKBLU
452 BLK

(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK .
A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C REQUEST SIGNAL
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/CEVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER
452 CIRCUITS
6-29-93
PS 16541
DTC71
A/C EVAPORATORTEMPERATURE SENSOR CIRCUIT
(OPEN OR SHORTED)

The A/C system uses an A/C evaporator temperature sensor mounted in the A/C evaporator core to monitor
AJC temperature for use by the PCM. The PCM uses this information to cycle the A/C compressor clutch "ON"
and "OFF," so optimum cooling is attained. The A/C evaporator temperature sensor will also prevent A/C
evaporator core freeze up. The PCM will disable the A/C compressor clutch whenever A/C evaporator
temperature is below 2C (36F).
The A/C evaporator temperature sensor contains a two wire probe (thermistor) that is positioned in the center
of the evaporator core. The two wire probe is part gf the A/C evaporator temperature sensor interface module.
The interface module works in conjunction with the PCM to determine A/C evaporator temperature.
OTC 71 Will Set When: A/C is requested, the PCM detects an open, short to ground, or a short to voltage in
the A/C evaporator temperature circuits, and all conditions met for 3 seconds.
Action Taken (PCM will default to): OTC 71 will be stored in the PCM memory but will not turn on the

1. A/C evaporator temperature should be between
these values.
2. With the A/C evaporator temperature sensor
harness disconnected, normal voltage on CKT 732
is near 5 volts. If a short to voltage is suspected,
reconnect sensor harness and backprobe terminal
"B?' of sensor harness using a DVM. If 5 volts or
more is indicated, then CKT 732 is shorted
voltage.
Diagnostic Aids: The A/C evaporator temperature

sensor and harness is located under the passenger side
instrument panel.
If A/C evaporator temperature sensor needs to be
replace, refer to SECTION lB.
DTC 71
(OPEN OR SHORTED)

USING A TECH 1, MONITOR A/C EVAPORATOR TEMPERATURE.
IS A/C EVA PORA TOR TEMPERATURE -7C (19F) OR 32C (90F).
DTC71
INTERMITTENT.
DISCONNECT A/C EVAPORATOR TEMPERATURE SENSOR.

PROBE TERMINAL "C" OF A/C EVAPORATOR TEMPERATURE
SENSOR HARNESS WITH A TEST LIGHT TO B +.
RECONNECT SENSOR HARNESS.

BACK PROBE TERMINAL "B" OF
A/CEVAPORATOR
TEMPERATURE SENSOR
HARNESS WITH A OVM TO
GROUND.
IS 5 VOL TS OR MORE
INDICATED?
DISCONNECT A/C EVAPORATOR

TEMPERATURE SENSOR.
DOES TECH 1 DISPLAY A/C
OF 32C (90F).
IGNITION "OFF."
DISCONNECT PCM
CONNECTOR "D".
PROBE TERMINAL "B" OF
A/C EVAPORATOR
TEMPERATURE SENSOR
HARNESS WITH A TEST
LIGHTTOB+.
DOES TEST LIGHT
ILLUMINATE?
FAULTY A/C
EVAPORATOR
TEMPERATURE
SENSOR.
DISCONNECT A/C
SENSOR.
MEASURE VOLTAGE AT
TERMINAL "B" OF A/C
SENSOR HARNESS.
IS VOLTAGE ABOUT 5 VOLTS?
FAUL TY A/C EVAPORATOR

TEMPERATURE SENSOR
CONNECTION
OR
FAULTY A/C EVAPORATOR
TEMPERATURE SENSOR.
CKT7320PEN
OR
FAULTY PCM
CONNECTION
OR
FAULTY PCM.
6-26-93
PS 16542
PCM
IM ~ ffi----:: :;~
SVOLT
REFERENCE
VSSGROUND

CRUISE CONTROL
MODULE
INSTRUMENT
PANEL
K
(220
VSSOUTPUT
78-93
PS16656
DTC72
VEHICLE SPEED SENSOR LOSS
(AUTOMATIC TRANSMISSION ONLY)
5.7L {VIN P)
11
F" CARLINE (SFI)
The speed sensor circuit consists of a magnetic induction type sensor and wiring. Gear teeth pressed on the
output shaft induce an alternating current in the sensor.
The PCM compensates for various axle ratios and converts the signal into a square wave for use by the
speedometer, cruise control, antilock brakes, and TC system.
DTC 72 Will Set When: Not in PIN, transmission output speed changes greater than 1000 RPM, or in PIN,
transmission output speed change greater than 2048 RPM. No DTC 28, and engine speed greater than 200 RPM.
All conditions met for 2 seconds.
Action Taken (PCM will default to): A delayed (soft) landing to third gear. OTC 72 will be stored in the
PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
DTC 72 Will Clear When: The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" then
"ON."

1. The TC system must be disabled when performing
this step. Whenever the ignition key is cycled to
the "OFF" position and then cycled back "ON," the
TC system will default "ON."
2. An intermittent connection at the VSS or PCM
may cause a OTC 72 to set. Inspect the harness
and all related connectors. Check for damaged or
pushed out terminals.
3. Be sure harness is routed away from hot exhaust
components.
Diagnostic Aids:
OTC 24 will set when no vehicle speed is

detected at start off.
OTC 72 will set when vehicle speed has been
detected and is lost.
DTC72
VEHICLE SPEED SENSOR LOSS
(AUTOMATIC TRANSMISSION ONLY)
IGNITION "OFF."
RAISE DRIVE WHEELS.
STARTENGINE.
DISABLE "TC" SYSTEM.
WITH ENGINE IDLING IN GEAR, TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOESIT?.
IGNITION "OFF."
. DISCONNECT vss HARNE'ss CONNECTOR AT TRANSMISSION.
CONNECT SIGNAL GENERATOR TESTER J 33431-B TO VSS HARNESS
CONNECTOR
. IGNITION "ON," TESTER "ON" AND SET TO GENERATE A VSS SIGNAL.
THE TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE O.
DOESIT?
G)
DTC IS INTERMITTENT. IF NO
FACING.PAGE.
CHECK CALIBRATION I.D. FOR MOST

CURRENTAND/OR INCORRECT SOFTWARE.
CKT4000R401 OPEN,
SHORTED TO GROUND,
SHORTED TOGETHER,
OR
FAULTY PCM.
7-12-93
PS 16652
6E3-A-134 S.7L (VIN P) DRIVEABILITY AND EMISSIONS
TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
PCM
1 - + - - - - - - - - - 1 2 2 9 LT BLU/WHT
PRESSURE CONTROL
SOLENOID LOW
. . . , . . _ - - - - - - - - - 1 2 2 8 RED/BLK
PRESSURE CONTROL
SOLENOID HIGH
PRESSURE CONTROL
SOLENOID (PCS)
21-93
PS16708
DTC73
(CURRENT ERROR)

The pressure control solenoid is a PCM controlled device used to regulate transmission line pressure. The
PCM compares TP voltage, engine RPM and other inputs to determine the appropriate line pressure for a given
load. The PCM will regulate the pressure by applying a varying amperage to the pressure control solenoid. The
applied amperage can vary from 0.1 to 1.1 amp. The PCM then monitors the amperage at the return line.
DTC 73 Will Set When: The return amperage varies greater than 0.16 amp from the commanded amperage
for at least one second, and no OTC 75 stored.
Action Taken (PCM will default to): Full line pressure will be applied causing harsh shifts. OTC 73 will
be stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
"ON."

refer to circled number{s) o'n the diagnostic chart.
1. This test checks the ability of the PCM to
command the pressure control solenoid.
2. This test checks for voltage at PCM.
Diagnostic Aids: Check for poor connections at

PCM and at transmission connector.
DRIVEABILITY AND EMISSIONS 5.7l (VIN P) 6E3-A-135
DTC73
(CURRENT ERROR)
5.7L (VIN P)
11
F" CARLINE (SFI)
INSTALL TECH 1.
ENTER MISC TESTS/TRANSMISSION/PCS CONTROL.
USING TECH 1, APPLY 1.0 AMPS THRU 0.1 AMPS WHILE OBSERVING
DESIRED PCS AND ACTUAL PCS.
IS ACTUAL PCS READING ALWA VS WITHIN 0.16 AMPS OF DESIRED PCS?
IGNITION "OFF."
INSTALLJ 39775JUMPER HARNESS/PROBE KIT ON THE
TRANSMISSION EXTERNAL WIRING HARNESS CONNECTOR.
JUMPERJ 39775 CAVITIES "M" AND "R".
USING J 39200 DVM ON 10 AMP SCALE, CONNECT (IN
SERIES) TO CAVITIES "C" AND "D."
USING TECH 1, APPLY 1.0 AMPS THRU 0.1 AMPS WHILE
OBSERVING DESIRED PCS AND J 39200 DVM READING.
IS DESIRED PCS ALWAYS WITHIN 0.16 AMPS OF J 39200
DVM READING?
PROBLEM IS INTERMITTENT REFER TO "DIAGNOSTIC AIDS."
IGNITION "OFF."
CK TRANS WIRING CONNECTOR TERMINAL TENSION ON
THE PCS CIRCUITS. IF OK, REFER TO SECTION 7A14A
(4L60E) OR 7A17A (4L80E)" INTERNAL WIRING HARNESS
CHECK" FOR INTERNAL PCS CIRCUIT DIAGNOSIS.
VERIFY CKTs 1228 AND 1229 ARE NOT OPEN OR

SHORTED. ALSO VERIFY TERMINAL TENSION ON THESE
CIRCUITS AT THE PCM CONNECTOR. IF OK, REPLACE PCM.
4-26-93
PS 16751
SEE 8i.JA-47C201
r,
39PNK
LEJ5217
#11 (U/P)
.,__
10AMP
TO EB/TCM
SE-teE
8A-82
39
PNK
39PNK
5201
.
.
39 PNK
_... TOIGN
___ .....
"TRACTION
ENGAGED"
C200
1656
1656
LTGRN- 83 -LTGRN
5211
r: :,
L :.J
PCM
1656
LTGRN
INSTRUMENT
CLUS
C2~ E
- R
- -, C2
A
1656 LT GRN
P102
- - _..,.:..J
I
CRUISE CONTROL RELEASE SWITCH
86 BRN
(PART OF TCC/CRUISE
CRUISE CONTROL I
CONTROL RELEASE SWITCH)
MODULE :.-.i
TERMINAL "D"
e--f'e1.
B+
TRACTION
CONTROL
SYSTEM
ACTIVE SIGNAL
7-8-93
PS18170
(U/H) = UNDERHOOD ELECTRICAL CENTER
DTC74
TRACTION CONTROL SYSTEM (TCS) CIRCUIT LOW
The PCM receives an input signal f'rom the traction control system to indicate when a traction control event is
occurring. The B + signal during normal operation is pulled to zero volts during the traction control event. The
PCM will inhibit upshifts, downshifts and TCC operation during a traction control event.
Transmission range in park or neutral.

TCS/ASR active signal input at zero volts.
All condition(s) met for longer than 2 seconds.
Action Taken (PCM will default to):

Inhibit 4th gear if in hot mode.
OTC 74 Will Clear When: Fault conditions no longer exist; and the ignition switch is cycled "OFF" then
"ON."

1. If fault conditions are present, the scan tool will
display "YES." A short to ground in an external
component or wiring could be the cause.
Diagnostic Aids: If this OTC sets intermittently,

wiggle wire harness and connectors while observing
scan display. If scan display changes from "NO" to
"YES" then wiring is faulty.
Use shapshot mode to trigger on this OTC, then
review data when DTC set to identify code setting
conditions.
Refer to SECTION BA for electrical circuit wiring.

1
DTC74
TRACTION CONTROL SYSTEM (TCS) CIRCUIT LOW
11
11
5.7L (VIN P) F CARLINE (SFI)
INSTALL SCAN TOOL.

IGNITION "ON" ENGINE "OFF."
OBSERVE "TCS/ASR ACTIVE" ON SCAN TOOL
DISPLAY.
IS "YES" DISPLAYED INDICATING THE CIRCUIT
IS LOW (ZERO VOLTS)?
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C" (CLEAR).
IGNITION "ON."
IS "YES" STILL DISPLAYED ON SCAN TOOL?
EXTERNAL TRACTION CONTROL SYSTEM

ACTIVE CIRCUIT IS SHORTED TO GROUND.
REFER TO ABS/TCS DIAGNOSTIC SYSTEM
CHECK IN SECTION 5E2.
ELECTRICAL SYSTEM CHECKS OKAY AT

THIS TIME. REFER TO DIAGNOSTIC AIDS.
5-26-93
PS 18171
TO OTHER CIRCUITS
PCM
#15 (U/H)
TO ...... - - - - - - - 1 f A . , - - - - - - - 5 3 9 p N K - - . . . - - - 5 3 9 P N K
IGNITION
10 AMP
539 PNK
PCM IGNITION FEED

PCM IGNITION FEED
3-26-93
PS 17226
DTC75
CKT 539 is the ignition feed for the PCM.
DTC 75 Will Set When: The ignition is "ON" and PCM terminals "B30" and "D3" voltage is less than the
graduated scale of: -40C (-40F) = 7.3 volts, 90C (194F) = 10.3 volts, or 150C (304F) = 11.7 volts, with engine
speed greater than 1000 RPM for 4 seconds.
Action Taken (PCM will default to): During the time the failure is present, the pressure control solenoid is
turned "OFF" (maximum line pressure), there is a soft landing to third gear, and TCC operation is inhibited.
(The setting of additional diagnostic trouble codes may result.) DTC 75 will be stored in the PCM memory but
will not turn "ON" the Malfunction Indicator Lamp (MIL).
DTC 7 5 Will Clear When: The fault condition(s) no longer exist.
1. This test checks for normal battery voltage
between 9-15 volts.
2. This test checks if the low voltage display is due to
the generator, B+ voltage supply CKT(s), or PCM.
If the voltage is less than 9 volts, the PCM is OK.
Diagnostic Aids: If diagnostic trouble code sets

when an accessory is operated, check for poor
connections or excessive current draw. Refer to
SECTION SA of appropriate service manual for circuit
details. Also, check for poor connections at starter
solenoid or fusible link.
DTC75
5.7L (VIN P) .. F" CARLINE (SFI}
G)
ENGINE OPERATING GREATER THAN 800 RPM.

NOTE BATTERY VOLTAGE ON SCAN TOOL.
IS SYSTEM VOLTAGE LESS THAN 9 VOLTS?
CHECK BATTERY VOLTAGE AT BATTERY.

IS BATTERY VOLTAGE GREATER THAN 9. VOLTS7

"DIAGNOSTIC AIDS." .
IGNITION "OFF."
IGNITION "ON."
W!TH J 39200, PROBE B + VOLTAGE INPUT TERMINALS.
IS VOLTAGE INPUT LESS THAN 9 VOLTS?
REFER TO SECTION 603 FOR

CHARGING SYSTEM DIAGNOSIS.
FAULTY CONTROL MODULE CONNECTOR

OR
FAULTY CONTROL MODULE.
5-7-93
PS 17066
6E3-A-140 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS
PCM
PRIMARY (OR #1)
COOLING FAN
RELAY CONTROL
J
--------c~~K-~---335DKGRN
C100
1 - - - - - 409 LT BLU -
TO COOLING FAN
1------402 RED _..TO FUSELINK

(U/H)
#6(U/H)
- - - - 5 4 1 BRN - - - - - - ~ - - TO IGNITION
10AMP
TO OTHER
CIRCUITS
FOR DETAILED FAN CIRCUIT DIAGRAMS REFER TO

PCM WIRING DIAGRAMS AT THE FRONT OF THIS SECTION.
6-26-93
PS 18464
ore 11
COOLING FAN RELAY CONTROL CIRCUiT
Ignition voltage is supplied directly to the primary (or #1) cooling fan relay coil on CKT 541. The Powertrain
Control Module (PCM) controls the relay by providing the ground path through CKT 335.
When the PCM is commanding a component "ON," the voltage of the control circuit should. be "low" (near O
volts). When the PCM is commanding the control circuit to a component "OFF," the voltage poterttial of the
If the fault detection circuit senses a voltage other than what is expected, the fault line status will change and
the DTC will set.

1. The Tech 1 will enable the circuit for 4 minutes.
to "O'') when warm.


coil terminals ("02" and "D5") to avoid improper
diagnosis.

DTC77
COOLING FAN RELAY CONTROL
CIRCUIT

USING TECH 1 "MISC TEST," ACTIVATE
"FAN CONTROL PCM A 11 ".
DOES THE PRIMARY COOLING FAN RELAY
OPERATE?
IGNITION "OFF."
DISCONNECT THE PRIMARY (OR #1) COOLING
FAN RELAY.
CONNECT TEST LIGHT BETWEEN THE RELAY COIL

IGNITION "ON."
ISIT?
KEY"OFF."
KEY "ON."
MEASURE CURRENT FROM HARNESS TERMINAL,
"A 11" TO GROUND FOR 2 MINUTES.
DOESIT?

USING TECH 1 "MISC

TEST'.' ACTIVATE
"FAN CONTROL PCM
A11".
"A."
LIGHT SHOULD BE
"ON .."
IS IT?
IS LIGHT OFF?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF RELAY
CONNECTOR TO
GROUND.
LIGHT SHOULD BE
DISCONNECT
PCM
CONNECTOR
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
ISIT?

ISIT?

OR
OR
FAULTY PCM.
OPEN
RELAY
IGNITION
FEED
CIRCUIT.
RELAY CONTROL
CIRCUIT SHORTED
TOB+.
6-29-93
PS 18654
PCM
TRANSMISSION RANGE
PRESSURE SWITCH ASSEMBL V
B+
.,.__ _ _ _ _ _ _ _ 1224PNK
.,.__ _ _ _ _ _ _ 1225 DK BLU
B+
. . . . . - - - - - - - - 1226RED
TRANSMISSION
~ CONNECTOR
1
...,___ _ _ _ _ _ 1227 BLK/VEL
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
sv
~ - - TFT SIGNAL
I-'---------- 470 BLK

6-7-93
PS 18401
DTC79
5.7L (VIN P) .. F" CARLINE (SFI)
The Transmission Fluid Temperature (TFT) sensor is a thermistor within the TR pressure switch assembly,
that controls the signal voltage to the PCM. The PCM supplies a 5 volt reference signal to the sensor on CKT
1227. When the transmission fluid is cold, the sensor resistance is high and the PCM will sense high signal
voltage.
DTC 79 Will Set When: Signal voltage indicates a transmission fluid temperature greater than 146C
(295F) and has not cooled to less than 137C (280F) for 30 minutes, and no DTC 58 or 59 set. If TFT becomes
greater than 151 C (306F), a DTC 58 will set.

1. This test checks for skewed or shorted circuit.
2. This test simulates a DTC 59.
about 100C then stabilize.

the possibility of a "skewed" sensor. A "skewed'.'
enabled complaints.
Check transmission fluid. Refer to "Fluid
Checking Procedure."
DTC79
11

BEEN PERFORMED?

TEMPERATURE OF GREATER THAN 146C (29SF)?
IGNITION "OFF."

SECTION 7A14A (4L60E)OR 7A17A (4L80E) OF
OTC IS INTERMITTENT.

FAULTY CONTROL MODULE OR
CONNECTIONS.
5-11-93
PS 17931
TORQUE
CONVERTER
ASSEMBLY
PCM
TCCCONTROL
~
TCCCONTROL
FEED BACK
g"'
Fl f
+-ii + + f
+1
+ COOLER
LINE (FROM PUMP)
422 TAN/BLK
#11 (U/H)
IGNITION
.......__ _ _ _ _ 239 PNK - - - . . - - - - SWITCH
10A
(U/H) = UNDERHOOD ELECTRICAL CENTER
PS 18406
DTC80
The PCM energizes the Torque Converter Clutch (TCC) solenoid by grounding CKT 422. The TCC solenoid
allows converter release fluid to exhaust past the #9 check ball, applying the TCC. The TCC solenoid will deenergize when the PCM no longer provides a ground. When the TCC solenoid is de-energized, this will block
exhaust fluid, and release the TCC.
The PCM monitors the difference in engine speed and the calculated transmission input shaft speed ..With
the transmission selector in "D3" or "D4", indicated gear 2, 3, or 4, and TCC locked, the scan tool should display
TCC slip speed of -50 RPM to + 50 RPM.
DTC 80 Will Set When: TCC slip speed is greater than 100 RPM, TCC indicates "ON," gear indicates 2, 3, or
4, manual valve indicates "D3" or "D4", no DTC 28, TP between 0% and 35%, TFT between 60C and 100C. All
conditions must be met for 10 seconds.
Action Taken (PCM will default to):
Set line pressure to max (harsh shifts).
Inhibit 4th gear if in hot mode.
"ON."

actual selected range.
2. This test checks the 'torque converter for slippage
while in a commanded locked-up state.
Diagnostic Aids:
Check for poor connections at pass-thru

connector.
A faulty trans range pressure switch assembly
may set DTC 80.
DTC80
NOTICE: PERFORM FLUID CHECKING PROCEDURE

BEFORE PROCEEDING WITH DIAGNOSIS CHART,
INSTALL SCAN TOOL.

APPLY BRAKE PEDAL AND SELECT EACH
TRANSMISSION RANGE 01, 02, 03, 04, N, R, P.
DOES EACH SELECTED TRANS RANGE MATCH
TRANS RANGE SW ON SCAN TOOL?
DRIVE VEHICLE IN 4th GEAR AND TCC ENGAGED.

USE SNAPSHOT MODE TO RECORD DATA PARAMETERS.
IS TCC SLIP SPEED EVER GREATER THAN 100 RPM FOR
10 SECONDS WHILE TCC IS ENGAGED?

REFER TO TORQUE CONVERTER CLUTCH (TCC)
DIAGNOSIS IN SECTION 7 A 14A (4L60E).
MECHANICAL COMPONENT FAILURE.

REFER TO "SYMPTOM DIAGNOSIS
CHARTS" SECTION 7A14A (4L60E). FOR
PROBABLE MECHANICAL FAILURES.
6-24-93
PS18605
PCM
TRANSMISSION WIRING
CONNECTOR ASM.
2-3 SHIFT
SOLENOID
2-3 SHIFT SOLENOID

CONTROL
1223 V E L J B L K - - - - - - - - - - - .
239 PNK
TO TCC
SOLENOID
TO 1-2 SHIFT
SOLENOID
#11 (U/H)
--(~TO
10 AMP
IGNITION
SWITCH
2-3 SHIFT SOLENOID
TO 3-2 CONTROL
SOLENOID
(U/H)
FEEDBACK
7-8-93
PS18403
DTC81
TRANSMISSION 2-3 SHIFT SOLENOID CIRCUIT
11
The 2-3 shift solenoid is used to control fluid flow acting on the 2-3 shift valves. The solenoid is a normally
open exhaust valve that is used with the 1-2 shift solenoid to allow four different shifting combinations. The
solenoid is attached to the control valve body within the transmission. Ignition voltage is supplied directly to the
2-3 shift solenoid. The Powertrain Control Module (PCM) controls the solenoid by providing the ground path
through CKT 1223.
OTC 81 Will Set When: The PCM commands the solenoid "ON" and voltage remains high (B +) for 2 seconds.
The PCM commands the solenoid "OFF" and voltage remains low (zero volts) for 2 seconds.
Action Taken (PCM will default to): If the solenoid is shorted "OFF" third gear only will occur. If the
solenoid is shorted "ON" second gear only will occur. OTC 81 will be stored in the PCM memory but will not turn
"ON" the Malfunction Indicator Lamp (MIL).
"ON."
'OTC Chart Test Description:
Number(s) below
trans~ission wiring for shorts.

transmission.
CHART 4L60E
Gear
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
DTC81
I
I

SOLENOID CIRCUIT
INSTALL TECH 1.
COMMAND 2-3 SHIFT SOLENOID "ON"/"OFF" THREE TIMES
WHILE LISTENING AT BOTTOM OF TRANSMISSION PAN
(USE STETHOSCOPE IF NECESSARY}.
IGNITION "OFF."
(ADDITIONAL DTCs WILL SET.}
INSTALLJ 39775 JUMPER HARNESS/PROBE KIT ON THE
CONNECT TEST LIGHT FROM CAVITY ''E'' OF J 39775 TO
GROUND.
IS TEST LIGHT "ON"?
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
INSTALL TEST LIGHT FROM CAVITIES "E" TO "B" OF

J39775.
COMMAND 2-3 SHIFT SOLENOID "ON"/"OFF"
THREE TIMES.
IS TEST LIGHT "ON" WHEN COMMANDED ON, AND
"OFF" WHEN COMMANDED OFF?
CHECK CKT 1223 FOR AN OPEN OR SHORT

FROM CONTROL MODULE TO TRANS
WIRING CONNECTOR.
IF OK, REPLACE CONTROL MODULE.

CHECK OK.
REFER TO "INTERNAL WIRING
HARNESS CHECK," IN SECTION
7A14A (4L60E} OR 7A 17A (4L80E}.
REPAIR OPEN OR SHORT TO GROUND IN

THE IGNITION VOLTAGE FEED CIRCUIT TO
THE TRANSMISSION.
IF THE FUSE IS OPEN, CHECK THE
TRANSMISSION INTERNAL WIRING
HARNESS OR SOLENOID FOR SHORT TO
GROUND.
4-13-93
PS 17093

PCM
TRANSMISSION
WIRING
CONNECTOR ASM.
1-2 SHIFT
SOLENOID
1-2 SHIFT SOLENOID

CONTROL
1222 LT GRN
-------------1
#11 (U/H)
239 P N K - - - . . . . ( ~ TO IGNITION
10 AMP
SWITCH
T02-3
SHIFT
SOLENOID
12 SHIFT SOLENOID
fEEDBACK
T03-2
CONTROL
SOLENOID
(U/H)
7.9.93
PS18404
DTC82
TRANSMISSION 1-2 SHIFT SOLENOID CIRCUIT
5. 7L (VIN P) 11 F" CARLINE (SFI)
The 1-2 shift solenoid is used to control fluid flow acting on the 1-2 and 3-4 shift valves. The solenoid is a
normally open exhaust valve that is used with the 2-3 shift solenoid to allow four different shifting combinations.
The solenoid is attached to the control valve body within the transmission. Ignition volt~ge is supplied directly to
the 1-2 shift solenoid. The Powertrain Control Module (PCM) controls the solenoid by providing the ground path
through CKT 1222.
.
DTC 82 Will Set When: The PCM commands the solenoid "ON" and voltage remains high (B+) for 2 seconds.
The PCM commands the solenoid "OFF" and voltage remains low (zero volts) for 2 seconds.
Action Taken (PCM will default to): The transmission will only allow second and third gear, or first and
fourth gear. DTC 82 will set if the PCM detects the wrong voltage potential for 26 seconds on CKT 459.
"ON."

refer to circled number(s) on the diagnostkchart.
transmission wiring harness for shorts.
Diagnostic Aids: Check all connections for the

transmission.
CHART4L60E
Gear
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
DTC82
SOLENOID CIRCUIT
11
INSTALL TECH 1.
IGNITION "ON." ENGINE "OFF."
COMMAND 1-2 SHIFT SOLENOID "ON"/"OFF" THREE TIMES WHILE LISTENING
AT BOTTOM OF TRANSMISSION PAN (USE STETHESCOPE IF NECESSARY).
IGNITION "OFF."
INSTALL J 39775 JUMPER HARNESS/PROBE KIT ON THE EXTERNAL WIRING CONNECTOR .
CONNECT TEST LIGHT FROM CAVITY 'T' OF J 39775 TO GROUND.
IS TEST LIGHT "ON"?
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
@]
INSTALL TEST LIGHT FROM CAVITIES "E" TO "A" OF J 39775.
1-2 SHIFT SOLENOID "ON"/"OFF" THREE TIMES.

COMMAND
TEST LIGHT "ON" WHEN COMMANDED "ON," AND
IS"OFF"
WHEN COMMANDED "OFF"?

CHECK CKT 1222 FOR AN OPEN OR SHORT FROM THE

TRANSMISSION EXTERNAL WIRING CONNECTOR TO
THE CONTROL MODULE CONNECTOR.
If OKAY, REPLACE PCM.
EXTERNAL TRANSMISSION WIRING CHECK OKAY.

IN SECTION 7A14A (4L60E) OR 7A17A (4L80E).
4-13-93
PS 17094
PCM
REVERSE INHIBIT
SOLENOID
541 BRN
1652LTGRN
~_l
--
MOUNTED TO
TRANSMISSION
~~
541 BRN
REVERSE INHIBIT
SOLENOID CONTROL
C100
10 AMP
3 00 ORN
TO
~GNITION
- TO EGR VACUUM CONTROL SIGNAL SOLENOID VALVE, EVAP

- CANISTER PURGE SOLENOID VALVE, SKIP SHIFT SOLENOID AND H02S
HEATERS
(U/H)
6-26-93
NS15380
DTC83
REVERSE INHIBIT SYSTEM
(MANUAL TRANSMISSION)

The reverse lockout solenoid will be energized when the PCM grounds CKT 1652, which will allow the.
transmission to be shifted into reverse. The PCM will enable the reverse lockout solenoid whenever vehicle speed
is below 4 mph. When vehicle speed is above 5 mph, the PCM will de-energize the reverse lockout solenoid, which
will prohibit the transmission from being shifted into reverse.
OTC 83 Will Set When: The PCM detects the wrong voltage potential on CKT 1652 for 26 seconds.

1. The reverse inhibit solenoid will be enabled
whenever vehicle speed is below 5 mph. If there is
a fault in the vehicle speed sensor circuit and the
PCM is not receiving VSS signal, the reverse
inhibit solenoid would be enabled at speeds above
5 mph (8 km/h) and the shifter could be placed into
reverse. With the ignition "OFF" the transmission
should not shift into reverse.

current flow is detected a circuit check will be
to "O") when warm.
3. Raise the vehicle enough to gain access to the
reverse lockout solenoid electrical harness and
still be able to turn the ignition "ON."
DTC83
REVERSE INHIBIT SYSTEM
'1'
\.:...,) t
t
t
t
IF OTC 24 IS SET, PERFORM THAT CHART FIRST.

IGNITION "OFF."
FULLY DEPRESS CLUTCH PEDAL.
CAN TRANSMISSIQN BE SHIFTED INTO REVERSE?
5. 7L (VIN P)

USING TECH 1 "MISC TEST," ACTIVATE REVERSE INHIBIT SOLENOID.
DOES SOLENOID OPERATE?
11
F" CARLINE (SFI)
FAUL TV REVERSE INHIBIT SOLENOID

OR
INTERNAL TRANSMISSION PROBLEM.
KEY "OFF."
KEY "ON."
USING DVM J 39200 ON 10 AMP SCALE, MEASURE CURRENT FROM
HARNESS TERMINAL "06" TO GROUND FOR 2 MINUTES.
CURRENT DRAW SHOULD MEASURE LESS THAN 1.5 AMPS (BUT NOT "0").
DOESIT?
NO
0 .
IGNITION "OFF."
RAISE VEHICLE.
DISCONNECT REVERSE INHIBIT SOLENOID.
CONNECT TEST LIGHT BETWEEN SOLENOID
HARNESS CONNECTOR TERMINALS
IGNITION "ON."
ISIT?
CONNECT TEST LIGHT FROM IGNITION FEED

CIRCUIT OF SOLENOID HARNESS TO GROUND.
ISIT?

OR
OPEN SOLENOID DRIVER
CIRCUIT
OR
FAULTY PCM.
OPEN SOLENOID
IGNITION FEED
CIRCUIT.
GROUND OUTPUT/FIELD SERVICE ENABLE TERMINAL.

ISIT?
DISCONNECT PCM
CONNECTOR "D".
IS LIGHT "ON"?
6-30-93
MS 12456

TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
3-2CONTROL
SOLENOID
PCM
r---,
3-2CONTROL
SOLENOID
r--r---+-----1-1 S
687 WHT
#11 (U/H}
239 PNK ~ I G N I T I O N SWITCH
10A
TOTCC
SOLENOID
TO 2-3
SHIFT
SOLENOID
TO 1-2
SHIFT
SOLENOID
(U/H}
3-2CONTROL
FEEDBACK
= UNDER HOOD ELECTRICAL CENTER
7-9-93
PS18405
DTC84
AUTOMATIC TRANSMISSION 3-2 CONTROL SOLENOID CIRCUIT
Hydraulically, the 3-2 control solenoid coordinates the apply rate of the 2-4 band with the hydraulic release of
the 3-4 clutch during a 3-2 downshift.
The PCM continually monitors the 3-2 circuit duty cycle depending on the commanded state of the circuit
terminal "B13". When the transmission is in first gear the duty cycle of the solenoid is equal to O ("OFF"). When
the transmission is in second gear or higher the duty cycle of the solenoid will be about 90% ("ON"). When the
transmission downshifts, 3-2, the duty cycle of the solenoid will drop.
DTC 84 Will Set When: The PCM commands the solenoid "ON," and the voltage remains high (B+) for 5
seconds or the PCM commands the solenoid "OFF," and the voltage remains low (zero volts) for 5 seconds.
Action Taken (PCM will default to): A soft landing to third gear and maximum transmission line
pressure. OTC 84 will be stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp
(MIL).
"ON."

1. This test checks the function of the 3-2 control
solenoid and the internal transmission harness.
2. This test checks for power to the 3-2 control
solenoid from the ignition through the fuse.

transmission connector.
The 3-2 control solenoid feedback normally
oscillate "ON/OFF" when the duty cycle is applied.
DTC84
AUTOMATIC TRANSMISSION 3-2 CONTROL
SOLENOID CIRCUIT
11
INSTALL TECH 1.
RECORD THEN CLEAR ores.
ENTER MISC TESTS/TRANSMISSION/ 3-2 SOL.
TIMES WHILE LISTENING AT BOTTOM OF TRANSMISSION PAN
IGNITION "OFF."
INSTALLJ 39775-JUMPER HARNESS/PROBE KITON THE
GROUND.
IS TEST LIGHT "ON"?
INSTALL TEST LIGHT FROM CAVITIES "E" TO "S" OF J 39775.

TIMES.
IS TEST LIGHT "ON" WHEN 3-2 CONTROL SOLENOID IS
COMMANDED "ON" TO "100%", AND "OFF" WHEN
COMMANDED TO "0% "?
REMOVE J 39775 FROM THE EXTERNAL WIRING

CONNECTOR AND INSTALL IT ON THE TRANSMISSION
INTERNAL WIRING CONNECTOR.
WITH J 39200-DVM MEASURE RESISTANCE ACROSS 'T'
AND "S" OF J 39775.
IS RESISTANCE 9-14Q?
CLEAR DTC(s)
AND RETEST.
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSIS AIDS."
REPAIR OPEN OR SHORT

TO GROUND IN THE
IGNITION VOLTAGE FEED
CIRCUIT TO THE
TRANSMISSION.
CHECK FOR OPEN OR SHORT IN 3-2

CONTROL CIRCUIT.
IF OK, REPLACE PCM.
REPLACE 3-2 CONTROL SOLENOID OR INTERNAL

WIRING HARNESS.
REFER TO "VALVE BODY" IN "ON-VEHICLE
SERVICE" IN SECTION 7A 14A FOR REPLACEMENT
PROCEDURE.
4-13-93
MS 13465

PCM
TO REVERSE INHIBIT SOLENOID, EVAP

CANISTER PURGE SOLENOID VALVE, EGR
VACUUM CONTROL SIGNAL SOLENOID
VALVE AND H02S HEATERS
c
F
..
SKIP SHIFT
SOLENOID
CONTROL
SKIP SHIFT SOLENOID
541BRN ~ - - - - 5 8 7 G R Y - - - - 4
C100
- - - - - - - 1 T O OTHER CIRCUITS
#6
10
AMP
(U/H)
3000RN
lo
IGNITION
6-29-93
PS18470
DTC84
SKIP SHIFT SOLENOID CIRCUIT

Ignition voltage is supplied to the skip shift solenoid on CKT 541. The PCM controls solenoid operation by
providing the ground path for CKT 587. During certain light load operating conditions the PCM energizes the
skip shift solenoid which is mounted on the transmission. When this system is . enabled, it is possible to shift from
1st gear to 4th gear only. This maximizes fuel economy.
The skip shift solenoid will be enabled if all of the following conditions are met.
Engine running.
Vehicle speed greater than 15 mph but less than 21 mph.
Throttle position less than 35%.
Engine coolant temperature greater than 77C (171 F).
BARO greater than 76 kPa.
The PCM uses the measured RPM and the vehicle speed to calculate what gear the vehicle is in. It is this
calculation that determines when the skip shift solenoid should be turned "ON."
The skip shift (if all above criteria are met) will occur only once per upshift cycle. The skip shift system is not
re-enabled unless vehicle speed drops below 1 mph.
Action Taken (PCM will default to): DTC 84 will be stored in the PCM memory but will not turn "ON" the.

by the PCM.
to "O") when warm.
3.
The remaining circuit checks will identify a circuit


DTC84
SKIP SHIFT SOLENOID CIRCUIT
5.7L (VIN P)
CD

SKIP SHIFT SOLENOID.
DOES THE SOLENOID OPERATE?
KEY "OFF."
KEY "ON."
MEASURE CURRENT FROM HARNESS
TERMINAL, "813" TO GROUND FOR 2 MINUTES.
1.5 AMPS (BUT NOT "O").
DOES IT?

11
F" CARLINE (SFI)
IGNITION "OFF."
DISCONNECT THE SKIP SHIFT SOLENOID HARNESS
CONNECTOR.
IGNITION "ON."
ISIT?
USING TECH 1 "MISC

TEST" ACTIVATE THE
SKIP SHIFT SOLENOID.
LIGHT SHOULD BE
"ON."
ISIT?
CONNECT TEST
LIGHT FROM
IGNITION FEED
CIRCUIT OF
SOLENOID
CONNECTOR TO
GROUND.
LIGHT SHOULD BE
"ON."
ISIT?
DISCONNECT
PCM
CONNECTOR
"B."
IS LIGHT OFF?
FAUL TY SOLENOID
CONNECTION
OR
FAULTY
SOLENOID.
CONNECT TEST LIGHT FROM CONTROL

CIRCUIT OF SOLENOID CONNECTOR
TO GROUND.
ISIT?

OR
OPEN SOLENOID CONTROL
CIRCUIT
OR
FAULTY PCM.
CONTROL
CIRCUIT.
OPEN
SOLENOID
IGNITION
FEED
CIRCUIT.
SOLENOID
CONTROL CIRCUIT
SHORTED TO B +.
6-29-93
PS 18653
PCM
TCCCONTROL
FEED BACK
B.....
f i t . . . . . . . . . . . COOLER
'"
LINE (FROM PUMP)
CCSIG _ _ _ _ _ _. .
422 TAN/BLK
#11 (U/H)
IGNITION
- - - - - - 239 PNK _ _ _,......___ SWITCH
10A
:<NDCL
(U/H)= UNDERHOOD ELECTRICAL CENTER
PS18406
DTC85
TRANSMISSION TCC STUCK "ON"
11
The PCM energizes the ~orque Converter Clutch (TCC) solenoid by grounding CKT 422. The TCC solenoid
allows converter release fluid to exhaust past the #9 check ball, applying the TCC. The TCC solenoid will deenergize when the PCM no longer provides a ground. When the TCC solenoid is de-energized, this will block
exhaust fluid, and release the TCC.
DTC 85 Will Set When: TCC slip speed -20 to +20, TCC commanded "OFF," gear indicates 2, 3, or 4, TP
indicates greater than 25%, manual valve indicates "03" or "04", no OTC 21, 22, or 28, engine speed greater than
300 RPM. All conditions must be met for 4 seconds.
Action Taken (PCM will default to): TCC is "ON" in all gears. OTC 85 will be stored in the PCM memory
DTC.85 Will Clear When: The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" then
"ON."

l. This test checks the mechanical state of the TCC
when the PCM commands the TCC solenoid
"OFF." TCC slip speed should increase.
Diagnostic Aids: If the TCC is mechanically stuck

"ON," vehicle speed is zero, brakes are applied, and 02
is selected, the TCC fluid will mechanically apply the
TCC causing an engine stall.
DTC85
TRANSMISSION TCC STUCK "ON"
5. 7L (VIN P) F" CARLINE (Sf I)
'1'
~
INSTALL SCAN TOOL.

,
DRIVE VEHICLE IN 04 RANGE IN 4th GEAR UNDER STEADY
ACCELERATION. (TP SENSOR INDICATES ANGLE GREATER THAN
25%) SNAPSHOT TCC SLIP SPEED AND TCC SOLENOID STA TE.
IS TCC SLIP SPEED BETWEEN -20 AND + 20 RPM (4L60E), -5. AND
+ 10 RPM (4L80E) WHILE TCC SOLENOID DISPLAYS "OFF"?
THE TORQUE CONVERTER CLUTCH IS

MECHANICALLY STUCK "ON" REFER TO
SYMPTOM DIAGNOSIS CHARTS TCC STUCK
"ON" SECTION 7A14A (4L60E) OR 7A17A (4L80E)
OF THE APPROPRIATE SERVICE MANUAL.

REFER TO "TORQUE CONVERTER CLUTCH
(TCC) DIAGNOSIS" IN "DIAGNOSIS" OF
SECTION 7 A 14A (4L60E) OR 7 A 17 A (4L80E)
OF THE APPROPRIATE SERVICE MANUAL.
4-8-93
PS 17052
TCC
SOLENOID
TRANSMISSION
WIRING
CONNECTOR
ASSEMBLY
PCM
r---,
I
.-----.----.------+--t T t-+--------,-------
TCCCONTROL
422 TAN/BLK
#11 (U/H)
10A
SWITCH
T03-2
CONTROL
SOLENOID
T02-3
SHIFT
SOLENOID
(U/H)
l
TCCCONTROL
FEEDBACK
7-9-93
PS18407
DTC90
TRANSMISSION TCC SOLENOID CIRCUIT
then controls TCC apply and release. The PCM monitors TP voltage, vehicle speed and other inputs to determine
when to energize the TCC solenoid. Ignition voltage is supplied directly to the TCC solenoid. The Powertrain
Control Module (PCM) controls the solenoid by providing the ground path through CKT 422.
OTC 90 Will Set When: The PCM commands the TCC solenoid "ON" and the voltage stays high (B+) for 2
seconds. The PCM commands the TCC solenoid "OFF" and the voltage drops to zero volts for 2 seconds.
Action Taken (PCM will default to): "NoTCC will occur, and no fourth gear if in hot mode ..DTC 90 will be
stored in the PCM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL).
"ON."
'OTC Chart Test Description:
Number(s) below
transmission harness or TCC solenoid.

DTC90
CIRCUIT
11
5.7L (VIN P F" CARLINE (SFI
INSTALL TECH 1
ENTER MISC TESTS/TRANSMISSION/TC( SOLENOID .
COMMAND
SOLENOID "ON"/"OFF" THREE TIMES WHILE LISTENIN~ AT
rec
IGNITION "OFF."
INSTALL J 39775 JUMPER HARNESS/PROBE KffON THE EXTERNAL WIRING CONNECTOR .
CONNECT TEST LIGHT FROM CAVITY "E" OF J 39775 TO GROUND
IS TEST LIGHT "ON"?
ELECTRICAL SYSTEM
CHECK OK. REFER TO
"DIAGNOSTIC AIDS."
INSTALL TEST LIGHT FROM CAVITIES "E" TO "T"

(4L60E) OR 'T' TO "S" (4LSOE) OF J 39775.
COMMAND
SOLENOID "ON"/"OFF" THREE TIMES .
rec

IGNITION VOLTAGE FE ED CIRCUIT TO THE
SJ
CHECK CKT 422 (4L60E) OR CKT 1350 (4L80E) FOR

SECTION 7A14A (4L60E) OR 7A17A (4L80E).
4-13-93
PS 17530
PCM
TO OTHER
CIRCUITS
r----------,
I
I
SKIP SHIFT LAMP

CONTROL DRIVER
I
I
I ~
~ ~ ~ - + 1 ~ - - - - > - - - t - l~~~~-K~~-37SWHT
6KIP SHIFT LAMP
10AMP
I
I....
C230
I
I
_________ ....
INSTRUMENT
PANEL
(1/P) = LOCATED IN INSTRUMENT i>ANEL FUSE BLOCK.
7-9-93
MS10648
DTC91
SKIP SHIFT LAMP CIRCUIT
5.7L (VIN P)
11
11
F CARLINE (SFI)
The skip shift lamp display is in the instrument panel. When the skip shift lamp is illuminated, the PCM is
energizing the skip shift solenoid in the transmission and the gear shift can only be moved from 1st to 4th gear.
This increases fuel economy. The lamp is controlled by the PCM and is turned "ON" by grounding CKT 375. The
skip shift lamp will be enabled if all of the following conditions are met.
Engine running.
Vehicle speed greater than 15 mph but less than 21 mph.
Throttle position less than 35%.
Engine coolant temperature greater than 77C (171 F).
BARO greater than 76 kPa.
The PCM uses the measured RPM and the vehicle speed to calculate what gear the vehicle is in. It is this
calculation that determines when the skip shift lamp should be turned "ON."
The skip shift (if all above criteria are met) will occur only once per upshift cycle. The skip shift system is not
re-enabled unless vehicle speed drops below 1 mph.
Action Taken (PCM will default to): DTC 91 will be stored in the PCM memory, but will not illuminate
the Malfunction Indicator Lamp (MIL).

1. This should not turn "ON" the skip shift lamp. If
the lamp is "ON," there is a short to ground in
CKT 375 wiring or a fault in the PCM.
2. The PCM should ground CKT 375 and the skip
shift lamp should come "ON."
3. This checks the skip shift lamp circuit up to the
PCM connector. If the skip shift lamp illuminates,
then the PCM connector is faulty or the PCM does
not have the ability to ground the circuit.
4.
For electrical diagnosis of the instrument panel,

refer to SECTION BA. For skip shift lamp bulb
replacement, refer to SECTION BC.

DTC91
SKIP SHIFT LAMP CIRCUIT
5.7L (VIN P)
11
F" CARLINE (SFI)
IGNITION "ON,'" ENGINE "OFF."

IS THE SKIP SHIFT LAMP '"ON"?

IS THE SKIP SHIFT LAMP "OFF"?
CKT 375 SHORTED TO

GROUND
OR
FAUL,:y 1/P CLUSTER.
USING TECH 1 ''MISC TEST"

ACTIVATE THE SKIP SHIFT LAMP.
IS THE LAMP "ON"?
DTC91 IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.

CONNECT A FUSED JUMPER FROM TERMINAL
"015" TO GROUND.
DOES THE Sl(IP SHIFT LAMP ILLUMINATE?
FAULTY PCM
CONNECTION
OR
FAULTY PCM.
CKT 375 SHORTED.TO B +

OR
FAULTY BULB
OR
OPEN IGNITION FEED TO BULB.
6-5-93
PS 18469
PCM
I<0 g ffi-----:: : ~
SVOLT
REFERENCE
VSSGROUND

CRUISE CONTROL
MODULE
INSTRUMENT
PANEL
K
C220
VSSOUTPUT
7-8-93
PS16656
DTC97
VSS OUTPUT CIRCUIT
The PCM receives the vehicle speed sensor signal on CKT 400.. The PCM processes this signal and sends it to
the various components which use vehicle speed data through CKT 817.
OTC Chart Test Description: Numbe.r(s) below

1. The ASR system must be disabled when
performing this step. Whenever the ignition key is
cycled to the "OFF" position and then cycled back
"ON" the ASR system will default "ON."
2. Use J 35616-A (connector test adapter kit) to probe
PCM harness terminals so damage does not occur
to the terminals.
3. Refer to SECTION 8A-33 for complete diagnosis of
CKT817.

DTC97
VSS OUTPUT CIRCUIT
5.7L (VINP) F" CARLINE (SFI)
11
NOTICE:
THIS CHART ASSUI\IIES
THERE IS NO OTC 24 OR 72 SET.
IGNITION "OFF."
RAISE DRIVE WHEELS.
START ENGINE.
DISABLE "TC" SYSTEI\II.
WITH ENGINE IDLING IN GEAR, SPEEDOI\IIETER SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOES IT?
IGNITION "OFF."
DISCONNECT PCI\II CONNECTOR "B".
INSTALL SIGNAL GENERATOR TESTER J 33431-B
TO PCI\II ELECTRICAL HARNESS TERIIIIINAL "88"
(ONE TERI\IIINAL CONNECTED TO THE PCI\II
ELECTRICAL HARNESS AND THE OTHER TO
GROUND).
IGNITION "ON," TESTER ''ON" AND SET TO
GENERATE A VEHICLE SPEED SIGNAL.
DOES SPEEDOI\IIETER INDICATE VEHICLE. SPEED?
FOR FURTHER DIAGNOSIS OF CKT 817, REFER TO

SECTION 8A-33.
OTC 97 IS INTERIIIIITTENT. REFER TO

FAULTY PCI\II CONNECTION

OR
FAULTY PCI\II.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRI\II OTC DOES NOT RESET.
6-8-93
PS 17230
PCM
INSTRUMENT
PANEL
TACHOMETER
D
+-------<<------------121WHT
C230
-E
TACHOUTPUT
FOR MORE DETAILED CIRCUIT DESCRIPTION REFER TO SECTION SA.
6-27-93
PS 16714
DTC99
TACH OUTPUT CIRCUIT
The PCM receives the low resolution signal from the distributor on CKT 453. The PCM modifies this signal
and sends it to the tachometer on CKT 121.
OTC 99 Will Set When: The PCM detects the wrong voltage potential for'26 seconds on CKT 121.
Action Taken (PCM will default to): DTC 99 will be stored in the PCM memory b11t will not turn "ON" the

1. Use J 35616-A (connector test adapter kit) to probe
PCM harness terminal so damage does not occur to
the terminals.
2. Refer to SECTION 8A-81 for further diagnosis of
CKT 121.

These may cause a:n intermittent. Check for damaged
DTC99
TACH OUTPUT CIRCUIT
G)
START ENGINE.
WITH ENGINE IDLING, TACHOMETER SHOULD INDICATE ENGINE RPM.
DOESIT?
IGNITION "OFF."
INSTALL SIGNAL GENERATOR TESTER
J 334318 TO PCM ELECTRICAL HARNESS
TERMINAL "A13" (ONE TERMINAL
CONNECTEofTO THE PCM ELECTRICAL
HARNESS AND THE OTHER TO GROUND).
IGNITION "ON," TESTER "ON" AND SET TO
GENERATE A VEHICLE SPEED SIGNAL.
DOES TACHOMETER INDICATE ENGINE RPM?
FOR FURTHER DIAGNOSIS OF

CKT 121, REFER TO SECTION SA.
OTC 9915 INTERMITTENT. REFER TO


OR
FAULTY PCM.
6-28-93
PS 18467
BLANK
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-B-1
SECTION B
SYMPTOMS
CONTENTS
Important Preliminary Checks

Before Starting
Symptom
Visual/Physical Check
lntermittents (1 of 2)
Hard Start
Surges and/or Chuggles
Lack of Power, Sluggish or Spongy
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses
Rough, Unstable, or Incorrect Idle, Stalling (1 of 2)
Poor Fuel Economy
Excessive Exhaust Emissions or Odors
Dieseling, Run-On
Backfire
Restricted Exhaust System Check - Chart B-1
PCM Connector "A" Symptom Chart
PCM Connector "B" Symptom Chart
PCM Connector "C" Symptom Chart
PCM Connector "D" Symptom Chart
. .. .
. . .. . .
.. .. . . .
.... ... . . ..
.. .. . . .
.....
...
.. . . . . . .
...
.......
. . . . . . . .. . . .. .
...
. . .. .
.......... .... ..
...
.....
.. .. . . .. ..
.. .........
. . . . . ..
...
. . ...
Page B-2
Page B-2
Page B-2
Page B-2
Page B-3
Page B-5
Page B-6
Page B-7
Page B-8
Page B-9
Page B-10
Page B-11
Page B-13
Page B-14
Page B-15
Page B-16
Page B-17
Page B-18
Page B-20
Page B-22
Page B-24
6E3-B-2 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
IMPORTANT PRELIMINARY CHECKS
BEFORE STARTING
Before using this section you should have performed th~ "On-Board Diagnostic (OBD) System
Check" and determined that:
1. The PCM and MIL are operating correctly.
2. There are no DTC(s) stored.
3. Tech I data is within normal operating range as listed in "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A".
SYMPTOM
Verify the customer complaint, and locate the correct symptom ih the table of contents. Check
the items indicated under that symptom.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a Careful Visual/Physical Check. The importance of
this step cannot be stressed too strongly - it can lead to correcting a problem without further checks
and can save valuable time. This check should include:
Vacuum hoses for splits, kinks, and proper connections, as shown on "Vehicle Emission
Control Information" label. Check thoroughly for any type ofleak or restriction.
Mass Air Flow (MAF) sensor installation. The arrows on the plastic portion of the sensor
must point toward the engine.
Air intake ducts for collapsed or damaged areas.
Air leaks at throttle body mounting area, Mass Air Flow (MAF) sensor and intake manifold
sealing surfaces.
Ignition wires for cracking, hardness, proper routing and carbon tracking.
Wiring for proper connections, pinches and cuts.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-B-3
INTERMITTENTS
{Page 1 of 2)
Definition:

or store a OTC.
DO NOT use the Diagnostic Trouble Code (DTC) charts in "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A" for intermittent problems. The fault must be present
to locate the problem.
Most intermittent problems are caused by faulty electrical connections or wiring. Perform
careful visual/physical check as described at start of "Symptoms," Section "6E3-B". Check for:
Poor mating of the connector halves or a terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminal. All connector terminals in the problem circuit
should be carefully reformed or replaced to ensure proper contact tension.
Poor terminal to wire connection. This requires removing the terminal from the. connector
body to check. Refer to "Introduction" in SECTION SA. Also, check underhood electrical
center for corrosion.
If a visual/physical check does not find the cause of the problem, the vehicle may be driven with a
J 39200 Digital Multimeter connected to a suspected Circuit. A Tech 1 can also be used to help
detect intermittent conditions. An abnormal voltage, or reading, when the problem occurs,
indicates the problem may be in that circuit. If the wiring and connectors check OK, and a OTC
was stored for a circuit having a sensor, except for DTCs 43, 44, 45, 64, and 65 substitute a
known good sensor and recheck.
Loss of diagnostic code memory. To check, disconnect MAP and idle engine until the MIL comes
"ON." OTC 34 should be stored, and kept in memory when ignition is turned "OFF." If not, the
PCM is faulty.
An intermittent MIL with no stored DTC may be caused by:

Ignition coil shorted to ground and arcing at ignition wires or plugs.
MIL wire to PCM shorted to ground.
Output/field service enable terminal/wire to PCM, shorted to ground.
PCM grounds, refer to PCM wiring diagrams.
If the intermittent condition exists as a "start and then stall," check for DTC(s) relating to the
theft deterrent systems.
6E3-B-4 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
INTERMITTENTS
Definition:
(Page 2 of 2)
or store a DTC.
Check for an electrical system interference caused by a defective relay, PCM driven solenoid, or
switch. They can cause a sharp electrical surge. Normally, the problem will occur when the
faulty component is operated.
Check for improper installation of electrical options such as lights, cellular phones, etc.
All Ignition Control (IC) wires should be routed away from secondary ignition wires, distributor,
coil and generator. All wires from the PCM to distributor should have a good connection.
Check for open diode across NC compressor clutch, and for other open diodes (refer to wiring
diagrams).
If problem has not been found, refer to "PCM Connector Syinptom" charts at the end of
HARD START
Definition:
Engine cranks OK, but does not start for a

long time. Does eventually run, or may start
but immediately dies.
PRELIMINARY CHECKS
Make sure the driver is using the correct starting procedure.
SENSORS
CHECK: Engine Coolant Temperature (ECT) sensor using a scan tool, compare engine coolant
temperature with ambient temperature on a cold engine.

If engine coolant temperature reading is 5 degrees greater than or less than ambient
air temperature on a cold engine, check resistance in engine coolant sensor circuit or
sensor itself. Compare ECT resistance value to the "Diagnostic Aids" chart on DTC
15 chart.
CHECK: MAP sensor, use CHART C-lD,
CHECK: Mass Air Flow (MAF) sensor installation. A MAF sensor that is installed backwards can
cause a rich condition. A malfunctioning MAF sensor may cause a no start or hard
starts.
CHECK: TP sensor for binding or a high 'l'P .sensor voltage with the throttle closed (should read
between d_ and .9 volt).
FUEL SYSTEM
CHECK: Fuel pump relay operation - pump should turn "ON" for 2 seconds when ignition is
turned ''ON." Use CHART A-5 ..
CHECK: Both injector fuses (visual inspect).
NOTICE: A faulty in-tank fuel pump check valve will allow the fuel in the lines to drain back to
the tank after engine is stopped. To check for this condition, perform fuel system diagnosis
CHART A-7.
IGN1TION SYSTEM
CHECK:
CHECK:
CHECK:
CHECK:

Bare or shorted ignition wires.
Loose ignition coil ground.
Coil fuse.
Distributor vent system (if so equipped). Refer to "Distributor Ignition (DI) System,"
Section "6E3-C4".
ADDITIONAL CHECKS
CHECK: IAC operation - use CHART C-2C.
CHECK: Basic engine problem. Refer to SECTION 6A.
CH ECK: Calibration I. D. for most current and/or incorrect software. (Refer to service bulletins.)
6E3-B"'6 5.7L (VIN P) DRIVEABILITY AND EMlSSIONS
SURGES AND/OR CHUGGLES

Definition:
Engine power variation under steady throttle or cruise. Feels like the
vehicle speeds up and slows down with no change in the accelerator pedal.
PRELIMINARY CHECKS
Perform the careful visual/physical check as described at start of"Symptoms," Section "6E3-B".
Be sure driver understands transmission torque converter clutch, and A/C compressor operation
as explained in the owner's manual.
SENSORS
CHECK: Heated Oxygen Sensors (H02S). The Heated Oxygen Sensors (H02S) should respond
quickly to different throttle position, if they don't, check the H02S for silicon or other
contaminates from fuel, or use of improper RTV sealant. The sensors may have a white
powdery coating and result in a high but false signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel delivered to the engine, causing a severe
driveability problem. For more information, refer to "Powertrain Control Module (PCM)
.
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify a
problem.
Lean - Long term fuel trim near 160. Refer to '.'Diagnostic Aids" on facing page of DTCs 44 and
64.
.'
Rich - Longterm fuel trim near 108. Refer to "Diagnostic Aids" on facing page of DTCs 45 and
65.
CHECK: Fuel pressure while condition exists, use CHART A-7.
CHECK: In-line fuel filter. Replace if dirty or plugged.
IGNITION SYSTEM
CHECK: For ignition misfire, refer to "6E3-C4".
CHECK: For proper ignition voltage output using spark tester J 26792 (ST 125).
burned electrodes, or heavy deposits. Repair or replace as necessary. Also, check

condition of distributor cap, rotor and ignition wires.
CHECK: Distributor vent system (if so equipped). Refer to "Distributor Ignition (DI) System,"
Section "6E3-C4".
ADDITIONAL CHECKS
CHECK: Injector harness locations. Make sure each injector harness is connected to the correct
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
injector/cylinder according to the firing order (firing order: 1-8-4-3-6-5-7-2).

MAF connections.
Vacuum lines for kinks or leaks.
EGR-There should be np EGR at idle, use CHART C-7.
Generator output voltage. Repair ifless than 9 or more than 16 volts.
.
Calibration I.D. for most current and/or incorrect software. (Refer to service bulletins.)
DRIVEABILITY AND EMISSIONS 5.7l (VIN P) 6E3-B-7
LACK OF POWER, SLUGGISH OR SPONGY

Definition:
"
Engine delivers less than expected power.

Little or no increase in speed when accelerator
pedal is pushed down part way.
PRELIMINARY CHECKS
Compare customer's vehicle to similar unit. Make sure the customer has an actual problem.
Remove and check air filter for dirt, or for being plugged. Replace as necessary.
FUEL SYSTEM
CHECK: Restricted fuel filter.
IGNITION SYSTEM
CH ECK: KS system for excessive spark retard activity. Refer to CHART C-5. Use Tech 1.
CHECK: Secondary voltage using a shop oscilloscope or a spark tester J 26792 (ST 125), to check
for a weak coil.

Section "6E3-C4".
ADDITIONAL CHECKS
CHECK: PCM grounds for being clean, tight and in their proper locations. Refer to PCM wiring
diagrams.
CHECK: EGR operation for being open or partly open all the time.
Use CHART C-7.

CHECK: Generator output voltage. Repair ifless than 9 or more than 16 volts.
CHECK: Exhaust system for possible restriction, use CHART B-1.
Inspect exhaust system for damaged or collapsed pipes.

Inspect muffiers for heat distress or possible internal failure.
For possible plugged catalytic converter. Check backpressure by removing AIR
check valves near exhaust manifolds.
CHECK: TC system cable adjuster assembly. Loss of performance can result from an improperly
adjusted system which could prevent the throttle from attaining WOT. Refer to
SECTION 5E2.
CHECK: Torque Converter Clutch (TCC) for proper operation. Refer to SECTION C-8.
CHECK: Calibration I.D. for most current and/or incorrect software. (Refer to service bulletins.)
ENGINE MECHANICAL
CHECK: Engine valve timing and compression. Refer to SECTION 6A.
CHECK: Engine for correct or worn camshaft. Refer to SECTION 6A.
6E3-B-8 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
DETONATION/SPARK KNOCK
Definition:
A mild to severe ping, usually worse under acceleration. The engine

makes sharp metallic knocks that change with throttle opening.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of "Symptoms," Section "6E3~B".
Park/Neutral Position (PNP) switch. Be sure Tech 1 indicates drive with gear selector in drive or
overdrive, use CHART C-lA.
If Tech 1 readings are normal (refer to facing page of "On-Board Diagnostic (OBD) System
Check") and there are no engine mechanical faults, fill fuel tank with a premium gasoline that
has a minimum octane reading of 92 and re-evaluate vehicle performance.
CHECK: EGR system for not opening, use CHART C-7.
CHECK: TCC operation, TCC applying too soon, refer to SECTION 7 A14A or Automatic
Transmission Control System," Section "6E3-C8".
COOLING SYSTEM
Check for obvious overheating problems:

Low engine coolant:
Restricted air flow to radiator, or restricted water flow through radiator.
Inoperative electric cooling fan circuit(s), use CHART C-12.
Correct coolant solution should be a 50/50 mix of GM #1052753 or equivalent anti-freeze
coolant and water.
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify problem.
Lean - Long term fuel trim near 160. Refer to "Diagnostic Aids" on facing page of DTCs 44and 64.
Rich - Long term fuel trim near 108. Refer to "Diagnostic Aids" on facing page of DTCs 45 and 65.
IGNITION SYSTEM
CHECK: Spark plugs for proper heat range. Refer to "Owner's Manual."
CHECK: KS system for no retard, use CHART C-5.
Section "6E3-C4".
ENGINE MECHANICAL
CHECK: For excessive oil in the combustion chamber.
Valve oil seals for leaking.

CHECK: Combustion chambers for excessive carbon buildup. Remove carbon with top engine
cleaner and follow instructions on can.

CHECK: Perform a cylinder compression test. Refer to SECTION 6A.
CHECK: For incorrect basic engine parts such as cam, heads, pistons, etc.
ADDITIONAL CHECKS
CHECK: Calibration I.D. for most current and/or incorrect software. (Refer to service bulletins.)
HESITATION, SAG, STUMBLE

Definition:
Momentary lack of response as the accelerator is

pushed down. Can occur at all vehicle speeds.
Usually more severe when first trying to make
the vehicle move, as from a stop sign. May cause
engine to stall if severe enough.
PRELIMINARY CHECKS
SENSORS
CHECK: TP sensor - Check TP sensor for binding or sticking. TP sensor signal voltage should
increase at a steady rate as throttle is moved toward Wide Open Throttle (WOT).
t
CHECK: MAP sensor- use CHART C-lD.
FUEL SYSTEI\II
CHECK: Evaporative Emission (EVAP) canister purge system for proper operation, use
CHARTC-3.
CHECK: Fuel injectors. Perform injector balance test, use CHART C-2A/Tech 1.
IGNITION SYSTEM
CHECK: Spark plugs for being fouled, or for there being faulty secondary wiring.
CHECK: Ignition system ground.
Section "6E3-C4".
ADDITIONAL CHECKS
CHECK:
t CHECK:
CHECK:
CHECK:
CHECK:
EGR operation, use CHART C-7.
Engine thermostat functioning correctly and proper heat range.
Generator output voltage. Repair if less than 9 or more than 16 volts.
Injector harness locations. Make sure injector harness is connected to the correct
injector/cylinder according to the firing order (firing order 1-8-4-3-6-5-7-2).
6E3-B-10 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS
CUTS OUT, MISSES

Definition:

PRELIMINARY CHECKS
CYLINDER BALANCE TEST
Perform misfire check in "Distributor Ignition (DI) System," Section "6E3-C4".
ENGINE MECHANICAL
CHECK: Compression. Perform compression check on questionable cylinder(s). If compression is
low, repair as necessary. Refer to SECTION 6A.

CHECK: Base engine. Remove rocker covers, check for bent pushrods, worn rocker arms, broken
valve springs, worn camshaft lobes and valve timing, repair as necessary. Refer to
SECTION 6A.
ADDITIONAL CHECKS
Section "6E3-C4".
CHECK: For EMI interference. An engine miss condition can be caused by Electromagnetic
Interference (EMI) on the reference circuit. EMI can usually be detected by monitoring
engine RPM with a scan tool. A sudden increase in RPM with little change in actual
engine RPM change, indicates EMI is present. If the problem exists, check routing of
secondary ignition wires, check distributor ground circuit.
CHECK: Intake and exhaust manifold passage for casting flash.
DRIVEABILITY AND EMISSIONS 5.7L,(VIN P) 6E3-B-11

STALLING
(Page 1 of 2)
Definition:
Engine runs unevenly at idle. If severe, the engine

or vehicle may shake. Engine idle speed may vary
in RPM. Either condition may be severe enough to
stall the engine.
PRELIMINARY CHECKS

CHECK: PCM grounds for being clean, tight and proper routing. Refer to PCM wiring diagrams.
FUEL SYSTEM
NOTICE: Monitoring long term fuel trim will help identify the cause of the problem. If the
system is running lean (long term fuel trim near 160), refer to "Diagnostic Aids" on facing page
of DTCs 44 and 64. If the system is running rich (long term fuel trim near 108), ref'er to
"Diagnostic Aids" on facing page of DTCs 45 and 65.
CHECK: Incorrect minimum idle .speed may be caused by foreign material accumulation in the
CHECK:
CHECK:
t CHECK:
CHECK:
CHECK:
t CHECK:
throttle bore, coking on the throttle valve or on the throttle shaft, .or throttle body
tampering.
Injector harness locations make sure each injector harness is connected to the correct
For injectors that are shorted internally. Compare injector resistance. Injector
.resistance should be within one ohm of each other.
Injector balance, use CHART C-2A.
For fuel in pressure regulator hose. If fuel is present, replace regulator assembly.
Evaporative Emission (EVAP) control system, use CHART C-3.
The Heated Oxygen Sensors (H02S) should respond quickly to different throttle
positions, if they don't, check the Heated Oxygen Sensors (H02S) for silicon
contamination from fuel, or use of improper RTV sealant. The sensors will have a white
powdery coating, and will result in a high but false signal voltage (rich exhaust
indication). The PCM will then reduce the amount of fuel delivered to the engine,
causing a severe driveability problem. Refer to "Powertrain Control Module (PCM) and
Sensors,'' Section "6E3-C l" for more information.
IGNITION SYSTEM
CHECK: Perform misfire check in "Distributor Ignition (DI) System," Section "6E3-C4".
Section "6E3-C4".
ENGINE MECHANICAL
CHECK: Perform a cylinder compression check. Refer to SECTION 6A.
CHECK: For correct camshaft or weak valve springs. Refer to SECTION 6A.
6E3-B-12 5.7L {VIN P) DRIVEABILITY AND EMISSIONS
ROUGH, UNSTABLE, OR IN.CORRECT IDLE,

STALLING
Definition:
{Page 2 of 2)
Engine runs unevenly at idle. If severe, the engine
or vehicle may shake. Engine idle speed may vary
in RPM. Either condition may be severe enough to
stall the engine.
ADDITIONAL CHECKS
CHECK: MAP sensor, use CHART C-lD.
CHECK: Throttle linkage for sticking or binding.
CHECK: PNP switch circuit. Use CHART C-lA, or use Tech 1 and be sure scan tool indicates
vehicle is in drive with gear selector in drive or overdrive.

CHECK: IAC operation, use CHART C-2C.
CHECK: EGR valve. There should be no EGR at idle, use CHART C-7.
CHECK: NC signal to PCM, Tech 1 should indicate NC is being requested whenever A/C is
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
selected. If problem exists with NC "ON," check NC system operation, use CHART
C-10.
Check AIR system. There should be no air to exhaust ports while in "Closed Loop." Use
CHARTC-6.
Crankcase ventilation valve for proper operation by placing finger over inlet hole in
valve end several times. Valve should snap back. If not, replace valve. Refer to
"Crankcase Ventilation System," Section "6E3-Cl3".
For broken motor mounts.
Generator output voltage. Repair ifless than 9 or more than 16 volts.
POOR FUEL ECONOMY

Definition:
Fuel economy, as measured by an actual road

test, is noticeably lower than expected. Also,
economy is noticeably lower than it was on
this vehicle at one time, as previously shown
by an actual road test.
PRELIMINARY CHECKS
Perform the careful visual/physical check as described at start of "Symptoms," Section "6E3-8".
Visually (physically) check: Vacuum hoses for splits, kinks, and proper connections as shown on
Check owner's driving habits.
Is NC "ON" full time (defroster mode "ON")?
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Check air cleaner element (filter) for being dirty or plugged.
IGNITION SYSTEM
CHECK: Spark plugs.
Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
Section "6E3-C4".
COOLING SYSTEM
CHECK: Engine thermostat for.faulty part or for wrong heat range. Refer to SECTION 68.
ENGINE MECHANICAL
CHECK: Compression. Refer to SECTION 6A.
ADDITIONAL CHECKS
CHECK: TCC operation. Refer to SECTION 7A14A or "Automatic Transmission Control System,
Transmission Range (TR) Pressure Switch Assembly," Section "6E3-C8". A Tech 1
should indicate an RPM drop, when the TCC is commanded "ON."

CHECK: For exhaust system restriction, use CHART 8-1.
CHECK: For proper calibration of speedometer.
CHECK: Air intake system and crankcase for air leaks.
6E3-B-14 5.7L {VIN P) DRIVEABILITY AND .EMISSIONS
EXCESSIVE EXHAUST EMISSIONS OR ODORS

Definition:
Vehicle fails an e.mission test. Vehicle has

excessive "rotten egg" smell. (Excessive odors do
not necessarily indicate excessive emissions.)
PRELIMINARY CHECKS
Perform "On-Board Diagnostic (OBD) System Check."

If emission test shows excessive CO and HC check items which can cause an engine to run rich
(long term fuel trim near 108), refer to "Diagnostic Aids" on facing page of DTCs 45 and 65.
If emission test shows excessive NOx, check items which can cause an engine to run lean or tog
hot.
COOLING SYSTEM
If the Tech 1 indicates a very high engine coolant temperature and the system is running lean:
CHECK: Engine thermostat for faulty part or for wrong heat range. Refer to SECTION 6B.
CHECK: Cooling fan operation, use CHART C-12.
FUEL SYSTEM
NOTICE: If the system is running rich (long term fuel trim near 108), refer to "Diagnostic Aids"
on facing page of DTCs 45 and 65.
If the system is running lean (long term fuel trim near 160) refer to "Diagnostic Aids" on facing
page of DTCs 44 and 64.
CHECK: For properly installed fuel cap.
CHECK: Injector harness locations. Make sure each injector is connected to the correct

CHECK: Injector balance test, use CHART C-2NTech 1.
CHECK: EVAP canister for fuel loading, use CHART C-3.
IGNITION SYSTEM
CHECK: Spark plugs, ignition wir~s, and ignition components. Refer to SECTION 60.
Section "6E3-C4".
ADDITIONAL CHECKS
CHECK: EGR valve for not opening, use CHART C-7.
CHECK: For lead contamination of catalytic converter (look for the removal of fuel filler neck
restrictor).
CHECK: Carbon build-up. Remove carbon with top engine cleaner. Follow instructions on can.
CHECK: Crankcase ventilation valve for being plugged, stuck or blocked crankcase ventilation
hose or fuel in the crankcase.

CHECK: Calibration I. D. for most current and/or incorrect software. (Refer to service bulletins.)
DIESELING, RUN-ON
Definition:
Engine continues to run after key is turned

"OFF," but runs very roughly. If engine runs
smoothly, check ignition switch and
adjustment.
PRELIMINARY CHECKS
FUEL SYSTEM
CHECK: Injectors for leaking. Refer to "Fuel System Diagnosis," CHART A-7.
BACKFIRE
Definition:
Fuel ignites in the intake manifold, or in

exhaust system, making loud popping
noise.
PRELIMINARY CHECKS
IGNITION SYSTEM
CHECK: Proper ignition coil output voltage with spark tester J 26792 (ST 125).

CHECK: Ignition wires for crossfire, also inspect distributor cap, ignition wires, and proper
routing of ignition wires.

Section "6E3-C4".
NOTICE: If an intermittent condition exists in the distributor ignition system, refer to

"Distributor Ignition (DI) System," Section "6E3-C4" or SECTION 60.
ENGINE MECHANICAL
CHECK: Compression - Look for sticking or leaking valves, worn camshaft lobe, refer to
SECTION 6A.
CHECK: Valve timing, refer to SECTION 6A.
CHECK: Intake and exhaust manifold passages for casting flash.
FUEL SYSTEM
CHECK: Perform fuel system diagnosis check, use CHART A-7.
CHECK: Fuel injectors. Perform injector balance test, use CHART C-2A/Tech 1.
ADDITIONAL CHECKS
CHECK: EGR gasket for faulty or loose fit.
CHECK: EGR operation for being open all the time, use "Exhaust Gas Recirculation (EGR)"
CHARTC-7.
CHECK: Secondary air injection system, use CHART C-6.
CHECK: Intake and exhaust manifold for casting flash.
CHART B-1
RESTRICTED EXHAUST SYSTEM CH ECK
Proper diagnosis for a restricted exhaust system is essential before any components are replaced.
CHECK AT AIR PIPE: {Left and Right Side AIR Pipes)

1.
2.
3.
Remove the rubber hose at the exhaust manifold AIR pipe check valve. Remove check valve.
Connect Exhaust Backpressure kit (with air adapter) J 35314-A.
Insert the nipple into the exhaust manifold AIR pipe.
CHECK VALVE
RIGHT SIDE AIR PIPE
EXHAUST BACKPRESSURE KIT (J 35314-A)
LEFT SIDE AIR PIPE
AIR CROSSUNDER PIPE
PS 17500
DIAGNOSIS:
1.
2.
3.
4.
5.
With the engine idling at normal operating temperature, observe the exhaust system backpressure
reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi).
Increase engine speed to 2000 RPM and observe gage. Reading should not exceed 20.7 kPa (3 psi).
If the backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure.
If there are no obvious reasons for the excessive backpressure, the three way catalytic converter is
suspected to be restricted and should be replaced using current recommended procedures.
4-30-93
MS 12889
CONNECTOR" A" SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
CKT
#
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAULTY CIRCUIT
A1
A2
PCM GROUND
451
BLK/WHT
ENGINE GROUND
Al
INJECTOR #1 c..oNTRoL
1744
BLK
INJECruR#1 "A"
18 (3)
ROUGH IDLE, ENGINE MISS
A4
INJECTOR #4 CONTROL
844
LTBLU/BLK
INJECTOR #4 ''A"
18 (3)
AS
INJECTOR #6 CONTROL
846
YEL/BLK
INJECTOR #6' A"
18 (3)
A6
INJECTOR #7 CONTROL
877
RED/BLK
INJECTOR #7' A"
18 (3)
A7
FP RELAY CONTROL
465
EGR VACUUM CONTROL SIGNAL

435
GRY
A 10 SECONDARY \.UULING
FAN/HIGH SPEED FAN CONTROL
473
DKBLU
ENGINE CRANKS BUT WILL NOT START
LONG CRANK TIME BEFORE ENGINE

STARTS
DKGRN/WHT FUEL PUMP RELAY

"C2"
AS
A9
A 11 PRIMARY COOLING FAN/LOW

SPEED FAN CONTROL
A 12 EBTCM TP SENSOR SIGNAL
335
DKGRN
EGRVACUUM
CONTROL SOL.
VALVE "B"
EARLY
PRODUCTION;
SECONDARY
COOLING FAN
RELAY "F5"
LATE
PRODUCTION:
COOLING FAN
RELAY #2 UFS"
AND COOLING FAN
RELAY #3 "J2"
EARLY
PRODUCTION:
PRIMARY COOLING
FAN RELAY "02"
LATE
PRODUCTION:
COOLING FAN
RELAY #1 "02"
27 (3)
32
DETONATION, STALL, ROUGH IDLE, AND

POOR PERFORMANCE
EARLY PRoDU\.1 ION:
SECONDARY COOLING FAN INOPERATIVE
OR "ON" AT ALL TIMES.
77 (3,4)
LATE PRODUCTION:
HIGH SPEED FANS INOPERATIVE
(OPERATING AT LOW SPEED ONLY), HIGH
SPEED FANS OPERATE WHENEVER LOW
SPEED REQUESTED AND RIGHT FAN ON
HIGH AT ALL TIMES.
EARLY PRODUCTION:
PRIMARY COOLING FAN INOPERATIVE OR
"ON" AT ALL TIMES.
LA TE PRODUCTION:
LOW SPEED FANS INOPERATIVE OR "ON"
AT ALL TIMES. HIGH SPEED FANS: RIGHT
FAN ONLY.
464
TAN/BLK
EBTCM"A14"
121
WHT
99(3)
INOPERATIVE TACHOMETER
A 14 AIR PUMP RELAY CONTROL
436
BRN
AIR PUMP RELAY

"E2"
29 (3)
AIR PUMP INOPERATIVE OR "ON" AT ALL

TIMES
A 15 I RAN!> MODE LAMP CONTROL
1493
DKBLU
A13 rACH OUTPUT
.,,
"
LAMP uN"" AT ALL TIMES OR "OFF" AT

ALL TIMES
A16
A17
'
(1)
(2)
(3)
(4)
OPEN CIRCUIT
GROUNDED CIRCUIT
SHORTED TO VOLTAGE
71-93
CONT.
DRIVEABILITY AND EMISSIONS 5.7l {VIN P) 6E3-B-19
CONNECTOR" A" SYMPTOMS CHART

32 PIN CONNECTOR
#
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
A18 PCM GROUND
551
TANtvvHT
ENGINE GROUND
A 19 INJECTOR #2 CONTROL
1745
LTGRN/BLK
INJECTOR #2 'A"
18 (3)
845
BLK/WHT,
INJECTOR #5 "A"
18 (3)
1746
PNK/BLK
INJECTOR #3 "A"
18 (3)
878
DKl:ILU/WHT
INJECTOR #8 "A"
18 (3)
A23 TRACTION CONTROL SYSTEM

SPARK RETARD REQUEST
463
ORN/BLK
EBTCM "814"
PIN FUNCTION
CKT
...
A24
A25 FUEL ENABLE SIGNAL
229
DKBLU
DTC{s)
AFFECTED

FAUL TV CIRCUIT
ENGINE CRANKS BUI vvlLLNu, :)IART
POOR PERFORMANCE, EBTCM OTC 74

'
THEFT DETERRENT
MODULE
46(3)
A26
A27
A28
A29
A30
A31
'
vs; GROUND
A32 VS> SIGNAL
(1)
(2)
(3)
(4)
OPEN CIRCUIT
GROUNDED CIRCUIT
SHORTED TO VOLTAGE
RIF.ER TO SECTION SA
401
PPL
VSS"A"
24(1)
INOPERATIVE SPEEDOI\IIETER,
INOPERATIVE CRUISE CONTROL
400
VEL
VSS "B"
24(3)
INOPERATIVE CRUISE CONTROL
..
7-1-93
MS 12082

11
CONNECTOR 8" SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
81
A/C REQUEST SIGNAL
762
DKGRN/WHT
HVAC CONTROL
ASSEMBLY "A"
82
453
RED/BLK
TEST CONNECTOR
DTC(s)
AFFECTED

FAUL TV CIRCUIT
INOPERATIVE A/C (1)
A/C "ON" AT ALL TIMES (2)
16(3)
"D"
DISTRIBUTOR "A"
83
DISTRIBUTOR REFERENCE LOW

SIGNAL
632
PNK/BLK
ENGINE CRANKS BUT WILL NOT START (1)
TEST CONNECTOR
"D'. .
DISTRIBUTOR "D"
84
85
IGNITION CONTROL
423
WHT
IGNITION COIL
MODULE "B"
41 (1.4)
42 (2)
86
SENSOR GROUND
470
BLK
ECT"A"
TP SENSOR "B"
ELECTRONIC
TRANS"M"
15 (1)
21 (1)
LACK OF POWER, ROUGH IDLE, HIGH IDLE
87

SOLENOID
1222
LTGRN
TRANSMISSION
"A''
82 (3.4)
2nd AND 3rd, OR 1t AND 4th GEARS ONLY
88
VSSOUTPUT
817
DKGRN/WHT
CRUISE MODULE
"K"
I/P"D1"
97 (3.4)
H\IOPERA TIVE CRUISE
812 TRANSMISSION 2-3 SHIFT

SOLENOID
1223
VEL/BLK
TRANSMISSION
"B"
81 (3.4)
2nd OR 3rd GEAR ONLY,

NOTCCAPPLV
813 TRANSMISSION 3-2 SHIFT

SOLENOID CONTROL
(AU TOMA TIC)
OR
SKIP SHIFT SOLENOID CONTROL
(MANUAL)
687
WHT
TRANSMISSION
84(3,4)
HARSH 3-2 DOWNSHIFT, 3rd GEAR ONL V
89
810
811
814 DISTRIBUTOR IGNITION FEED
"S"
.OR
OR
587
GRV
631
RED
OR
OR
SOLENOID "A"
TEST CONNECTOR
84(1,2)
OR
INOPERATIVE SKIP SHIFT(1),4th GEAR
ONLV(2)
"("
DISTRIBUTOR "C"
340
ORN
816 SENSORGROUND
452
BLK
*
MAP"A"
IAT"A"
A/C REFIG.
PRESSURE SENSOR
23 (1)
33 (1)
66 (1)
71 (1)

POOR PERFORMANCE A/C INOPERATIVE
"A''
A/C EVAP TEMP
SENSOR "C"
817
818
.819 MAF SENSOR SIGNAL
(1)
(2)
(3)
(4)
492
YEL
MAF"A"
48 (3.4)
ENGINE STALL, HESITATION WHEN

MALFUNCTION OCCURS
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
CONT'D

11
11
CONNECTOR 8 SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC{s)
AFFECTED

FAULTY CIRCUIT
430
PPL/WHT
TEST CONNECTOR
"B"
DISTRIBUTOR "B"
36 (3,4)
59
DKGRN
A/C CLUTCH RELAY

"84"
A/C CLUTCH "A"
68(4)
69 (1)
828 5 \IOLT REFERENCE
474
GRY
TPSENSOR"A"
22(3)
HIGH IDLE; LACK OF PERFORMANCE
829 5 \IOLT REFERENCE
416
GRY
A/C EVAPORATOR
TEMPERATURE,
SENSOR "A",
MAP"C",
A/C REFRIGERANT
PRESSURE SENSOR
34(3)
66 (3)
INOPERATIVE A/C
830 PCIIII IGNITION FEED
439
PNK
831 PCIIII BATTERY FEED
340
ORN
820 HIGH RESOLUTION SIGNAL
821 A/CCLUTCH STATUS
ENGINE SURGE, LACK OF PERFORMANCE
A/C INOPERATIVE
822
823
824
825 1
826
827
"B"
832
(1)
(2)
(3)
(4)
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
6-30-93
MS 12461
CONNECTOR "(.f' SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
,,..
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

~.AULTY CIRCU.IT
C1
IACCOIL "A" HIGH
1747
LTBLU/WHT
IAC"D"
INCORRECT IDLE, SURGE, STALL
C2
IAC COIL" A" LOW
1748
LT BlU/BLK
IAC"C"
IAC COIL "B" LOW
444
LTGRN/BLK
IAC"A"

C3
C4
cs
C6
IAC COIL "B" HIGH
1749
LTGRN/WHT
IAC"B"
C7
BANK 2 (RIGHT)
H02SLOW
1667
TAN
H02S"A"
63 (1)
ROUGH IDLE, LEAN EXHAUST, POOR

PERFORMANCE AND POOR FUEL
ECONOMY
CB
BANK 2 (RIGHT)
H02S HIGH
1666
PPL
H02S "B"
63 (1)
EXHAUST ODOR, POOR PERFORMANCE,

POOR FUEL ECONOMY AND "OPEN LOOP";
64 (2)
C9
C10
C11 TRACTION CONTROL SYSTEM
"ACTIVE" SIGNAL
C12
832
LTBLU
EBTCM"A16"
C13 PERFORMANCE MODE.SWITC.H

SIGNAL
553
LTBLU
PERFORMANCE/.
TRACTION
CONTROL
PROGRAM,SWITCH
74(2)
.*
NO AGGRESSIVE Sl:IIFT PATTERN
"K
C14 BRAKE SWITCH SIGNAL
420
PPL
BRAKE SWITCH
"A"'
C1 S PNP SIGNAL
434
ORN/BLK
PNP SWITCH "B"
C16 TRANSMISSION PRESSURE

CONTROL SOLENOID HIGH
C17
1228
RED/BLK
TRANSMISSION
37 (3)
NOTCC
38 (4)
POOR FUELECONOMY,.STALL, INCORRECT
IDLE
73 (3)
HAR.SH TRANSMISSION SHIFTS
"("
..
C18
. C19 BANK 1 (LEFT) H02S LOW
(1)
(2)
(3)
(4)
1653
TAN/WHT
H02S "A"
13 (1)
ROUGH IDLE, LEAN EXHAUST, POOR

PERFORMANCE AND POOR FUEL
ECONOMY
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
REFER TO ELECTRICAL DIAGNOSIS (SECTION BA).
6-30-93
CONT'D
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-B-23

11
CONNECTOR C" SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
C20 BANK 1 (LEFT) H02S HIGH
C21 IATSENSORSIGNAL
CKT
#
1665
472
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAULTY CIRCUIT
PPUWHT
H02S "B"
13 (1)
44(2)
EXHAUST ODOR, POOR PERFORMANCE,

POOR FUEL ECONOMY AND "OPEN LOOP"
STATUS
23 (1)
POOR FUEL ECONOMY
TAN
IAT"B"
25 (2)
C22 TP SENSOR SIGNAL
417
DKBLU
TP SENSOR "C"
21 (4)
22 (3)
C23 MAP SENSOR SIGNAL
432
LTGRN
MAP"B"
33 (4)
34 (3)
410
YEL
ECT"B"
14 (2)
HIGH IDLE, LACK OF PERFORMANCE

HARSH TRANSMISSION SHIFTS
MODIFIED TRANSMISSION SHIFT PATTERN
C24
C25 ECT SENSOR SIGNAL
15 (1)
EXHAUST ODOR, ROUGH IDLE, POOR FUEL

ECONOMY, TCC APPLY COLD
28 (3)
NO TCC, HARSH SHIFTS
28 (3)
NO TC(:, HARSH SHIFTS
28 (3)
NO TCC, HARSH SHIFTS
C26
C27
C28 TRANSMISSION RANGE SIGNAL
"All'
1224

"B"
1225
1226
"c
PNK
TRANSMISSION
"N"
DKBLU
TRANSMISSION
"R"
RED
TRANSMISSION.'
"P"
C31
C32 PCM GROUND
(1)
(2)
(3)
(4)
451
BLK/WHT
ENGINE BLOCK
. ENGINE CRANKS BUT WILL NOT START
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
REFER TO ELECTRICAL DIAGNOSIS (SECTION BA).
6-30-93
MS 12083
6E3-B-24 5.7L (VIN P) DRIVEABILITYAND EMISSIONS
CONNECTOR "D" SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
01
PCM GROUND
551
TAN/WHT
ENGINE BLOCK
02
TRANSMISSION PRESSURE
CONTROL SOLENOID LOW
1229
LTBLU/WHT
TRANSMISSION
PCM IGNITION FEED
439
PNK
REVERSE INHIBIT SOLENOID
1652
LTGRN
MANUAL
TRANSMISSION
03
"o
DTC(s)
AFFECTED

FAULTY CIRCUIT
73 (3)
HARSH TRANSMISSION SHIFTS

04
05
06
CONTROL
83(3,4)
UNABLE TO SHIFT INTO REVERSE OR WILL

GO INTO REVERSE AT ANY SPEED
"A"
07
08
09

MIL CONTROL
010 EVAP CANISTER PURGE

459
DKGRN/WHT A/C CLUTCH RELAY

"BS"
68 (2)
A/C INOPERA TIV.E
70 (3)
419
BRN/WHT
11 (3,4)
428
DKGRN/WHT
EVAP CANISTER
PURGE SOLENOID
VALVE "B"
26 (3)
45 (2)
ROUGH RUN, FUEL ODOR

NOTCCAPPLY
..
MIL "ON" AT ALL TIMES OR MIL "OFF" AT

ALL TIMES
011 TRANSMISSION TCC SOLENOID
422
TAN/BLK
TRANSMISSION
"T"
90 (3)
012 A/C REFRIGERANT PRESSURE

SENSOR SIGNAL
380
RED/BLK
A/C REFRIGERANT
PRESSURE SENSOR
"C"
66 (3.4)
A/C INOPERATIVE
91 (3, 4)
SKIP SHIFT LAMP "ON" AT ALL TIMES OR

"OFF" AT ALL TIMES
013
014
015 SKIP SHIFT LAMP CONTROL
375
WHT
016
017
018
019
(1)
(2)
(3)
(4)
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
7-9-93
CONT.
PCM Connector "D" Symptom Chart (7 of 8)
CONNECTOR "D" SYMPTOMS CHART

32 PIN CONNECTOR
PIN FUNCTION
020 OUTPUT/FIELD SERVICE ENABLE
CKT
#
448
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
WHT/BLK
DLC"B"
DTC(s)
AFFECTED

FAULTY CIRCUIT
FIELD SERVICE INOPERATIVE (1)
MIL FLASHING WHILE ENGINE IS RUNNING
{2)
021
022 KS SIGNAL
496
DKBLU
KNOCK SENSOR
43 (3,4)
LACK OF PERFORMANCE DETONATION
732
DKBLU
A/C EVAPORATOR
TEMPERATURE
SENSOR "B"
71 (3)
INOPERATIVE A/C
1227
YEUBLK
TRANSMISSION
58 (2)
"L''
59 (1,4)
EARLY OR DELAYED TRANSMISSION

SHIFTS
023
024 A/C EVAPORATOR
025
026
027
028 TRANSMISSION FLUID
029
030 SERIAL DATA
800
TAN
DLC"M"
EBTCM "A11"
DERM "811"
NO TECH 1 COMMUNICATIONS {NO DA TA)
031
032
(1)
(2)
(3)
(4)
OPEN CIRCUIT.
GROUNDED CIRCUIT.
SHORTED TO VOLTAGE.
7-9-93
MS 12462
PCM Connector "D" Symptom Chart (8 of 8)
6E3-C-1 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
SECTION C
COMPONENT SYSTEMS
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread-locking compound wiH be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed,
parts or system damage could result.
Section "C" provides information on the following:
General description of components and systems.
On-vehicle service.
Part names and group numbers.
Diagnostic charts. These include a functional check of the system as well as diagnosis of any problem
found in the functional check.
For locations of components, wiring diagrams, and PCM terminal end view, refer to the front of Section
"6E3-A".
Following are the sub-section identification and the system covered:
C1 Powertrain Control Module (PCM) and Sensors Page C1 1
C2 Fuel Metering System Page C2-1
C3 Evaporative Emission (EVAP) Control System
Page C3-1
C4 Distributor Ignition (DI) System Page C4-1
cs Knock Sensor (KS) System Page CS-1
Page C61
C6 Secondary Air Injection (AIR) System
C7 Exhaust Gas Recirculation (EGR) System Page C7-1
ca Automatic Transmission Control System Page C8-1
C10 A/CClutchCircuitDiagnosis Page C10-1
C12 Electric Cooling Fan(s)
PageC12-1
C13 Crankcase Ventilation System . Page C13-1
Page C14-1
C14 Air Intake System
. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC CHARTS
The diagnostic charts for each system are found after the on-vehicle service and parts information at the back of
each section. Following are the charts found in this section.
Chart C-1A
Chart C-1 D
Chart C-2C
Chart C-3
Chart C-4A
Chart .C-48
Chart C-5
Chart C-6
Chart C-7
ChartC-8A
ChartC-88
Chart C-8C
Chart C-10
Chart C-12A
Chart C-128
Park/Neutral Position (PNP) Switch Diagnosis

Manifold Absolute Pressure (MAP) Output Check
Id Ie Air Control (IAC) Valve Check
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Check

Distributor Ignition (DI) System Check ( 1 of 2)
Misfire Check
Knock Sensor (KS) System Check
Secondary Air Injection (AIR) System Check

Exhaust Gas Recirculation (EGR) System Check (1 of 2)
Transmission Range (TR) Pressure Switch Assembly Circuit Check

Performance Mode Switch Indicator Lamp Control Circuit Check
Performance Mode Switch Signal Circuit Check
A/C Clutch Circuit Diagnosis ( 1 of 3)
Electric Cooling Fan Control Circuit Diagnosis (1 of 2)
(Non A/C and Early Production A/C)
Electric Cooling Fan Control Circuit Diagnosis (1 of 4)

(Late Production A/C)
Page C1-16
Page C1-18
Page C2-20
Page C3-6
Page C4-4
Page C48
Page CS-4
Page C6-6
Page C7-4
Page C8-10
Page C812
Page C8-14
Page C10-4
Page C12-4
Page C12-8
DRIVEABILITY AN.D EMISSIONS 5.7L (VIN P) 6E3-C1-1
SECTION C1
POWERTRAIN CONTROL MODULE (PCM} AND SENSORS

CONTENTS
General Description
Powertrain Control Module (PCM) .....
PCM Function
Memory
ROM
. . ....... . .. . . . .. ..
. . .... .. . . . . . ... . . .
. . . . . . . . . . .. . .. . . . .
RAM
EEPROM

Long Term Fuel Trim r
Speed Density System
Information Sensors
Sensor
Knock Sensor
Sensor

Mass Air Flow (MAF) Sensor ,
lntak~AirTemperature(lAT)Sensor
Vehi~le Speed Sensor (VSS) ..
Transmission Fluid Temperature
(TFT) Sensor
A/C Refrigerant Pressure Sensor ..
A/C Evaporator Temperature
Sensor
C1-3
C1-3
C1-3
C1-3
C1-4
C1-4
C:1-5
C1-6
C1-7
C1-7
C1-7
A/C Request Signal

(Automatic Only)

Reference Signal

Diagnosis
C1-1
C1-1
C1-2
C1-2
C1-2
C1-2
C1-2
C1-2
C1-2
C.1-2
C1-3
C1-7
C1-7
C1-7
C.1-7
PCM Inputs .
C1-8
Sensor
Knock Sensor
MAP Sensor
MAF Sens9r . . . . . . . . . . . -'
. . . . . . . . . . . . . .. . .
IA T Sensor
Heated Oxygen Sensor (H02S) .

Response Time
Heated Oxygen Sensor
Contaminants
A/C Request Signal

Reference Signal

On-Vehicle Service
PCM and Components Replacement
PCM
EEPROM Programming
Functional Check

Sensor
C1-8
C1-8
C1-8
C1-8
C1-8
C1-8
C1-8
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-10
C1-10
C1-12
Sensor
C1-1 2
MassAirFlow(MAF)Sensor
intakeAirTemperature(IAT)Sensor
(aank 1 or Bank 2)
KnockSensor(KS)
C1-12
C1-13
C1-13
C1-14
C1-14
C1-14
C1-14
C1-14
C1-8
GENERAL DESCRIPTION
The Powertrain Control Module (PCM) (Figure
Cl-1} is the control center of the fuel injection system.
It constantly looks at the information (rom various
sensors, and controls the systems that affect vehicle
performance.
The PCM also performs a diagnostic function
check of the system. It can recognize operational
problems and alert the driver through the Malfunction
Indicator Lamp (MIL) and store a DTC or DTCs which
identify the prQblem areas .to aid the technician in
making repairs.
KNOCK SENSOR MODULE D
PCM ~(CLEAR) ACCESS COVER.(BLUE)
~=::::::::::::::::ID
.:::::::::::::::::)
=====[=======l~
A
(RED)
(BLACK)
PS 17345
Figure C1-1 - Powertrain Control Module (PCM)
Refer to "Introduction," SECTION 6E for more

information. on using the diagnostic function of the
PCM.
6E3-C1-2 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

PCM Function
The PCM supplies 5 or 12 volts to power various
sensors or switches. This is done through resistances
in the PCM which are so high in value that a test ligil';t
will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low.
Therefore, the use of a 10 megohm input impedance
digital voltmeter (J 39200) is required to assure
accurate voltage readings.
Memory
There are three types of memory storage within
the PCM: ROM, RAM and EEPROM.
ROM
Read Only Memory (ROM) is a permanent memory
that is physically soldered to the circuit boards within
the PCM. The ROM contains the overall control
programs. Once the ROM is programmed, it cannot tie
changed. The ROM mem<>ry is non-erasable, and does
not need power to be retained.
RAM
Random Access Memory (RAM) is the
microprocessor "scratch pad." The processor can write
into, or read from this memory as needed. This
memory is erasable and needs a constant supply of
voltage to be retained. If the voltage is lost, the
memory is lost.
EEPROM
Memory (EEPROM) is a permanent memory that is
physically soldered to the circuit boards within the
PCM. The EEPROM contains the overall control
algorithms. The EEPROM can be reprogrammed by
using the Tech 1 scan tool or other Techline
terminal/equipment.

The short term fuel trim is a PCM erasable
memory register that will contain a number between O
and 255. The neutral value for the short term fuel
trim is 128; any deviation from this value indicates the
short term fuel trim is changing the injector pulse
width. The amount of pulse width change depends on
how far the short term fuel trim value is from 128. The
short term fuel trim changes the pulse width by
varying the "Closed Loop" factor of the base pulse
width equation. As the PCM monitors the oxygen
sensor's input, it is constantly varying the short term
fuel trim value.
The value is updated very quickly, therefore, the short

term fuel trim only corrects for short term mixture
trends: The correction of long term mixture tr.ends is
the function oflorig term fueltrim.
Long Term Fuel Trim

The long term fuel trim is a matrix of cells
arranged by RPM and MAP. Each cell of the long term
fuel trim is a register like the short term fuel trim. As
the engine operating conditions change, the PCM will
switch from cell to cell to determine what "long term
fuel trim" factor to use in the base pulse width
equation.
While in any given cell, the PCM also monitors the
short term fuel trim. If the short term fuel trim is far
enough from 128, the PCM will chahge the long term
fuel trim value. Once the long term fuel trim value is
changed, it should force the short term fuel trim back
toward 128.
If the mixture is still not correct (as judged by the
H02S), the short term fuel trim will continue to have a
large deviation from the ideal 128. In this case, the
long term fuel trim value will continue to change until
the short term fuel trim becomes balanced.
Both the short term fuel trim and l~ng term fuel
trim have limits which vary by calibration. If the
mixture is off enough so that long term fuel trim
reaches the limit of its control and still cannot correct
the condition, the short term fuel trim would also go to
its limit of control in the same direction. If the
mixture is still not corrected by both short term fuel
trim and long term fuel trim at their extreme values, a
Heated Oxygen Sensor (H02S) DTC will likely result.
Under the conditions of power enrichment, the PCM
sets the short term fuel trim to 128 and freezes it there
until power enrichment is no longer in effect. This is
done so the "Closed Loop" factor and the long term fuel
trim will not try to correct for the commanded richness
of power enrichment.
SPEED DENSITY SYSTEM

Three specific data sensors provide the PCM with
the basic information for fuel management portion of
its operation. That is three specific signals to the PCM
establish the engine speed and air density factors.
The engine speed signal comes from the distributor
low resolution circuit. The PCM uses this information
to determine engine speed (RPM).
Air density is derived from IAT and MAP sensor
in_puts. The IAT sensor measures the air temperature
that is entering the engine. The IAT signal works in
conjunction with the MAP sensor to determine air
density. As the intake manifold pressure increases,
the air density in the intake manifold also increases
and additional fuel is required.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-C1-3

This information from the IAT and MAP sensors is
used by the PCM to control injector pulse width.
The speed density system is only needed when
there is a Mass Air Flow (MAF) sensor malfunction. If
the PCM detects a malfunction with the MAF sensor
circuit, the PCM will default to speed density fuel
management.
INFORMATION SENSORS
The Engine Coolant Temperature (ECT) sensor
(Figure Cl-2) is a thermistor (a resistor which changes.
value based on temperature) immersed in the engine
coolant stream. Low coolant temperature produces a
high resistance, while high temperature causes low
resistance.
The PCM supplies a 5 volt signal to the ECT
through a resistor in the PCM and measures the
voltage. The voltage will be high when the engine is
cold, and low when the engine is hot. By measuring
the voltage, the PCM knows the engine coolant
temperature. Engine coolant temperature affects most
systems the PCM controls.
A failure in the ECT circuit should set either a
OTC 14 or 15. Remember, these DTCs indicate a
failure in the engine coolant temperature sensor
circuit, so proper use of the chart will lead to either
repairing a wiring problem or replacing the sensor to
properly repair a problem.
Knock Sensor
The knock sensor (Figure Cl-A.)is mounted to the
right lower side of the engine block.
When abnormal engine vibrations (spark knock)
are present, the sensor produces a voltage signal which
is sent to the PCM.
Refer to "Knock Sensor (KS) System," Section
"6E3-C5" for further information on the Knock Sensor
(KS) system.
HARNESS CONNECTOR
LOCKING TAB
SENSOR
SS 1640-6E
Figure C1-2 - Engine Coolant Temperature (ECT)

Sensor

The Manifold Absolute Pressure (MAP) sensor
(Figure Cl-5), is a pressure sensor that measures
changes in intake manifold pressure. The pressure
changes as a result of engine load and speed. The MAP
sensor converts this to a voltage output.
A closed throttle on engine coastdown would
produce a relatively low MAP output voltage, while a
wide-open throttle would produce a high MAP output
voltage. This high output voltage is produced because
the pressure inside the manifold is the same as outside
the manifold, so you measure 100% of outside air
pressure. Manifold Absolute Pressure (MAP) is the
OPPOSITE of what you would measure on a vacuum
gage. When manifold pressure is high, vacuum is low.
The MAP sensor is also used to measure barometric
pressure under certain conditions, which allows the
PCM to automatically adjust for different altitudes.
The PCM sends a 5 volt reference signal to the
MAP sensor. As the manifold pressure changes, the
electrical resistance of the MAP sensor also changes.
By monitoring the sensor output voltage, the PCM
knows the manifold pressure. The PCM uses the MAP
sensor to control ignition timing. The MAP sensor is
also used for speed density fuel management. When
the PCM detects a malfunction with the Mass Air Flow
(MAF) sensor circuit, the PCM will default to speed
density.
MAP
kPa
100
30
20
10
Hg
29.6 26.6 23.7 20.7 17.7 14.8 11.8 8.9
5.9
2.9
1.1
0.6
0.3
0.3
4.9
90
4.4
80
3.8
70
3.3
60
50
2.7 2.2
40
1.7
Mass Air Flow (MAF) Sensor

The Mass Air Flow (MAF) sensor (Figure Cl-3)
measures the amount of air that is ingested by a
vehicle's engine. This information is required by the
engine's Powertrain Control Module (PCM) to
schedule fuel and maintain the desired air/fuel ratio.
The MAF sensor used on this vehicle is a hot wire
type and is used to measure air flow rate. The Mass
Air Flow (MAF) output frequency is a function of the
power required to keep the air flow sensing elements
(hot wires) at a fixed temperature above ambient
temperature. As air flows through the MAF sensor,
the "hot wires" are cooled. The amount of cooling is
proportional to the rate of air flow. As air flow
increases, a greater amount of current is required to
maintain the "hot wires" at a constant temperature.
The MAF sensor converts the changes in current draw
to a frequency signal read by the PCM. The PCM
calculates air flow (grams per second) based on this
signal. A failure in the MAF sensor circuit should set
a OTC 48.
6E3-C1-4 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
SENSOR
2
ELECTRICAL CONNECTOR
65 2648-6E
Figure C1-5 - Manifold Absolute Pressure (MAP)
l>S 17338
Figure C1-3 - MAF Sensor
HARNESS CONNECTOR
2
LOCKING TAB
SENSOR
SS 1640-6E
Figure C1-6 - Intake Air Temperature (IAT) Sensor
KNOCK SENSOR (KS)

35 0023-6E
Figure C1-4 - Knock Sensor

The Intake Air Temperature OAT) sensor (Figure
Cl-6) is a thermistor (a resistor which changes value
based on temperature). It is mounted in the air intake
duct. Low temperature produces a high resistance and
high temperature causes low resistance.
The PCM supplies a 5 volt signal to the sensor
through a resistor in the PCM and measures the
voltage. The voltage will be high when the intake air
is cold, and low when the intake manifold air is hot.
By measuring the voltage, the PCM knows the intake
air temperature.
A failure in the IAT sensor circuit should set either
a DTC 23 or OTC 25.
The Heated Oxygen Sensor (H02S) (Figure Cl-7)

is essentially a small variable battery; it has the
ability to produce a low voltage signal that feeds
information on engine exhaust oxygen content to the
PCM.
The H02S is constructed from a material
(zirconia/platinum) that conducts ~lectricity under
certain conditions. At operating temperature, 315C
(600F), the element becomes a semiconductor. A
platinum coating on the outer surface of the element
stimulates further combustion of the exhaust gases
right at the'surface and this helps keep the element up
to the desired temperature. The H02S has an inter
cavity which is filled with atmospheric (reference) air.
The atmosphere has approximately 21 % oxygen in it.
In this electrical circuit this inter cavity is the positive
( +) terminal. The outer surface of the element is
exposed to the exhaust gas stream. It is the negative
(-) or ground terminal. The oxygen concentration,
differences between the reference air and exhaust
gases produce small voltages (refer to Figure Cl-8).
DRIVEABILITY AND EMISSIONS S. 7L (VIN P) 6E3-C1-5

A rich exhaust (excessive fuel) has almost no
oxygen. When there is a large difference in the
amount of oxygen touching the inside and outside
surfaces, there is more conduction, and the sensor puts
out a voltage signal above 600 m V. With lean exhaust
(excessive oxygen) there is about two percent oxygen
in the exhaust. This is a smaller difference in oxygen
from the outside surfaces which results in less
conduction and a voltage signal below 300 m V. The
voltages are monitored and used by the PCM to "fine
tune" the air/fuel ratio to achieve the ideal mixture
desired.
The PCM sends a reference signal of 450 m V. The
reference signal serves to run the engine when it is in
"Open Loop" mode of operation. When the air/fuel
ratio is correct the PCM displays 450 m V. When the
engine is operating with a rich air/fuel ratio, there is a
reduction of free oxygen in the exhaust stream and the
oxygen voltage rises above the reference voltage.
When the engine is run lean, the voltage drops
below the reference voltage due to excess oxygen in the
exhaust stream. The H02S provides the feedback
information for the "Closed Loop" operating m:ode of
the fuel delivery system. The H02S indicates to the
PCM what is happening in the exhaust. It does not
cause things to happen. It is a type of gage: Low
voltage output = lean mixture = high oxygen content
in exhaust; high voltage output = rich mixture = low
oxygen content in the exhaust.
An open Heated Oxygen Sensor (H02S) circuit,
should set a OTC 13 or 63. A constant low voltage in
the H02S circuit should set a OTC 44 or 64. A
constant high voltage in the circuit should set a OTC
45 or 65 (refer to Figure Cl-9). OTCs 44, 45, 64, or 65
could also be set as a result of fuel system problems.
Refer to "OTC Charts" for conditions that can cause a
lean or rich system.
FOUR WIRE
IN-LINE
CONNEC"rOR
SEAT
OUTER ELECTRODE
& PROTECTIVE
COATING
PS 17733
Figure C1-7 - Heated Oxygen Sensor (H02S) Cutaway

View
OXYGEN SENSOR ELEMENT

The Throttle Position (TP) sensor (Figure Cl-10) is
apotentiometer connected to the throttle shaft on the
throttle body and is one of the most important sensors
for engine/transmission control. The TP sensor has
one end connected to 5 volts from the PCM and the
other to PCM ground. A third wire is connected to the
PCM to measure the voltage from the TP sensor. As
the throttle valve angle is changed (accelerator pedal
moved), the voltage output of the TP sensor also
changes.
At a closed throttle position, the voltage output of
the TP sensor is low (approximately .5 volt). As the
throttle valve opens, the output increases so that at
wide-open throttle, the output voltage should be near 5
volts.
By monitoring the output voltage from the TP
sensor, the PCM can determine fuel delivery based on
throttle valve angle (driver demand).
GASKET
. 21%
21%
EXHAUST
. GAS WITH
0%
OXYGEN
OXYGEN
OXYGEN
......
......
......
....
....
..
......
....
......
......
0.6V
MORE CONDUCTION
EXHAUST
GAS WITH
2%
OXYGEN
0.3V
LESS,CONDUCTION
9S6325-6E
Figure C1-8- Heated Oxygen Sensor Element
RICH
0.60v
RICH
0.60v
PCM H02S
REFERENCE
SIGNAL
0.45v
PCM H02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN
0.30v
NORMAL OPERATION
RICH TOO LONG - OTC 45 OR 65
RICH
0.60v
RICH
0.60v
PCM H02S
REFERENCE
SIGNAL
0.45v
PCMH02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN
0.30v
LEAN TOO LONG - OTC 44 OR 64
BETWEEN 0.3-0.6v TOO LONG - OTC 13 OR 63

3-24-93
PS 17346
Figure C1-9 - Normal Voltage and Abnormal Trends
CONTROL
MODULE
36

2
THROTTLE VALVE
9P0394-SY
Figure C1-10-Throttle Position (TP) Sensor
A broken or loose TP sensor can cause intermittent

bursts of fuel from the injector and cause an unstable
idle, because the PCM detects the throttle is moving.
If the TP sensor circuit is open, the PCM will set a
OTC 22. If the TP sensor circuit is shorted, the PCM
will interpret this signal as wide open throttle and a
OTC 21 will be set. A problem in any of the TP sensor
circuits will set either a OTC 21 or 22. Once a OTC is
set, the PCM will use a default value for TP sensor,
and some vehicle performance will return.
Refer to "On-Vehicle Service" for replacement of
TP sensor.
MS 10029
Figure C1-11 -Vehicle Speed Sensor

The Vehicle Speed Sensor (VSS) (Figure Cl-11) is
a pulse counter type input that informs the PCM how
fast the vehicle is being driven. The VSS system uses
an inductive sensor mounted in the tail housing of the
transmission and a toothed reluctor wheel on the.tail
shaft. As the reluctor rotates, the teeth alternately
interfere with the magnetic field of the sensor creating
an induced voltage pulse.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-C1-7

The VSS produces an AC voltage signal that increases
with vehicle speed. The PCM processes this signal and
sends it to the instrument panel, chime module and
cruise control module on CKT 817. Refer to OTC 24 or
DTC72.
TRANSMISSION FLUID TEMPERATURE (TFT)

SENSOR
temperature) used to indicate transmission fluid
input to determine the following:
Shift quality.
control valve body within the transmission. A fault in
the Transmission Fluid Temperature (TFT) sensor
circuit will set a DTC 58, 59, or 79.
A/C Refrigerant Pressure Sensor

This signal is used by the PCM to enable cooling
fans when head pressure reaches about 189 psi. If a
fauit is present in the A/C refrigerant pressure sensor
circuit, a DTC 66 and 67 will set, and the A/C clutch
would be disabled.
A/C Evapo'tator Temperature Sensor

This signal is used by the PCM to cycle the AJC
clutch "ON" and "OFF." The PCM will cycle the clutch
"ON" at 4C (39F) and "OFF" at 2C (36F). A failure
in the NC evaporator temperature sensor circuit will
result in a DTC 71 and A/C clutch would be disabled.
A/C Request Signal

This signal tells the PCM that the AJC selector
switch is turned "ON." The PCM uses this information
to adjust the idle speed when the air conditioning is
working. If this signal is not available to the PCM, the
AJC compressor will not engage.

(Automatic Only)
The Park/Neutral Position (PNP) switch indicates
to the PCM when the transmission is in park, neutral,
or drive. This information is used for the EGR and the
IAC valve operation.
rn
Important
Vehicle should not be driven with park/neutral

position switch disconnected, as idle quality will be
affected and a possible false DTC 24 (VSS) may set.
Refer to SECTION 8A for more information on the

PNP switch, which is part of the neutral/start and
backup light switch assembly. Refer to CHART C-lA
for PNP switch check.
Reference Signal
The distributor ignition system sends a signal to
the PCM to tell it both engine RPM and crankshaft
position. Refer to "Distributor Ignition (DI) System,"
Section "6E3-C4" for further information.
DIAGNOSIS
To display diagnostic trouble codes, use a Tech 1.
Grounding the DLC will not flash DTC(s), but will
enable most outputs when the ignition is "ON," engine
"OFF." Grounding the DLC while the engine is
running will cause the MIL to flash to indicate "Open"
or "Closed Loop." This is referred to as "Field Service
Mode."
To clear the DTCs from memory use the Tech 1 or: 11
Ignition "OFF."
Disconnect the #4 fuse (located in the'
instrument panel fuse block), for 30 seconds.
Since the PCM can have a failure which may affect
only one circuit, following the diagnostic procedures in
this section will determine which circuit has a problem
and where it is.
If a diagnostic chart indicates that the PCM
connections or PCM is the cause of a problem and the
PCM is replaced, the Knock Sensor (KS) module rri~st
be transferred to the new PCM and the new PCM must
then be programmed. If this does not correct the
problem, one of the following may be the reason:
There is a problem with the PCM terminal
connections. - The diagnostic chart will say
PCM connections or PCM. The terminals may
have to be removed from the connector in order
to check them properly.
The problem is intermittent. -This means that
the problem is not present at the time the
system is being checked. In this case, refer to
the "Symptoms," Section "6E3-B" portion of
the manual and make a careful physical
inspection of all portions of the system
involved.
6E3-C1-8 5.7L (VIN P) DRIVEABILITYAND EMISSIONS
Shorted solenoid, relay coil, or harness. Solenoids and relays are. turned "ON" and
"OFF" by the PCM using internal electronic
switches called "drivers."
A shorted solenoid, relay coil, or PCM harness will
not damage the PCM but will cause the component to
be inoperative.
J 34636 or BT-8405 testers or equivalent provide a
fast, accurate means of checking for a shorted coil or a
short to battery voltage.
PCM INPUTS
All of the sensors and input switches can be
diagnosed by the use of a Tech 1. Following is a short
description of how the sensors and switches can be
diagnosed by the use of a Tech 1. The Tech 1 can also
be used to compare the values for a normal running
engine with the engine you are diagnosing.

The Tech 1 displays engine coolant temperature in
degrees celsius and fahrenheit. After engine is
started, the temperature should rise steadily to about
90C (194F) then stabilize when the thermostat openl;.
If the engine has not been run for sever~Ji.,!iours
(overnight), the ECT and IAT should be close't'o each
other. A fault in the Engine Coolant 'femperature
(ECT) sensor circuit should set a DTC 14 or 15. The
DTC charts also contain a chart to check for: Engine
Coolant Temperature (ECT) sensor resistance values
1
IAT Sensor
The Tech 1 displays. temperature of the air
entering the engine and should be close to ambient air
temperature when engine is cold, and rise as
underhood temperature increases. If the engine has
not been run for several hours (overnight) the IAT
sensor temperature and ECT sensors should display
temperature readings close to each other. A failure in
the IAT sensor circuit s.hould set a DTC 23 or 25. The
DTC charts also contain a chart to ch,eck for sensor
resistance values relative to temperature.

The Tech 1 has several positions that will indicate
the state of the exhaust gases,' H02S voltage, short
term fuel trim, and long term fuel trim.
Normal Tech 1 voltage varies between 10 mV to
1000 mV (.Ol and 1.0 volt) while in "Closed Loop."
OTC 13 and 63 will set in one minute if voltage
remains between 350 mV and 550 mV, but the system
will go "Open Loop" in about 15 seconds.
The PCM self-diagnostic circuit looks for trends in
H02S voltage. If a trend is detected, the MIL (Service
Engine Soon) comes "ON."
A rich exhaust trend causes the sensor voltage to
stay above 700 m V for too long. This sets OTC. 45 or
OTC65.
Lean exhaust causes voltage to stay below 300 mV
for too long. This sets DTC 44 or 64. If voltage stays
between 350 m V and 550 m V for too fong, the PCM
sets DTC 13 or 63. This indicates an open H02S
circuit.
Knock Sensor
Response Time
The Tech 1 will indicate when knock is present.
Refer to "Knock Sensor (KS) System," Section "6E3C5" for further information on the KS system.
MAP Sensor
The Tech 1 displays manifold absolute pressure
and will display volts and kPa of pressure. Key "ON,"
engine stopped (no vacuum), MAP will display high
voltage or pressure, while at idle (high vacuum), MAP
will display low voltage or pressure. Likewise, on
acceleration MAP will display high and on
deceleration will display low voltage.
A failure in the MAP sensor circuit should result
in a DTC 33 or DTC 34.
MAFSensor
The Tech 1 displays grams per second. The PCM
converts the mass air flow sensor input signal into
grams per second, indicating the amount of air flow
entering the engine. A failure in the MAF sensor
circuit should result in a DTC 48.
Not only is it necessary for the H02S to produce a

voltage signal for rich or lean exhaust, it is also
important to respond quickly to changes. The PCM
senses the response times. If the H02S responds
slowly, the customer may complain of poor fuel
economy, rough idle or lack of performance. It may
also set false PCM DTCs because the PCM uses oxygen
sensor voltages for system checks.
Heated Oxygen Sensor Contaminants

Carbon
Black carbon or soot deposits result from over-rich

mixtures. However, carbon does not harm a sensor.
Deposits can be burned off in the engine by running it
at least part throttle for two minutes.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3,~C1-9

Silica
The PCM has the ability to auto-zero the TP sensor

voltage if it is between about .3-.9 volt. This means
that any voltage in this window will be determined by
the PCM to be 0% throttle. A failure in the TP sensor
circuit should set a DTC 21 or 22. The Tech 1 has the
ability to display the throttle angle and should be 0%
when the throttle is closed.
Certain RTV silicone gas~et materials give off

vapors that contaminate the oxygen sensor. The sandlike particles from the RTV silica embed in the
molecules of the sensor element and plug up the
surface, This results in "lazy" H02S response and
engine control. The sensor will also have a white-like
appearance.
There is also a possibility of silica contamination.
caused by silicone in the fuel. Careless fuel handling
practices with the transport containers can result in
unacceptable concentrations of silicone in the fuel at
the pump.
There is also a possibility of silica contamination
caused by silicon in lubricants used to install vacuum
hoses on fittings.
A/C Request Signal

The Tech 1 should indicate A/C request as "YES,"
when AJC is requested.

The Tech 1 should display "P-N" when in park or
neutral and "-R-DL" when in drive or reverse. Refer to
CHART C- lA for PNP switch diagnosis.
Lead
Reference Signal
Lead glazes sensors. It can be introduced when

regular, or leaded fuel, is burned. It is difficult to
detect lead contamination by visual inspection.
The Tech 1 will display this signal in RPM. Refer

to "Distributor Ignition (DI) System," Section "6E3C4" for more information on the distributor ignition
system.
Other Substances
Oil deposits will ultimately prevent sensor

operation. The sensor will have a dark brown
appearance. Causes of high oil consumption should be
checked. The additives in ethylene glycol can also
affect sensor performance.
This produces a white-like appearance. If
antifreeze enters the exhaust system, you will likely
encounter other, more obvious, symptoms of cooling
system trouble.
Vehicle Speed Sensor {VSS)

')t
.,
The Tech 1 reading should closely match the

speedometer reading with drive wheels turning. A
failure in the VSS circuit should set .a DTC 24 or 72.
ON-VEHICLE SERVICE
POWERTRAIN CONTROL MODULE {PCM)
Multiple Failures
If you encounter multiple or repeat H02S failures

on the same vehicle, consider contamination.
Leaded fuel, silica contamination from uncured,
low-grade (unapproved) RTV sealant, and high oil
consumption are possible.
A problem in the H02S circuit or fuel system
should set a DTC 13 or 63 (open circuit), DTC 44 or 64
(lean indication) or DTC 45 or 65 (rich indication).
Refer to applicable chart if any of these DTCs were
stored in memory.

The Tech 1 displays throttle position in volts and
percentage of throttle blade opening. The value should
display between about .3-.9 volt, with throttle closed
and ignition "ON," or at idle. Voltage should increase
at a steady rate as throttle is moved toward WOT
(about 4.6 volts).
Service of the PCM should x10rmally consistMlf

either replacement of the PCM or knock sen~r
module.
PCM AND COMPONENTS REPLACEMENT

PCM
rn
Important
To prevent internal PCM damage, the ignition
must be "OFF," when disconnecting or
reconnecting power to PCM (for example, battery
cable, PCM fuse,jumper cables, etc.).
l++f Remove or Disconnect .

2. ,PCM mounting hardware.
3. Connectors from PCM.
4. PCM from engine compartment.
5. PCM access cover.
6. Knock Sensor (KS) module.

/,
/!
(I
2
4
PCM ELECTRICAL CONNECTOR RETAINERS
2
HOOD ASSEMBLY
PASSENGER SIDE FENDER ASSEMBLY
PCM ELECTRICAL HARNESS

PS 17789
rn
Figure C112. PCM Location
Important
The Knock Sensor (KS) module must be

transferred to the replacement PCM,
The replacement PCM is supplied without a
EEPROM program. The replacement PCM must
be programmed before the vehicle will run.
E] Install or Connect
1.
2.
3.
4.
5.
6.
NewPCM.
Knock sensor module.
Knock sensor module access cover.
PCM electrical connectors.
PCM mounting hardware.
EEPROM PROGRAMMING
Use the following procedure to reprogram the
PCM:
CAUTION: The software/calibration used

for PCM reprogramming must match the
vehicle apprication, or improper
operation and/or vehicle damage may
occur.
Battery is charged.
Ignition is "ON."
Connections to the DLC and battery/cig.
lighter secure,
Follow the most current Techline
terminal/equipment instructions.
If the PCM fails to program, or if DTC 51 sets
during programming:
Check all PCM connections.
Check Techline terminal/equipment for latest
software version
Repeat reprogramming procedure. If it fails
again, replace the PCM. The replacement
PCM must be programmed.
Functional Check
Refer to "On-Board Diagnostic (OBD) System
Check," in "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A" in this
service manual.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
NOTICE: Care must be taken when handling
engine coolant temperature sensor. Damage to
engine coolant temperature sensor could affect
proper operation of the fuel injection system.
DRIVEABILITY AND E~ISSIONS 5.7L {VIN P) 6E3-C1-,11

2
BRACKET
PASSENGER SIDE WHEELHOUSING

PS 17791
PS 17347
Figure C1-13 PCM Removal
Figure C1-15 KS Module Removal
PCM BRACKET
POWERTRAIN CONTROL
MODULE (PCM)
APPLY PRESSURE IN
DIRECTION OF ARROWS
PS 17790
Figure C1-14 PCM Bracket Removal

1.
2.
3.
4.
5.

Drain coolant, refer to SECTION 68.
Raise vehicle.
ECT electrical connector.
Carefully back out engine coolant temperature
sensor from coolant pump.

1. Coat threads (ONLY) with sealer PN 1052080.
PS 17477
Figure C1-16 KS Module Removal
2. Engine coolant temperature sensor in coolant

pump.
l~I Tighten
3.
4.
5.
6.
Sensor to 23 Nm (171b. ft.).

Lower vehicle.
Fill coolant. Refer to SECTION 68.
!VIEWA!
IJJ
11]
WATER PUMP
MS 12021-6E
Figure C1-17 ECT Service
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR

1.
2.
3.
4.
l++l lnstall or Connect

1.
2.
~!
4.
5.
MAP SENSOR

Hold down bolts (2).
MAP sensor from intake manifold.
New MAP sensor seal (lightly coated with clean

engine oil).
MAP sensor to intake manifold.
Hold down bolts.
l~I Tighten
Bolts to 6 Nm (50 lb. in.).
MAP SENSOR SEAL
BOLTS
PS 17019
Figure C1-18 MAP Sensor Servke

3. Carefully loosen air duct clamps and remove MAF
sensor.
l++l lnstall or Connect
rn
MASS AIR FLOW (MAF) SENSOR
rn
Important
Embossed arrows on MAF sensor indicate air

flow and must point toward engine.
Important
Take care when handling the MAF. Do not

dent, puncture, or otherwise damage the
Honeycell located at the air inlet end of the
MAF. Do not touch the sensing elements or
allow anything (including cleaning solvents
and lubricants) to come in contact with them.
A small amount of GM lubricant (PIN =
99855406) may be used on the air duct only, to
aid in installation. Do not drop or roughly
handle the MAF.
1.
MAF sensor into air duct and tighten clamps.
l~I Tighten
MAF sensor clamps to 4 N m (36 lb. in.).

INTAKE AIR TEMPERATURE (IAT) SENSOR

l. Negative battery cable.
3. Carefully back out intake air temperature sensor
from air duct.

l. Intake air temperature sensor into air duct.
HEATED OXYGEN SENSOR (H02S) (BANK 1

ORBANK2)
NOTICE: The H02S uses a permanently attached
pigtail and connector. This pigtail should not be
removed from the H02S. Damage or removal of
the pigtail or connector could affect proper
operation of the H02S.
rn
DRIVER SIDE EXHAUST MANIFOLD
Important
Take care when handling the H02S. The in-line

electrical connector and louvered end must be kept
free of grease, dirt, or other contaminants. Also,
avoid using cleaning solvents of any type. Do Not
drop or roughly handle the H02S.
H02S ELECTRICAL CONNECTOR
BANK 1 H02S
PS 17792
Figure C1-19 - Bank 1 Heated Oxygen Sensor (H02S),l
f++I Remove or Disconnect
l.
2.
, 3.
4.
The H02S may be difficult to remove when engine

temperature is below 48C (120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
Raise vehicle.
Carefully back out H02S.
rn
Important
A special anti-seize compound is used on the

H02S threads. The compound consists of a
liquid graphite and glass beads. The graphite
will burn away, but the glass beads will
remain, making the sensor easier to remove.
New H02S will already have the compound
applied to the threads. If a sensor is removed
from an engine, and if for any reason 1t is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
PASSENGER SIDE EXHAUST MANIFOLD

2
H02S ELECTRICAL CONNECTOR
BANK2 H02S
PS 17793
l.
Coat threads of H02S with anti-seize compound

PIN 5613695 if necessary.
Figure C1-20 - Bank 2 Heated Oxygen Sensor (H02S)
6E3-C1-14 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS

PARK/NEUTRAL POSITION (PNP) SWITCH
The park neutral position switch is part of the
transmission position switch assembly.
Refer to SECTION 7A for location of PNP switch.
On-vehicle service and adjustment procedures are also
listed there.

For on-vehicle service procedures of the Vehicle
Speed Sensor (VSS); refer to SECTION 7.
KNOCK SENSOR (KS)

2
SCREW TP SENSOR A TT ACHING
MP 1224-AS
Figure C1-21 - Throttle Position (TP) Sensor Service
l~I Tighten
2.
3.
4.
H02S to 41 Nm (30 lb. ft.).

Lower vehicle.
1++1 Remove or Disconnect

1
2.
3.
Two TP sensor attaching screws, lockwashers and
retainers.
Throttle position sensor.

1.
2.
With throttle valve in the normal closed idle

position, install throttle position sensor on throttle
body assembly, making sure TP sensor pickup
lever lines up with tang on throttle actuator lever.
Retainers and two TP sensor screws.
l~I Tighten
TP sensor attaching screws to 2.0 Nm (18 lb. in.).
For on-vehicle service procedures of the knock

sensor, refer to "Knock Sensor (KS) System," Section
"6E3-C5".
PCM
ECT Sensor
MAP Sensor Bolt
(H02S)
TP Sensor Attaching Screws
3 Nm (26 lb. in.)

23 Nm (17 lb. ft.)
6 Nm (50 lb. in.)
41 N m (30 lb. ft.)

2.0 Nm (18 lb. in.)
DRIVEABILITYAND EMISSIONS 5.7L (VIN P) 6E3-C1-15
BLANK
6E3-C1-16 S.7L (VIN P) DRIVEABILITY AND EMISSIONS
c
PARK
NEUTRAL
POSITION
SWITCH
~ 11
451 BLK/WHT
PCM
ENGINE GROUND
#2 (1/P)
141 BRN
.rv
20AMP
Joo TO IGNITION
4340RN/BLK
24LTGRN
F
t:=:..RELEASE
TO HATCH
RELAY
4
C230
269YEL
5 YEL
{IIP)
TO STARTER
SOLENOID
12 VOLT
._ TO BACKUP LAMPS
TO THEFT
DETERRENT
RELAY
6-26-93
MS 12325
CHARTC-1A
PARK/NEUTRAL POSITION (PNP) SWITCH DIAGNOSIS
11
The Park/Neutral Position (PNP) switch contacts are closed to ground in park and neutral. When the gear
selector is positioned in reverse or drive range, the PNP switch will open and the PCM will interpret this signal
as drive or reverse.
The PCM uses the PNP signal as one of the inputs to control:
Vehicle Speed Sensor (VSS) diagnostics.
If CKT 434 indicates PNP (grounded), while in drive range, the EGR would be inoperative, resulting in
ossible detonation.
.! If CKT 434 always indicates drive (open), a drop in the idle speed may exist when the gear selector is moved
into drive ~ange.
(:hart Test Description: Number(s) below refer to

(ilircled number(s) on the diagnostic chart.
1. Checks for a closed switch to ground in park
position.
2. Checks for an open switch in drive range.
3. Make sure the Tech 1 indicates drive, even while
wiggling shifter to test for an intermittent or
misadjusted switch in drive range.
CHARTC-1A
PARK/NEUTRAL POSITION (PNP) SWITCH DIAGNOSIS
0 .
WITH TRANSMISSION IN PARK, SCAN TOOL

SHOULD INDICATE PARK OR NEUTRAL.
DOES IT?
SHIFT TRANSMISSION INTO DRIVE.

TECH 1 SCAN TOOL SHOULD DISPLAY A
CHANGE TO INDICATE DRIVE.
DOES IT?
DISCONNECT PNP SWITCH.

THIS SHOULD CAUSE SCAN
TOOL TO DISPLAY DRIVE
RANGE.
DOES IT?
FAULTY PNP SWITCH

CONNECTION
OR
PNP SWITCH MISADJUSTED
OR
FAULTY PNP SWITCH.
NO TROUBLE
FOUND. REFER TO
"INTERMITTENTS"
IN "SYMPTOMS,"
SECTION "B''.
CKT 434 SHORTED

TO GROUND
OR
FAULTY PCM.
DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR.

JUMPER HARNESS CONNECTOR TERMINALS "A" AND "B".
SCAN TOOL SHOULD INDICATE PARK OR NEUTRAL.
DOESIT?
JUMPER HARNESS
CONNECTOR (CKT 434)
TO ENGINE GROUND.
SCAN TOOL SHOULD
INDICATE PARK OR
NEUTRAL.
DOESIT?
FAUL TV PNP SWITCH CONNECTION

OR
PNP SWITCH MISADJUSTED
OR
FAUL TV PNP SWITCH.
,t
CKT4340PEN
OR
OR
PCM.
5-21-93
MS 12891

(MAP) SENSOR
MANIFOLD
ABSOLUTE __..
PRESSURE
(VACUUM)
PCM
A B C
TO TP SENSOR..- 474 GRY
'------4------- 416 GRY

' - - - - - - - - - - - - 432 LT GRN
' - - - - - - - - - - - - - - 452 BLK
6-5-93
MS 12081
CHART C-10
MANIFOLD ABSOLUTE PRESSURE {MAP) OUTPUT CH ECK
5.7L {VIN P) F" CARLINE {SFI)
11
(:ircuit Description:
The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which
result from engine load (intake manifold vacuum) and RPM changes; and converts these into a voltage output.
The PCM sends a 5 volt reference voltage to the MAP sensor. As the manifold pressure changes, the output
voltage of the sensor also changes. By monitoring the sensor output voltage, the PCM knows the manifold
pressure. A lower pressure (low voltage) output voltage will be about l - 2 volts at idle .. While a higher pressure
(high voltage) output voltage will be about 4 - 4.8 at Wide Open Throttle (WOT). The MAP sensor is also used,
under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different
altitudes. The PCM uses the MAP sensor to control fuel delivery and ignition timing.

circled number(s) on the diagnostic: chart.
rn
1.
3.
rn
Important
Be sure to use the same Diagnostic Test

Equipment for all measurements.
When comparing Tech 1 reading to a known good

vehicle, it is important to eompare vehicles that
use a MAP sensor having the same color insert or
having the same "Hot Stamped" number. Refer to
figures on facing page.
If MAP sensor voltage is greater than 5 volts,
check for a short to voltage on the MAP sensor
signal circuit.
2. Applying 34 kPa (10" Hg) vacuum to the MAP
sensor should cause the voltage to change. Voltage
change should be greater than 1.5 volts. Upon
applying vacuum to the sensor, the change in
voltage should be instantaneous. A slow voltage
change indicates a faulty sensor.
Check for vacuum leaks or restrictions at intake

mounting surface.
4.
Important

securely fastened.
Remove sensor from intake manifold and twist

sensor by hand (only) to check for intermittent
connection. Output changes greater than .10 volt
would indicate a bad sensor. If OK, replace sensor.
DRIVEABIUTY AND EMISSIONS 5.7L (VIN P) 6E3-C1-19
CHARTC-10
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
NOTICE:
THIS CHART ONLY APPLIES TO MAP SENSORS

HAVING GREEN OR BLACK COLOR KEY INSERT (SEE BELOW).
IF DTC 33 OR 3415 SET, USE THOSE CHARTS FIRST.

SCAN TOOL SHOULD INDICATE A MAP SENSOR VOLTAGE.
COMPARE THIS READING WITH THE READING OF A KNOWN GOOD VEHICLE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN .4 VOLT.
ISIT?
DISCONNECT AND PLUG VACUUM SOURCE TO MAP SENSOR.

CONNECT A HAND VACUUM PUMP TO MAP SENSOR.
START ENGINE.
NOTE MAP SENSOR VOLTAGE.
APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CH.ANGE.
SUBTRACT SECOND READING FROM THE FIRST. VOLTAGE VALUE
SHOULD BE GREATER THAN 1.5 VOLTS.
IS IT?
CHECK MAP SENSOR CONNECTION.

IF OK, REPLACE MAP SENSOR.
NO TROUBLE FOUND. CHECK MAP SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION. BE SURE THIS
SOURCE SUPPLIES VACUUM TO MAP SENSOR ONLY.
HOT-STAMPED
NUMBER
LS 8963-6E
Figure 1 - Color Key Insert
LS 9045-6E
Figure 2 - Hot Stamped Number
3-10-92
75 3162-6E
, BLANK
DRIVEAB-ILITYAND EMISSIONS 5.7L (VIN P) 6E3-C2-1
SECTION C2

CONTENTS
General Description
Purpose
Modes of Operation
Starting Mode .
Clear Flood Mode
Run Mode
Acceleration Mode
Deceleration Mode
Fuel Cutoff Mode
Fuel Supply Components
Fuel Rail Assembly
Fuel Injectors
Fuel Pressure Regulator ~ssembly
Diagnosis
Fuel Pump Relay
Fuel Pump and Engine Oil Pressure
Indicator Switch
Fuel System Pressure Test
See Section 6E3, Chart A-7
C2-1
C:2-1
C2-1
C2-1
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-3
C2-3
C2-4
C2-4
C2-4
C2-5
C2-5
(2-5
C2-5
C2-5

S.ee Chart C-28
On-Vehicle Service
Service Information
Thread-Locking Material
Fuel Pump Relay

Fuel Pump and Engine Oil Pressure
Indicator Switch
Sequential Multi port Fuel Injection (SFI)
Compo~ents . . . . . . . . . . . . . . . . .
Fuel Rail Assembly
Fuel Pressure Connection Assembly
Fuel Outlet Tubes
Fuel Crossover Tube Assembly

Fuel Injectors
. Fuel Pressure Regulator Assembly

IAC Valve/Coolant Cover Assembly
Clean Air Cover and Gasket
Air Vent Valve Assembly

Chart C-2A- Injector Coil/Balance Test
Procedure (1 of 3)
Chart C-2C- Idle Air Control

(IAC) Valve Check
C2-6
C2-6
C2-6
C2-6
C2-7
C2-7
C2-7
C2-7
C2-9
C2-9
C2-11
C2-11
C2-12
C2-13
C2-14
C2-14
C2-16
C2-16
C2-17
C2-17
C2-18
C2-24
GENERAL DESCRIPTION
PURPOSE
The function of the fuel metering system is to
deliver the correct amount of fuel to the engine under
all operating conditions. Fuel is delivered to the
engine by individual fuel injectors mounted in the
intake manifold near each cylinder.
The main control sensors are the Heated Oxygen
Sensors (H02S) located in the exhaust system. The
H02S tells the Powertrain Control Module (PCM)
how much oxygen is in the exhaust gas. The PCM
changes the air/fuel ratio to the engine by controlling
the fuel injectors. The best mixture to minimize
exhaust emissions is 14. 7 to 1, which allows the threeway catalytic converters to operate the most
efficiently. Because of the constant measuring and
adjusting of the air/fuel ratio, the fuel injection system
is called a "Closed Loop" system.
MODES OF OPERATION
The PCM looks at voltages from several sensors to
determine how much fuel to give the engine. The fuel
is delivered under one of several conditions called

modes. All modes are controlled by the PCM and are
described below.
Starting Mode
the fuel pump relay for two seconds allowing the fuel
pump to build up pressure. The PCM first checks
speed density, then switches to the Mass Air Flow
(MAF) sensor. Engine Coolant Temperature (ECT),
Throttle Position (TP), and Manifold Absolute
Pressure (MAP) sensors are also used to determine the
proper air/fuel ratio for starting. This ranges from
1.5:1 at -36C (-33F) to 14.7:1 at 94C (201F) running
temperature. The PCM controls the amount of fuel
delivered in the starting mode by changing how long
the injectors are energized. This is done by pulsing the
injectors for very short times.
6E3-C2-2 S.7L (VIN P) DRIVEABILITY AND EMISSIONS

Clear Flood Mode
If the engine floods, it can be cleared by pushing
the accelerator pedal down all the way. The PCM then
pulses the injectors at an air/fuel ratio of 20: 1. The
PCM holds this injector rate as long as the throttle
stays wide open and the engine speed is below 300
RPM. If the throttle position becomes less than 80%,
the PCM returns to the starting mode.
Run Mode
The run mode has two conditions called "Open
Loop" and "Closed Loop."
When the engine is first started, and engine speed
is above 400 RPM, the system begins "Open Loop"
operation. The PCM ignores the signal from the H02S
and calculates the air/fuel ratio based on inputs from
the ECT, MAP, MAF, and TP sensors.
The system stays in "Open Loop" until the
following conditions are met:
1. Both H02S have varying voltage output,
showing that they are hot enough to operate
properly. (This depends on temperature.)
2. The ECT sensor is above a specified
temperature .
3. A specific amount of time has elapsea after
starting the engine.
Specific values for the above conditions exist for
each different engine, and are stored in the
Memory (EEPROM). When these values are reached,
the system begins "Closed Loop" operation.
In "Closed Loop," the PCM calculates the air/fuel
ratio (injector on-time) based on the signal from
various sensors, but mainly the H02S. This allows the
ait/fuel ratio to stay very close to 14.7:1.
Acceleration Mode
When the driver pushes on the accelerator pedal,
air flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, .the PCM increases the pulse width to the
injectors to provide extra fuel during acceleration. The
amount of fuel required is based on throttle position,
coolant temperature, manifold air pressure, mass air
flow and engine speed.
Deceleration Mode
When the driver releases the accelerator pedal, air
flow into the engine is reduced.
The corresponding changes in throttle position,
manifold air pressure and mass air flow are relayed to
the PCM, which reduces the injector pulse width to
reduce fuel flow. If the deceleration is very rapid, or
for long periods (such as long closed throttle coast-
down), the PCM shuts "OFF" fuel completely to protect

the Warm-Up three-way catalytic converter.

When battery voltage is low, the PCM
compensates for the weak spark delivered by the
distributor by:
Increasing the amount of fuel delivered;
Increasing the idle RPM; and
Increasing ignition dwell time.
Fuel Cutoff Mode

To prevent possible engine damage from overspeed, the PCM cuts off fuel from the injectors when
the engine speed is above approximately 5800 RPM.
Also, see rapid deceleration in "Oeceleration Mode."
FUEL METERING SYSTEM COMPONENTS

The fuel metering system is made up of the
following parts:
Fuel supply components (fuel tank, pump,
lines).
Fuel pump electrical circuit.
Fuel rail assembly, including:
Fuel injectors.
Fuel pressure regulator assembly.
Throttle body assembly, including:
Idle Air Control (IAC) valve.
FUEL SUPPLY COMPONENTS

The fuel supply is stored in the fuel tank. An
electric fuel pump, located in the fuel tank with the
fuel level, sensor assembly, pumps fuel through an inline fuel filter to the fuel rail assembly. The pump is
designed to' provide fuel at a pressure greater than i~
needed by the injectors. The fuel pressure regulator,
part of the fuel rail assembly, keeps fuel available to
the injectors at a regulated pressure. Unui:;ed fuel is
returned to the fuel tank via a separate line. For
further information, refer to SECTION 6C for
replacement procedures covering the fuel tank, fuel
pump, in-line filter, and fuel lines.
FUEL PUMP ELECTRICAL CIRCUIT

the fuel pump relay for two seconds, causing the fuel
pump to pressurize the fuel system. If the PCM does
not receive ignition reference pulses (engine cranking
or running) within two seconds, it shuts "OFF" the fuel
pump relay, causing the fuel pump to stop.

As a backup system to the fuel pump relay, the fuel
pump also can be energized by the fuel pump and
engine oil pressure indicator switch. The switch has
two internal circuits. One operates the oil pressure
indicator or gage in the instrument cluster, and the
other is a normally open switch which closes when oil
pressure reaches about 28 kPa (4 psi). If the fuel pump
relay fails, the fuel pump and engine oil pressure
indicator switch run the fuel pump.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold. The
fuel pump and engine oil pressure indicator switch
energizes the fuel pump as soon as oil pressure reaches
about 28 kPa (4 psi).
FUEL RAIL ASSEMBLY

Figure C2-1
The fuel rail assembly is mounted to the engine

intake manifold and performs several functions; it
positions the injectors in the intake manifold, it
distributes fuel evenly to the, injectors, and it
integrates' the fuel pressure regulator into the fuel
metering system.
5
SOLENOID ASSEMBLY ,
HOUSING - SPRAY
SPACER & GUIDE ASM
SPRING - CORE
CORE SEAT
HOUSING - SOLENOID
VALVE - BALL
10
SOLENOID
PLATE - DIRECTOR
11
FILTER - FUEL INLET
BACKUP - 0-RING
PA,0496SY,
Figure C22 Fuel Injector Assembly
CONNECTION - FUEL PRESSURE

2
REGULATOR ASSEMBLY -FUEL PRESSURE
TUBE - FUEL OUTLET
TUBE - FUEL INLET

PA 1374-AS
Figure C21 Fuel Rail Assembly
Fuel Injector
Figure C2-2
The sequential multiport fuel injection (SFI) topfeed fuel injector assembly is a solenoid- operated
device, controlled by the PCM, that meters pressurized

fuel to a single engine cylinder. The PCM energizes
the injector solenoid, which opens a ball valve,
allowing fuel to flow past the ball valve, and through a
recessed flow director plate. The director plate has six
machined holes that control the fuel flow, generating a
conical spray pattern of finely atomized fuel at the
injector tip.
Fuel is directed at the intake valve, causing it to
become further atomized and vaporized before
entering the combustion chamber.
An injector that is stuck partly open would cause
loss of pressure after engine shut down. Consequently,
long cranking times would be noticed on some engines.
Dieseling could also occur, because some fuel could be
delivered to the engine after the ignition is turned
"OFF."

Figure C2-3
The fuel pressure rgufator is a diaphragmoperated relief valve with fuel pump pressure on one
side, and regulator spring pressure and intake
manifold vacuum on the other. The regulator's
function is to maintain a constant pressure differential
across the injectors at all tiines. The pressure
regulator compensates for engine load li>y increasing
fuel pressure as engine vacuumdrflpS.
With the ignition "ON" and engine "OFF" (zero
vacuum), system fuel pressure at the pressure test
connection should be 284-325 kPa (41-47 psi). If th.e
pressure is too low, poor performance could result. If
the pressure is too high, excessive odor and a
Diagnostic Trouble Code (DTC) 45/65 may result.
CHART A-7 has information on diagnosing fuel
pressure conditions.
almost closed, and air flow control is handled by a fixed

air bypass orifice and the Idle Air Control (IAC) valve,
described below. To prevent throttle valve icing
during. cool weather operation, engine coolant is
directed through the coolant cavity on the bottom of
the throttle body.
The throttle body also provides the location for
mounting the Throttle Position (TP) sensor and for
sensing changes in engine vacuum due to throttle
valve position.
Vacuum ports are located at, above, or below the
throttle valve to generate vacuum signals needed by
various components.
COVER
VALVE ASSEMBLY - IDLE AIR CONTROL
VACUUM CHAMBER
(VACUUM SOURCE TUBE NOT SHOWN) '
SEAL - 0-RING
VALVE - FUEL PRESSURE REGULATOR
BASE ASSEMBLY
FILTER - SCREEN (IF EQUIPPED)
DIAPHRAGM
SPRING
PA
1382 AS

Figure C2-5
NA 0493-SY
Figure C2-3 - Fuel Pressure Regulator Assembly

(Typical)
FigureC2-4
The throttle body assembly is attached to the
intake manifold, and is used to control air flow into the
engine, thereby controlling engine output. The
throttle valves within the throttle body are opened by
the vehicle operator through the accelerator
controls.During engine idle, the throttle valves are
0
SENS.OR - THROTTLE POSITION (TP)
The purpose of the IAC valve assembly is to control

engine idle speed, while preventin~ stalls due to
changes in engine load.
The IAC valve, mounted in the throttle body,
controls a portion of the bypass a.ir. An orifice located
between the throttle valves also supplies a constant
amount of bypass air. By moving a .conical valve
known as a pintle, "IN," towards the seat (to decrease
air flow); or "OUT," away from the seat (to increase air
flow), a controlled amount of air can be bypassed. I(
engine speed is too low, more air is bypassed to
increase RPM. If engine speed is too high, less air is
bypassed to decrease RPM.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-C2,.S

The PCM moves the IAC valve in small steps,
called counts. These can be measured and displayed
by a scan tool, which plugs into the Data Link
Connector (DLC).
During idle, the proper position of the IAC valve is
calculated by the PCM, based on battery voltage,
coolant temperature, engine load, and engine RPM. If
t.he RPM drops below specification and the throttle
valve is closed, the PCM senses a near stall condition
and cakulatesa new valve position to prevent stalling.
Engine idle speed is a function of total air flow into
the engine based on IAC valve. pintle position +
crankcase .ventilation valve flow + t.hrottle valve
opening + bypass orifice air flow + .calibrated
vacuum loss through acceSE!Ories.
Controlled idle speed is programmed into the
PCM, which determines the correct IAC valve
pintle position to maintain the desired id.le speed
for all engine operating conditions and loads.
The minimum idle air rate is set at the factory
with a stop screw. This setting allows enough air
flow by the throttle valves to cause the IAC valve
pintle to be positioned a calibrated number of steps
(counts), from the seat, during controlled idle
operation.
If the IAC valve is disconnected and reconnected
with the engine running, the idle speed may be
wrong. If this occurs, reset the IAC valve by
depressing the accelerator pedal slightly, start and
run engine for five seconds, then turn ignition
"OFF" for ten seconds.

The TP sensor is mounted on the side of the
throttle body opposite the throttle lever. It senses the
throttle valve angle and relays that information to the
PCM. Knowledge of throttle angle is needed by the
PCM to generate the requited injector control signals
(pulses). Refer to "Powertrain Control Module (PCM)
DIAGNOSIS
FUEL PUMP RELAY
Figure C2-6
side kick panel/dead pedal (left foot rest). For
diagnosis of the fuel pump relay circuit, refer to
CHARTA-5.

2
BODY ASSEMBLY -THROTTLE
VALVE -THROTTLE
PINTLE - IAC VALVE
ELECTRICAL INPUT SIGNAL
AIR INLET
NA0494-SY
Figure C2-5 - IAC Valve Air Flow Diagram
I
i
FUEL PUMP AND ENGINE OIL PRESSURE

INDICATOR SWITCH
The fuel pump and engine oil pressure indicator is
threaded into a TEE fitting at the rear of the engine".
Refer to "On-Vehicle Service" for the locator view. For
diagnosis of the fuel pump relay circuit, refer to
CHART A-5.

Always start with the On-Board Diagnostic (OBD)
system check in the "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A". This
will reduce diagnosis time and prevent unnecessary
parts replacement. Diagnosis of the "Fuel Metering
System," is covered in CHART A-3, "Engine Cranks
But Won't Run," and CHART A-7, "Fuel System
Diagnosis:" These charts cover the diagnosis of the
injectors, pressure regulator, and the fuel pump.
A malfunction in the fuel metering system usually
results in either a rich or lean H02S signal. This
signal causes the PCM to change the fuel calculation
(injector pulse width). The change made to the fuel
calculation is indicated by a change in the short and
long term fuel trim values which can be monitored
with a scan tool.
6E3-C2-6 5. 7L (VIN P) DRIVEABILHY AND EMISSIONS

A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a
prolonged change is indicated by the long term fuel
trim value. Average fuel trim values are around 128,
but vary slightly fr~m engine to engine.
rn
Important
When using a scan toolto observe fuel trim values,

remember that if the system is in control, no action
is required unless a driveability symptom is
present. Listed below are examples of lean and
rich H02S signals with the system in control and
out of control.
A momentary lean H02S signal (system is in
Short term fuel trim value above 128 (adding
fuel).
A prolonged lean H02S signal (system is in
Long term fuel trim value above 128 (added
fuel).
A prolonged lean H02S signal (system is out of
Short term fuel trim value well above 128
(adding fuel).
Long term fuel trim value well above 128
(added fuel).
If both fuel trim values are fixed well above 128,
refer to OTC 44 or 64 for items which can cause a lean
H02S signal.
A momentary rich H02S signal (system is in
Short term fuel trim value less than 128
(reducing fuel).
A prolonged rich H02S signal (system is in
Long term fuel trim value less than 128
(reduced fuel).
A prolonged rich H02S signal (system is out of
Short term fuel trim value much less than 128
(reducing fuel).
Long term fuel trim value much less than 1.28
(reduced fuel).
If the fuel trim values are fixed well below 128,
refer to OTC 45 or 65 for items which can cause the
fuel control system to run rich. If a driveability
symptom exists, refer to the particular symptom in the
"Symptoms," Section "6E3-B" for additional items to
check.
ON-VEHICLE SERVICE
SERVICE INFORMATION
Thread-Locking Material
rn
Important
The hardware used to attach the Throttle Position

(TP) sensor is coated with thread-locking adhesive.
If the TP sensor is removed for service, inspect the
attaching screw threads. There should be enough
thread-locking material (adhesive or compound)
on the threads to insure proper relocking. If not,
clean the threads and apply Loctite 262 to the
threads before reassembly. Replacement screws
are included in the service screw assortment
package. New attaching hardware is included in
the service packages.
FUEL PUMP RELAY

Figure C2-6
The fuel pump relay is mounted inside the
passenger compartment, under the dash as shown in
Figure C2-6.
LEFT DOOR JAM ("A" PILLAR)

2
DEAD PEDAL BRACKET
FUEL PUMP RELAY

NS 15279
Figure C2-6 Fuel Pump Relay

cover fuel line fittings with a shop towel
before disconnecting to catch anr fuel
that may leak out. Place the towe in an
approved container when disconnect is
completed.

1.
2.

Fuel pump relay.

1.
2.
FUEL PRESSURE RELIEF PROCEDURE
Fuel pump relay.

FUEL PUMP AND ENGINE OIL PRESSURE

INDICATOR SWITCH
FigureC2-7
The switch is threaded into a TEE fitting at the
rear of the engine (Figure C2-7).
!++! Remove or Disconnect

1.
2.
Tool Required:
J 34730-1 Fuel Pressure Gage
1.
2.
3.
4.
Fuel pump and engine oil pressure indicator
switch.
5.

1.
2.
Fuel pump and engine oil pressure .indicator

switch.
6.
Ignition "OFF."
Disconnect negative battery cable to avoid possible
fuel discharge if an accidental attempt is made to
start the engine.
Loosen fuel filler cap to relieve tank vapor
pressure.
Connect gage J 34730-1 to fuel pressure valve.
Wrap a shop towel around fitting while connecting
Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel
connections are now safe for servicing.
Drain any fuel remaining in gage into an approved
container.
FUEL RAIL ASSEMBLY

Figures C2-8 through Cl-10
Tools Required:
J 37088-A FuelLine Release Tool Set
An eight digit identification number is stamped on
the fuel rail assembly. Refer to this model
identification number if servicing or part replacement
is required.
Names of component parts will be found on the
numbered list that accompanies the disassembled
view.
NOTICE:
Oil PRESSURE SENSOR/SWITCH
[I]
OIL PRESSURE SWITCH
MS 12305
Figure C2-7 - Fuel Pump and Engine Oil Pressure

Indicator Switch
SEQUENTIAL MULTIPORT FUEL INJECTION

(SFI} COMPONENTS
CAUTION:
To reduce the risk of fire and personal
injury, relieve the fuel system pressure
before servicing fuel system components.
After relieving system pressure, a small
amount of fuel may be released when
servicing fuel lines or connections. To
reduce the chance of personal injury,
Use care in removing the fuel rail assembly to

prevent damage to the injector electrical connector
terminals and the injector spray tips. When
removed, support the rail to avoid damaging its
components.
Prevent dirt and other contaminants from
entering open lines and passages. Fittings should
be capped, and holes plugged, during servicing
The upper and lower 0-rings are different colors
(black and brown). Be sure to install the black 0ring in the upper position and the brown 0-ring in
the lower position on the injector. The 0-rings are
the same size but are made of different materials.
6E3-C2-8 5:7L (VIN P) DRIVEABILITY AND EMISSIONS
~ Clean
Before removal, the fuel rail assembly may be

cleaned with a spray type engine cleaner, GM
X-30A or equivalent, following package
instructions. Do Not soak fuel rails in liquid
cleaning solvent.

1.
2.
3.
4.
5.
6.
7.
SHIFTID----SOURCE C O D E - - - - - - '
Ignition "OFF."
Relieve fuel system pressure. (Refer to the "Fuel
Fuel rail cover.
Quick-connect fittings at engine fuel pipes.
Slide rubber dust covers from quick-connect
fittings at engine fuel pipes.
Grasp both sides of fitting. Twist female connector
1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn

when using compressed air, as flying dirt
particles may cause eye injury:
PA 1313AS
Figure C2-8- Fuel Rail Assembly Identification.
8.
9.
Using compressed air, blow dirt out of fitting.

Choose correct tool from J 37088-A tool set for size
of fitting. Insert tool into female connector, then
push/pull inward to release locking tabs.
11.
12.
13.
14.
15.
FU EL RAIL ATTACHING BOLT

2
FUEL RAIL ASSEMBLY
INTAKE MANIFOLD
16.
17.
NS 15926
Figure C2-9 - Fuel Rail Removal and Installation
!l! Clean and Inspect
NOTICE: If it is necessary to remove rust or burrs

from fuel pipe, use emery cloth in a ni'.dial motion
with the pipe end to prevent damage to 0-ring
sealing surface.
Using a clean shop towel, wipe off male pipe
end.
Inspect both ends of fitting for dirt and burrs.
Clean or replace components/assemblies as
required.
Vacuum line at pressure regulator.
Vacuum lines to gain access to fuel rail and engine
fuel pipes.
Electrical harness from routing clips on fuel rail.
Engine fuel pipe retaining bolt.
Injector electrical connectors.
Identify connectors to their corresponding
injectors to assure correct sequential injector
firing order after reassembly.
Fuel rail assembly.
l+!+I
rn
1.
2.
~Clean
Important
l+-+I
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Install or Connect
Fuel rail assembly in intake manifold.

Fuel rail attaching bolts to 20 N m (15 lb. ft.).

Injector electrical connectors.
Make sure that each conn.ector is installed on
the proper injector to assure correct sequential
injector firing order.
Rotate injector(s) as required to avoid
stretching wire harness.
Engine fuel pipe retaining nut.
Electrical harness into routing clips on fuel rail.
Vacuuwlines
to intake manifold and fuel pressure
,,
regulator.
Quick-connect fittings to engine fuel pipes.
Apply a few drops of clean engine oil to the male
pipe end of engine fuel pipe, pressure gage adapter
or fuel line shutoff adapter.
Push both sides of fitting together to cause the
retaining tabs/fingers to snap into place.
Once installed, pull on both sides of fitting to make
sure connection is secure.
Slide dust covers over quick-connect fittings.
Fuel rail cover.
Ignition ''OFF."
~
IL'l'I

2. Relieve fuel system pressure.
Refer to the "Fuel Pressure Relief Procedure."

3. Fuel pressur~ connection valve assembly.

1. Fuel pressure connection valve assembly.
IL'l'I
l~I Tighten
3.
Area around fuel pressure connection with GM

X-30A or equivalent.
Assemble
Lubricate new lower injector 0-rings (brown) and

install on spray tip end of each injector.
1-++I
Figure C2-10
The fuel injector lower 0-ring (brown) uses a nylon

collar, called the 0-ring backup, to properly
position the 0-ring on. the injector. Be sure to
reinstall the 0-ring backup, or the sealing 0-ring
may move on the injector when installing the fuel
rail and result in a possible vacuum leak and
driveability complaints will occur.
1-+*+I
Disassemble
Injector lower 0-ring (brown) from spray tip end of

each injector. Discard 0-ring seals. Save 0-ring
back-up.
FUEL PRESSURE CONNECTION VALVE

ASSEMBLY
Inspect
Turn ignition switch to "ON" position for two

seconds, then turn "OFF" for ten seconds. Again
turn to "ON" position and check for fuel leaks.
Inspect

.seconds. Again turn the "ON" position, and check
f'lf f~,l leaks.
FUECOUTLET TUBE
Figure C2-11
l+-+I
Re~ove or Disconnect
Ignition "OFF."
Relieve fuel system pressure.
Refer to the "Fuel Rail Assembly Removal
Procedure."
1.
2.
3.
l+!+I
Disassembie
1. Fuel tube bracket and retaining screw.

2. Fuel outlet tube retainer clip.
3. Fuel outlet tube from pressure regulator.
4. 0-Ring from outlet tube and discard.
1-+*+I Assemble
Lubricate new 0-ring with clean engine oil and
install on fuel outlet tube.
2. Push fuel outlet tube into fuel pressure regulator.
3. Fuel outlet tube retainer clip.
4. Fuel tube bracket and attaching screw.
1.
l~I Tighten
Fuel tube bracket attaching screw to 5 Nm (44

lb. in.).
. '19,:
RAIL ASSEMBLY LH FUEL
13
CLIP FUEL OUTLET TUBE RETAINER
0-RING - FUEL CROSSOVER TUBE
14
SCREEN FILTER
TUBE ASSEMBLY - FUEL CROSSOVER
15
0-RING FUEL INLET FITTING
RETAINER - CROSSOVER TUBE
16
BRACKET FUEL TUBE
SCREW CROSSOVER TUBE RETAINER

ATTACHING
17
SCREW FUEL TUBE BRACKET ATTACHING
RAIL ASSEMBLY RH FUEL
18
TUBE ASSEMBLY - FUEL OUTLET
CAP FUEL PRESSURE CONNECTION
19
CLIP - INJECTOR RETAINER
VALVE ASSEMBLY FUEL PRESSURE

CONNECTION
20
0-RING UPPER INJECTOR
RETAINER AND SPACER ASSEMBLY
21
INJECTOR ASSEMBLY FUEL
10
REGULATOR ASSEMBLY FUEL PRESSURE
22
BACKUP 0-RING
11
SCREW PRESSURE REGULATOR ATTACHING
22
0-RING LOWER INJECTOR
12
0-RING FUEL OUTLET TUBE
PA0206XV
Figure C210 Fuel Rail Assembly
DRIVEABILITY AND EMISSIONS 5.7L (VIN
Pl
6E3-C2-11
3. Crossover tube assembly from fuel rails.

4. 0-rings from crossover tube assembly and discard.

Lubricate new crossover tube assembly 0-Rings
with clean engine oil and install on crossover tube.
2. Crossover tube assembly into fuel rail sections.
3. Crossover tube retainer attaching screws.
1.
l~I Tighten
crossover tube retainer attaching screws to 5
Nm (44 lb. in.).
Fuel tube bracket and attaching screw.
4.
l~I Tighten
5.
6.
7.
RETAINING NUT
2
ENGINE FUEL PIPE
FUEL RAIL
INTAKE MANIFOLD
IL'l'I Inspect
NS 15927
Figure C2-11 - Fuel Outlet Tube
,.. +I Install or Connect

2. Ignition "OFF."

seconds, then turn "OFF" for ten seconds. Again
FUEL CROSSOVER TUBE ASSEMBLY

Figure C2-10
l+ ..I Remove or Disconnect

1. Ignition "OFF."
Procedure."
l+!+I Disassemble
1. Fuel tube bracket attaching screw and bracket.
2. Crossover tube retainer attaching screws.

seconds, then turn to "OFF" for ten se.conds. Again
t")l;~:.;o "ON" position and check for fuel leaks.
=y?
FUELINJECTORS
Figures C2-12 and C2-13
[I] Important
IL11nspect
Fuel tube bracket attaching screw to 5 N m

(44 lb. in.).
Fuel rail assembly.
Ignition "OFF."
Use care in removing the fuel injectors to preven~

damage to the electrical connector pins on the
injector and the nozzle. The fuel injector is serviced
as a complete assembly only. The fuel injector is an
electrical component and should not be immersed
in any type of cleaner.

1. Ignition "OFF."
4. Fuel rail cover.
Procedure."
l+!+I Disassemble
Spread injector retainer clip to release injector

from rail.
2. Fuel injector.
3. Injector 0-ring seals from both ends of injector,
and discard. Save 0-Ring backup for use in
reinstallation.
1.
rn
ILI Inspect
Important
When ordering new fuel injectors, be sure to order

the correct injector for the application being
serviced.
The upper and lower fuel injector 0-rings use
different part numbers. To identify the the correct
0-ring, the upper 0-ring is black and the lower 0ring is brown. Both are the same size but are made
of different material.
When replacing injector 0-rings, be sure to install
the brown 0-ring in the lower position.
The fuel injector lower 0-ring uses a nylon collar,
called the 0-ring backup, to properly position the
0-ring on the injector. Be sure to reinstall the 0ring backup, or the sealing 0-ring may move on
the injector when installing the fuel rail and result
in a possible vacuum leak.
l+;+I Assemble
1.
2.
Lubricate new injector 0-ring seals with clean

engine oil, and install on injector.
New retainer clip onto injector.
Position clip on right side of the injector's
electrical connector.

seconds, then turn to "OFF" for ten seconds. Again
fUEL PRESSURE REGULATOR ASSEMBLY

Figure C2-4 and C2-10
rn
Important
The pressure regulator is serviced as a complete

assembly only.

1.
2.
3.
4.
5.
Ignition "OFF."
Relieve fuel system pressure.
Refer to "Fuel Pressure Relief Procedure."
Fuel rail cover.
Fuel rail assembly.
Refer to "Fuel Rail Removal."
!+!+I Disassemble
1.
2.
3.
4.
5.
6.
Fuel tube bracket attaching screw and bracket.

Pressure regulator attaching screw.
Pressure regulator from fuel rail.
Fuel outlet tube retainer clip and fuel outlet tube
from pressure regulator.
Pressure regulator inlet 0-ring and discard.
Fuel outlet tube 0-ring and discard.
!L'l'I Inspect
Filter screen for contamination.

contaminated, remove and discarci)_v.
If
!+;+I Assemble
1.
2.
MP 1296-AS
Figure C2-12 - Fuel Injector and Retainer Clip
3.
4.
Fuel injector assembly into fuel rail injector

socket, with electrical connector facing outward.
Push injector into socket until retainer clip locks
onto flange on fuel rail.
3.
4.
5.
l~I Tighten

1.
2.
3.
4.
5.
Fuel rail assembly.

Fuel rail cover.
Ignition "OFF."
Lubricate new pressure regulator inlet 0-ring

with clean engine oil and install on regulator.
Lubricate new fuel outlet tube 0ring with clean
engine oil and install on fuel outlet tube.
Fuel outlet tube into regulator and install retainer
clip.
Push pressure regulator into rail.
Pressure regulator attaching screw.
6.
Pressure regulator attaching screw to 10

Nm (89 lb. in.).
Refer to "Thread-Locking Material."
Fuel tube bracket and attaching screw.
!~I Tighten
Fuel tube bracket attaching screw to 5 Nm (44

lb. in.).
[JJ
GASKET
( ] ] THROTTLE BODY ASSEMBLY
[TI
BOLT
[ } ] THROTTLE POSITION SENSOR (TPS)
MS 12304-6E
Figure C2-14 - Throttle Body Removal (Typical)

A
PART NUMBER IDENTIFICATION
BUILD DATE CODE
MONTH 1-9 (JAN-SEPT) 0, N, D (OCT, NOV, DEC)
DAY
YEAR
MP 1222-AS
I 11 Ir_
Figure C2-13- Injector Part Number Location
'-y--J
DAY
OF
YEAR

2. Fuel rail cover.
4. Ignition "OFF."
!L1'1 Inspect

seconds, then turn to "OFF" for ten seconds. Again

Figure C2-14 through C2-16
The throttle body assembly repair procedures
cover component replacement with the unit on the
vehicle. However, throttle body replacement requires
that the complete unit be removed from the engine.
An eight digit part identification number is
stamped on the throttle body casting as shown in
Figure C2-14. Refer to this number if servicing, or
part replacement is required. For identification of
parts during repair, refer to the disassembled view
(Figure C2-15).
YEAR
8DIGIT
IDENTIFICATION
NUMBER
MP 1302-AS
Figure C2-15 - Throttle Body Identification
~ Clean
rn
Important
Do not soak the throttle body in cold

immersion type cleaner. The throttle valves
have a factory applied sealing compound (DAG
material is applied to outside edge of each
valve and throttle bore) to prevent air bypass
at closed throttle. Strong solvents or brushing
will remove the material. To clean the throttle
body following disassembly, use a spray type
cleaner such as GM X66-A or GM 1052626.
Use a shop towel to remove heavy deposits.
NOTICE: The TP sensor and IAC valve are

electrical components and should NOT come in
contact with solvent or cleaner, as they may be
damaged.
J++I Remove or Disconnect

1. Ignition "OFF."
3. Partially drain cooling system to allow hoses at
throttle body to be removed. Refer to SECTION
6B.
4. Air intake duct. Refer to "Air Intake System,"
Section "6E3-C14".
5. Electrical connectors from TP sensor and IAC
valve.
6. Vacuum lines.
7. Coolant hoses from throttle body.
8. Accelerator cable shield.
9. Accelerator control cable(s).
10. Throttle body attaching bolts.
11. Throttle body assembly and flange gasket.
Discard gasket.
Clean
NOTICE: Use care in cleaning old gasket

material from machined aluminum surfaces as
sharp tools may damage sealing ~urfaces.

2. TP sensor attaching screws.
3. TP sensor.
4. TP sensor static seal.
NOTICE: The TP sensor is an electrical

component and must not be soaked in any liquid
cleaner or solvent as damage may result.

1. TP sensor static seal.
2. With throttle valve in the closed position, install
the TP sensor on the throttle body assembly,
making sure TP sensor lever lines up with the TP
sensor drive lever on the throttle shaft.
3. TP sensor attaching screws coated with
appropriate thread-locking material.
Refer to "Thread-Locking Material."
l~I Tighten
Gasket sealing surfaces.
f++I Install or connect

1.
2.

Figure Cl-16
Throttle body assembly with new flange gasket.

Throttle body attaching bolts.
l~I Tighten
Throttle body attaching bolts to 15 Nm

(11 lb. ft.).
3. Accelerator control cable(s).

4. Coolant hoses to throttle body.
5. Vacuum lines.
6. Electrical connectors to TP sensor and IAC valve.
7. Accelerator cable shield.
8. Air intake assembly. Refer to "Air Intake
System," Section "6E3-C14".
9. Refill radiator. Refer to SECTION 6B.
10. Ignition "OFF."
IL'l'I Inspect
With the engine "OFF," check to see that the

accelerator pedal is free.
Depress pedal to the floor and release.
12. Reset IAC valve pintle position:
A. Depress accelerator pedal slightly.
B. Start and run engine for five seconds.
C. Turn ignition "OFF" for ten seconds:
D. Restart engine and check for proper idle
operation.
4.
TP sensor attaching screws to 2.0 Nm (18 lb.

in.).
TP sensor electrical connector.

Figures Cl-16 and Cl-17

1.
2.
3.
Electrical connector from IAC valve.

Air inlet assembly. Refer to "Air Intake System,"
Section "6E3-C14".
IAC valve assembly attaching screws.
IAC valve assembly.
NOTICE: On IAC valves that have been in

service: Do Not push or pull on the IAC valve
pintle. The force required .to move the pintle may
damage the threads on the worm drive. Also, do
not soak IAC v.alve in any liquid cleaner or
solvent, as damage may result.
Clean IAC valve 0-ring sealing surface, pintle

valve seat and air passage.
The IAC valve may be cleaned using GM
cleaner 1052626 or GM X-66A. Use a shop
towel or parts brush to remove heavy deposits.
Shiny spots on the pintle or seat are normal,
and do not indicate misalignment or a bent
pintle shaft.
COVER- CLEAN AIR
SCREW- IAC VALVE ATTACHING
SCREW - CLEAN AIR COVER ATTACHING
COVER ASSEMBLY - IACV/COOLANT
GASKET - CLEAN AIR COVER
10
GASKET - IACV/COOLANT COVER TO THROTTLE BODY
11
SEAL- STATIC
SCREW- IACV/COOLANT COVER ATTACHING
12
0-RING - IAC VALVE ASSEMBLY
13
SCREW-TP SENSOR ATTACHING
PA0211 XV

If air passage has heavy deposits, remove
throttle body for complete cleaning.
Inspect IAC valve 0-ring for cuts, cracks, or
distortion. Replace if damaged.
rn
Important
If installing a new IAC valve, be sure to replace

with an identical part. IAC valve pintle shape and
diameter are designed for the specific application.
l@I Measure (If Installing a New IAC Valve}

1.
2.
3.
0-RING - IAC VALVE
Distance between tip of IAC valve pintle and

mounting surface.
If greater than 28 mm, use finger pressure to
slowly retract the pintl,e. The force required to
retract the pintle of a new valve will not cause
damage to the valve.
Lubricate IAC valve Ocring with clean engine oil.

IAC valve assembly.
IAC valve attaching screws.
IAC valve attaching screws to 3 Nm (27 lb:

in.).
4. Air inlet assembly. Refer to "Air Intake System,"
Section "6E3-C14".
5. Electrical connectors to TP sensor, IATsensor, and
IAC valve.
6. Reset IAC valve pintle position:
A. Depress accelerator pedal slightly.
B. Start and release accelerator pedal, run engine
for five seconds.
C. Turn ignition "OFF" for ten seconds.
D. Restart engine and check for proper idle
operation.
IDLE AIR CONTROL VALVE/COOLANT COVER

ASSEMBLY
Figure C2-16
SCREW ASSEMBLY - IAC VALVE ATTACHING
DISTANCE OF PINTLE EXTENSION
DIAMETER OF PINTLE
LP 1220 AS
Figure C2-17 - Idle Air Control Valve Assembly
l~I Tighten
llI Clean ~nd Inspect
Clean gasket sealing surface.

Inspect gasket sealing surface for corrosion or
damage that Would cause a coolant leak. Replace
idle air coritrol va.lve/coolant cover assembly or
throttle body if necessary.
l}I Assemble
1.
2.
3.
New gasket.
Idle air control valve/coolant cover assembly
assembly.
screws.
l~I Tighten
screws to 3.2 Nm (28 lb. in.).
l+I Install and Conn.ect
Throttle body to intake manifold.

Refer to "Throttle Body Assembly."
CLEAN AIR COVER AND GASKET

Figure C2-15
Throttle body from intake manifold.

Refer to "Thro.ttle Body A~sembly."
l+!+I Disassemble
IAC valve.
Refer to "Idle Air Control (IAC) Valve."
2. Idle air control valve/coolant. cover assembly
screws.
3. Idle air control valve/coolant cover assembly and
gasket.
Discard gasket.
1.
2.
1.
Clean air cover attaching screws.

Clean air cover and gasket.
Discard gasket.
[L!J Clean
Gasket sealing surface.

1.
2.
New clean air cover gasket on throttle body.

Clean air cover.

3. Clean air cover attaching screws.
l~I Tighten
Clean air cover attaching screws to 3.2 Nm

(28 lb. in.).
AIR VENT VALVE ASSEMBLY

Figure C2-16
l+-+I Remove or Disconnect
Air vent valve assembly.
I-++! Install and Connect
Air vent valve assembly.
l~I Tighten
Air vent valve fitting to 5.0 Nm (44 lb. in.).
Fuel Rail Attaching Bolts
Fuel Tube Bracket Attaching
Screw
.
Crossover Tube Retainer
' Attaching Screws
Fuel Pressure Regulator
Att~ching Screw
Fuel Tube Retainer
Attaching Screw
Throttle Body
Attaching Bolts
TP Sensor Attaching
Screws
IAC Valve
Attaching Screws
IAC Valve/Coolant Cover
Attaching Screws
Clean Air Cover
Attaching Screws
Air Vent Valve Assembly
20.0 N m (15 lb. ft.)

5 Nm (44 lb. in.)
5 Nm (44 lb. in.)

10 Nm ( 89 lb. in.)
5 Nm (44 lb. in.)
15.0 Nm (ll lb. ft.)
2.0 Nm (18 lb. in.)
3.0 Nm (27 lb. in.)
3.2 Nm (28 lb. in.)
3.2 Nm (28 lb. in.)
5.0 Nm (44 lb. in.)
J 39200 DVM
...........
FUEL INJECTOR
- TESTER +
LOliV VEHICLE BATTERY
READY TO TEST
IN PROGRESS
TEST
r:::ll i::::J i::j c:J

r:::l r::J r::J
J:'i*'''_.._.,..J"'l...._-....1'11"'--
mV fl,....
V-OCG),ml
V-AC
Coil Test
Balance Test
4amp
2.5 amp
0.5 amp
0.5-2.5
amp
OFF
DIGITAL VOLT
METER(DVM)
4amp
+
POS
J 39200
NEG
PUSH TO START TEST
FUEL INJECTOR
TESTER J 39021
VEHICLE BATTERY
CHARTC-2A
(Page 1 of 3)

5.7L (VIN P) "F" CARLINE
Chart Test Description:
Number(s) below refer

1. This is the set-up step for performing the injector
coil test. Also read instructions included with
tools used for test.
2. Engine coolant temperature affects the tool's
ability to detect a faulty injector. If engine
coolant temperature is NOT between 50F and
95F the comparison chart (Page 2 of 3) must be
used.
second of test. The voltage reading should be
within range (see example). The voltage reading
may increase throughout the test as the injector
windings warm and the resistance changes. An
erratic voltage reading (one that jumps up and
down) indicates an intermittent connection
within the fuel injector.
Ohms
Voltage Spec.
at so - 95 F
11.8-12.6
5.7 - 6.6
Resistance
lnj#
Reading
Pass/Fail
6.3
5.9
6.2
2
3
6.1
P
4
r------------------------,
I
4.8
L------------------------~
6
6.0
P
EXAMPLE
5-20-93
PS 17395
DRIVEABILITY AND EMISSIONS S.7L (VIN P) 6E3-C2-19
CHARTC-2A
(Page 1 of 3)

5.7L {VIN P) F" CARLINE
11
ENGINE "OFF."
RELIEVE FUEL PRESSURE. (REFER TO "FUEL PRESSURE RELIEF" IN THIS
SECTION.)
ACCESS INJECTORS AS REQUIRED (REFER TO "ON-VEHICLE SERVICE" IN
THIS SECTION.)
CONNECT FUEL INJECTOR TESTER J 39021 TO VEHICLE BATTERY.
SET AMPERAGE SUPPLY SELECTOR SWITCH TO THE "COIL TEST" 0.5 AMP
POSITION.
CONNECT LEADS. FROM THE J 39200 DIGITAL VOLT METER(DVM) TO THE
FUEL INJECTOR TESTER.
SET DVM TO THE TENTHS SCALE (O.O).
CHECK ENGINE COOLANT TEMPERATURE.
IS IT BETWEEN 50 AND 95 F?

PRESS THE "PUSH TO START TEST" BUTTON AND OBSERVE DVM.
RECORD LOWEST VOLTAGE DISPLAYED AFTER FIRST SECOND OF
READING.
DOES ANY INJECTOR VOLTAGE READING FALL OUTSIDE
5.7-6.6 VOLTS, OR DO ANY HAVE ERRATIC VOLTAGE READINGS?
PROCEED TO "CHART C-2A

(PAGE 2 OF 3)".
REPLACE FAULTY INJECTORS.
PERFORM "INJECTOR BALANCE TEST (PAGE 3 OF 3)".
3-24-93
PS 17396
6E3;.C2-20 5. 7L {VIN P) DRIVEABILITY AND EMISSIONS
J 39200 DVM
FUEL INJECTOR
- TESTER +
c::J
t::J Cl Cl
11111 111=1
i=:J c:::J E:::J
~~."..~-...rl'----',,._-...
LOW VEHICLE BATTERY
READY TD TEST
TEST IN PROGRESS
mV
J 39200
V-Dcern,.A
V-AC
Cod Test
4amp
11 .....
OFF
DIGITAL VOLT
METER(DVM)
Balance Test
4amp
2.5 amp
0.5 amp
0.5-2.5
amp
POS
NEG
PUSH TO START TEST
FUEL INJECTOR
TESTER J 39021
VEHICLE BATTERY
,\
CHARTC-2A
{Page 2 of 3)

second of test. The voltage reading may increase
throughout the test as the injector windings
warm and the resistance changes. An erratic
voltage reading (one that jumps up and down)
indicates an intermittent connection within the
fuel injector.
2. From recorded voltages (see example), identify
the highest voltage reading recorded (other than
those above 9.5 volts). Subtract all other voltages
from the highest voltage recorded. The
subtracted value for any injector must not exceed
0.6 volt.
,--~~~--~~~~--~--,--------~
Highest Voltage Reading
: 7.1 Volts :
1-----------------------+-------1
I
Acceptable Subtracted Value : 0.6Volt :

I
I
I
I
Above/Below 50-95F.
'----------~--~~-----'--------j
lnj.
No.
Voltage
Reading
Subtracted
Value
6.9
5.8
7.0
0.2
Pass/Fail
r------------------------------,
9.8
F ,
L-------------------------------~
p
0.5
6.6
2
, 1
3
~ 4
5
6
1.3
F ~
L-------------------------------~
p
0.1
0.0
EXAMPLE
5-20-93
PS 17397
\
DRIVEABILITY AN.D EMISSIONS 5. 7L (VIN P) 6E3-C2-21
CHARTC-2A
(Page 2 of 3)

5. 7L (VIN P) "F" CARLINE
r----------------------,
: FROM "CHART C-2A (PAGE 1 OF 3)" :
L-
----------------

PRESS "PUSH TO START TEST" BUTTON AND OBSERVE DVM.
RECORD LOWEST VOLTAGE DISPLAYED AFTER THE FIRST
SECOND OF READING.
DOES ANY INJECTOR HAVE AN ERRATIC READING OR A
READING ABOVE 9.5 VOL TS?
---J
DI.SREGARD INJECTOR(S) WITH VOLTAGE

READING ABOVE 9.5 VOLTS OR ERRATIC
READINGS (JUMPS UP AND DOWN) FROM
CALCULATIONS. THESE INJEC1"'0'RS ARE
FAULTY AND MUST BE RPLAC(P.
FROM RECORDED VOLTAGES, IDENTIFY THE HIGHEST VOLTAGE

READING RECORDED (OTHER THAN THOSE ABOVE 9.5 VOLTS).
SUBTRACT ALL OTHER VOLTAGES FROM THE HIGHEST VOLTAGE
RECORDED.
DOES ANY SUBTRACTED VALUE EXCEED 0.6 VOLTS?
REPLACE ANY INJECTOR:

WHOSE SUBTRACTED VALUE HAS EXCEEDED 0.6 VOLTS.
WHOSE INITIAL READING WAS ABOVE 9.S VOL TS.
THAT HAD AN ERRATIC READING.
PERFORM "INJECTOR BALANCE

TEST (PAGE 3 OF 3)".
3-24-93
PS 17398
,
(INITIAL PRESSURE)
,
I
...,
I..._,
FUEL INJECTOR
TESTER
+(t
LOW VEHICLE BATTERY

Coil Test
li::::=::ll
4amp
2.5 amp
Balance Test
0.5 amp
IN JECTOR
CON NECTOR
2ND
READY TO TEST
TEST IN PROGRESS
4amp
0.5-2.5
amp
'I
I I
NEG
POS
PUSH TO ST ART TEST
READING
(PRESSURE AFTER DROP)
FUEL INJECTOR
TESTERJ 39021
VEHICLE BATTERY
EXAMPLE
CYLINDER
1sTReading
296 kPa
(43 psi)
296 kPa
(43 psi)
296 kPa
(43 psi)
2961<Pa
(43 psi)
296kPa 296 kPa

(43 psi) (43 psi)
2NDReading
131 kPa
(19 psi)
117 kPa
(17psi)
124kPa
(18 psi)
145 kPa
(21 psi)
131 kPa 130 kPa

(19 psi) (19 psi)
Amount of Drop
165 kPa
(24 psi)
179 kPa
(26 psi)
172 kPa
(25 psi)
151 kPa
(22 psi)
165 kPa 166 kPa

(24 psi) (24 psi)
166 kPa/24 psi ave.

10 kPa/1.5 ~si
156 kPa to 176 Pa
22.5 psi to 25.5 psi
OK
FAUL TY, RICH

(TOO MUCH
FUEL DROP)
OK
FAULTY.LEAN
(TOO LITTLE FUEL
DROP)
OK
OK
CHARTC-2A
(Page 3 of 3)

1. Engine cool down period (10 minutes) is
necessary to avoid irregular fuel pressure
readings due to "Hot Soak" fuel boiling.
2. Energize tester one time and record pressure drop
at the lowest point (Disregard any slight pressure
variations).
3. If the pressure drop of all injectors is within 10
kPa (1.5 psi) of the average fuel pressure drop, the
injectors are flowing properly. The actual
amount of pressure drop is calculated by
subtracting the second pressure reading from the
first pressure reading.
ENGINE
FUEL PRESSURE
RANGE
All engines EXCEPT

5. 7L (VIN J) Corvette
3. 1L (VIN W) Lumina VFV
284-325 kPa
(41-47 psi)

3.1 L(VIN W) Lumina VFV
333-376 kPa
(48-55 psi)
6-14-93
PS 17399
CHARTC-2A
(Page 3 of 3)

5.7L (VIN P} "F" CARLINE
CAUTION: TO REDUCE THE RISK OF FIRE AND

PERSONAL INJURY, WRAP A SHOP TOWEL AROUND
THE FUEL PRESSURE CONNECTION TO ABSORB ANY
FUEL LEAKAGE THAT MAY OCCUR WHEN
INSTALLING THE PRESSURE GAGE. PLACE TOWEL IN
APPROVED CONTAINER.
NOTICE: The entire test should NOT be repeated more than
once without running the engine to prevent flooding. {This
includes any retest on faulty injectors.)
[I] Important
The injector coil test should be performed prior to this test.
Refer to Page 1 of 3.
IF ENGINE IS AT OPERATING TEMPERATURE, ALLOW A 10 MINUTE "COOL DOWN" PERIOD.
IGNITION "OFF."
CONNECT FUEL PRESSURE GAGE.

ENERGIZE FUEL PUMP USING AVAILABLE METHOD FOR VEHICLE (FUEL PUMP TEST CONNECTOR OR TECH 1 SCAN
TOOL ENABLE).
PLACE OPEN END OF BLEED HOSE INTO AN APPROVED GASOLINE CONTAINER AND BLEED AIR FROM FUEL GAGE.
WITH FUEL PUMP RUNNING NOTE FUEL PRESSURE, PRESSURE SHOULD BE WITHIN SPECIFIED RANGE SHOWN ON
TURN FUEL PUMP "OFF." WHEN PUMP STOPS, PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY. IF
NOT, REFER TO CHART A-7
FACING PAGE. IF NOT, REFER TO CHART A-7.
I
CONNECT FUEL INJECTOR TESTER TO AN INJECTOR.
SET AMPERAGE SUPPLY SELECTOR SWITCH TO THE "BALANCE TEST" 0.5 - 2.5 AMP POSITION.
CYCLE FUEL PUMP "ON"f"OFF"TO PRESSURIZE FUEL SYSTEM .

RECORD STABILIZED FUEL PRESSURE (1 ST PRESSURE READING- SEE EXAMPLE ON FACING PAGE)
ENERGIZE FUEL INJECTOR BY DEPRESSING "PUSH TO START TEST" BUTTON
NOTE FUEL PRESSURE THE INSTANT THE FUEL PRESSURE GAGE NEEDLE STOPS. RECORD FUEL PRESSURE READING
(2ND PRESSURE READING - SEE EXAMPLE ON FACING PAGE).
I
REPEAT STEP 2 ON ALLINJECTORS.
SUBTRACT 2ND PRESSURE READING FROM 1ST PRESSURE READING TO OBTAIN PRESSURE DROP VALUES.,
ADD ALL PRESSURE DROP VALUES AND DIVIDE BY THE NUMBER OF FUEL INJECTORS TO GET THE AVERAGE
PRESSURE DROP.
ANY INJECTOR THAT HAS A 10 kPa (1.5 PSI) DIFFERENCE, EITHER MORE OR LESS FROM THE AVERAGE, IS
CONSIDERED FAULTY.
RETEST ANY INJECTOR THAT APPEARS FAULTY.
ANY INJECTOR THAT FAILS THE RETEST IS FAUL TY AND NEEDS TO BE REPLACED.
IF NO PROBLEM IS FOUND, REVIEW "SYMPTOMS" SECTION "B".

3-24-93
PS 17400
6~3-C2~24 S; 7L (VIN P) DRIVEABILITY AND EMISSIONS
PCM
- - - - - - - - - - - 1747 LT BLU/WHT
=~::t:J~------------ 1748 LT BLU/BLK
IAC COIL "A" HIGH

IAC COIL "A" LOW
t---------------1749LTGRN/WHT
IAC COIL "B" HIGH
- - - - - - - ' - - - - - - - - - 444 LT GRN/BLK
IAC COIL "B" LOW
6-29-93
NS 15658
CHARTC-2C
IDLE AIR CONTROL (IAC) VALVE CHECK
5.7L (VIN P) "Fi' CARLINE (SFI)
The PCM controls engine idle speed with the IAC valve. To increase idle speed, the PCM retracts the IAC
valve pintle away from its seat, allowing more air to bypass the throttle bore. To decrease idle speed, it extends
the IAC valve pintle towards its seat, reducing. bypass air flow. The scan tool will display the PCM commands to
the IAC valve in counts. Higher the counts indicate more air bypass (higher idle). The Lower counts indicate less
air is allowed to bypass (lower idle).
System too lean (high air/fuel ratio) - The idle
s:peed may be too high or too low.,h~ngine speed
1. The IAC tester is used to extend and retract the
may vary up and down and disconnecting the
IAC valve. Valve movement is verified by an
IAC valve does not help. OTC 44 or 46 may be
set.
engine speed change. If no change in engine speed
occurs, the valve can be retested when removed
Tech 1 H02S voltage will be less than 300 m V
(.3 volt). Chee~ for low regulated fuel
from the throttle body.
2. This step checks the quality of the l:AC movement
pressure, water in the fuel or a restricted
injector(s).
in Step 1. Between 700 RPM and about 1500 RPM,

System too rich (low, air/fuel ratio) - The idle
the engine speed should change, sn;ioothly with.
each flash of the tester light in both extend and
speed will be too low. Tech 1 IAC counts will
retract. If the IAC valve is retracted beyond the
usually be above 80. System is obviously rich
control range (about 1500 RPM), it may take many
and may exhibit black smoke .in exhaust.
Tech 1 H02S voltage will be fixed"above 800
flashes in the extend position before engine speed
will begin to drop. This is normal on certain
mV (.8 volt). OTC 45or 65 may set.
Check for high fuel pressure, leaking or
engines, fully extending IAC may cause engine
sticking injector(s). Silicone contaminated
stall. This may be normal.
oxygen sensors will be slow to respond.
3. Steps 1 and 2 verified proper IAC valve operation
Throttle body - Remove IAC valve and inspect
while this step checks the IAC circuits. Each Jamp
bore for foreign material.
on the node light should flash red and green while
the IAC valve is cycled. While the sequence of
IAC valve electrical connections - IAC valve
color is not important, if either light is ''OFF" or
connections should be carefully checked for
proper contact.
does not flash red and green, check the circuits for
Crankcase ventilation valve - An incorrect or
faults, beginning with poor terminal contacts.
faulty crankcase ventilation valve may result
in an incorrect idle speed.
Diagnostic Aids: A slow, unstable, or fast idle may
Refer to "Rough, Unstable, Incorrect Idle or
be caused by a nonIAC system problem that cannot be
Stalling" in "Symptoms," Section "6E2-B".
overcome by the IAC valve. Out of control range IAC
If intermittent poor driveability or idle
scan tool counts will be above 60 if idle is too low, and
symptoms are resolved by disconnecting the
zero counts if idle is too high. The following checks
should be made to repair a non-IAC system problem:
IAC, carefully recheck connections, valve
terminal resistance, or replace IAC .
Vacuum leak (high idle) - If idle is too high,
. stop the engine. Fully extend (low) IAC with

tester. Start engine. If idle speed is above 800
RPM, locate and correct vacuum leaks
including crankcase ventilation .. Al~o, check
for binding of throttle blade or linkage.
DRIVEABILITY AND EMISSIONS 5.7l (VIN P) 6E3-C2-25
CHARTC-2C
IGNITION "OFF," CONNECT IAC DRIVER* TO IAC VALVE.

SET PARKING BRAKE, BLOCK WHEELS, A/C "OFF."
IDLE ENGINE IN PARK.
INSTALL TECH 1 SCAN TOOL AND DISPLAY RPM.
WITH IAC DRIVER, EXTEND AND RETRACT IAC VALVE.
ENGINE RPM SHOULD DECREASE AND INCREASE AS IAC IS
CYCLED.
NO RPM CHANGE
RPM CHANGES
RPM SHOULD CHANGE SMOOTHLY WITH EACH

FLASH OF THE IAC DRIVER LIGHT FROM 700 RPM
TO ABOUT 1500 RPM.
DOES IT?
CHECK IAC PASSAGES.

IF OK, REPLACE IAC.
USING THE OTHER CONNECTOR ON THE

IAC DRIVER PIGTAIL, CHECK RESISTANCE
ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN IAC
TERMINALS" A" TO "B" AND "C" TO "D".
INSTALL APPROPRIATE IAC NODE LIGHT * IN IAC

HARNESS.
CYCLE IAC DRIVER AND NOTE LIGHTS.
BOTH LIGHTS SHOULD CYCLE RED AND GREEN
BUT NEVER "OFF" AS RPM IS CHANGED OVER ITS
RANGE.
DO THEY?
IF CIRCUIT(S) DID NOT TEST GREEN AND RED, CHECK

FOR:
FAULTY CONNECTOR TERMINAL CONTACTS.
OPEN CIRCUITS INCLUDING CONNECTIONS.
CIRCUITS SHORTED TO GROUND OR VOLTAGE.
FAUL TY PCM CONNECTION OR PCM.
IDLE AIR CONTROL (IAC)

VALVE CHECK
11
CHECK RESISTANCE BETWEEN

IAC TERMINALS "B" AND"('"
AND"A" AND"D".
SHOULD BE INFINITE.
REPLACE IAC VALVE

AND RETEST.
IAC DRIVER AND NODE LIGHT REQUIRED KIT

J 37027-A FROM: KENT-MOORE, INC.
IDLE AIR CONTROL VALVE AND
CIRCUIT OK. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
REPLACE IAC VALVE

AND RETEST.
7-9-93
MS 12719
6~3-C2-26 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
BLANK
\
SECTION C3
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

CONTENTS
General Description
Purpose
EVAP Canister
Evaporative Emission System
Control Valve

Diagnosis

C3-1
C3-1
C3-1
C3-1
C3-2
C3-2
C3-2
Visual Check of EVAP Canister

Functional Tests
Control Valve
On-Vehicle Service
EVAP Canister
EVAP Canister Hoses
C3-2
C3-2
C3-2
C3-2
C3-2
C3-3
C3-3
C3-3
C3-2
GENERAL DESCRIPTION
PURPOSE
The Evaporative Emission (EV AP) control system
used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the
fuel tank to an activated carbon (charcoal) storage
device (canister) to hold the vapors when the vehicle is
not operating. When the engine is running, the fuel
vapor is purged from the carbon element by intake air
flow and consumed in the normal combustion process.
EVAP CANISTER
uses a 1500 cc charcoal canister to absorb fuel vapors
from the gas tank.
When gasoline vapor builds enough to overcome
the spring tension of the EV AP pressure control valve,
the vapor will flow to the canister where it is absorbed
and stored by the charcoal. Under certain operating
conditions the PCM will command the purge solenoid
valve to open. This allows the vapor to flow into the
intake manifold for combustion.
17013138
17093194
TANK TUBE
2
AIR TUBE (FRESH AIR INLET)
PURGE TUBE
NA 1349-AS
EVAPORATIVE EMISSION SYSTEM

This system has a remote mounted canister purge
control solenoid valve. The PCM operates this
solenoid valve to control vacuum to the canister.
Under cold engine or idle conditions, the solenoid
valve is closed, which prevents vacuum from being
applied to the canister.
Figure C31 Fuel Vapor Canister
The PCM activates (or opens) the solenoid valve

and allows purge when:
Engine is warm.
After the engine has been running a specified
period of time.
Above a specified road speed.
Above a specified throttle opening.

EVAPORATIVE EMISSION (EVAP) PRESSURE
CONTROL VALVE
This system uses an in-line EVAP pressure control
valve as a pressure relief valve. Refer to diagram for
installation in system. When vapor pressure in the
tank exceeds approximately .5 kPa (. 7 psi). the
diaphragm valve opens, allowing vapors to vent to the
canister. A 1.14 mm (0.045 inch) orifice in the passage
leading to the canister tube causes pressure to drop
slowly, preventing the valve from oscillating
(buzzing). When the tank pressure drops below 5 kPa
(.7 psi), the valve closes causing vapors to be held in
the fuel tank.
17091151
RE SULTS OF INCORRECT OPERATION

Poor idle, stalling and poor driveability can be
caused by:
Inoperative purge solenoid valve.
Damaged canister.
Hoses split, cracked and, or not connected to
the proper tubes.
Evidence of fuel loss or fuel vapor odor can be
caused by:
Liquid fuel leaking from fuel lines.
Cracked or damaged canister.
Inoperative canister control valve.
Disconnected, misrouted, kinked, deteriorated
or damaged vapor hoses, or control hoses.
If the solenoid valve is open, or is not receiving
power, the canister can purge to the intake manifold at
the incorrect time. This can allow extra fuel during
warm-up, which can cause rough or un.stable idle.
DIAPHRAGM
DIAPHRAGM SPRING
CONTROL TUBE
TUBE TO CANISTER
UMBRELLA VALVE
RESTRICTION
7 TUBE TO FUEL TANK

NA 1358-AS
Figure C3-2 - EVAP Pressure Control Valve
DIAGNOSIS
connections tb control vacuum tube artd pump are

secure. If a:fter 10 seconds there is less than 17 kPa (5"
Hg) vacuum, the valve must be replaced' .
With 51 kPa (15" Hg) vacuum still applied to the
control vacuum tube, attach a short piece of hose to the
valve's tank tube side. Blow into the tube. You should
feel the air pass through the valve. If air dogs not pass
through, the valve must be replaced.
EVAPORATIVE EMISSION (EVAP) CANISTER

ON-VEHICLE SERVICE
The Evaporative Emission (EVAP) canister purge

solenoid valve operation is covered in CHART C-3 at
the end of this section.
EVAP CANISTER
f+-+I Remove or Disconnect

1.
VISUAL CHECK OF EVAP CANISTER
Cracked or damaged, replace EVAP canister.
FUNCTIONAL TESTS
Control Valve
With a hand vacuum pump, apply approximately
51 kPa (15" Hg) to the control vacuum tube. After ten
seconds, there should be at least 17 kPa (5" Hg)
vacuum remaining. Be sure the hand vacuum pump
being used does not have an internal leak and the hose
2.
3.
4.
5.
6.

Raise vehicle.
Driver side rear wheel housing liner.
Hoses from canister.
Canister from canister bracket.
Canister from vehicle.

1. Canister to vehicle.
2. Canister to canister bracket.
3. Hoses to canister.
4. Driver side rear wheel housing liner.
5. Lower vehicle.
DRIVEABILITY AND EMISSIONS 5. 7L {VIN P) 6E3-C3-3
FUEL TANK
!VIEWA!
EVAPORATIVE EMISSION PRESSURE CONTROL VALVE
FUEL FILLER NECK

NS 15274
Figure C3-3 - EVAP Canister Mounting
.----------3------
EVAP CANISTER PURGE SOLENOID VALVE

1.
2.
3.
4.

Ignition system test connector.
Electrical connector and hoses from solenoid valve.
Bracket and solenoid from intake manifold.

1.
Solenoid valve to intake manifold.
l~I Tighten
2.
3.
4.
Bolt to intake manifold to 5.8 Nm (52 lb. in.).

Electrical connector and hoses to solenoid valve.
Ignition test connector.
EVAP CANISTER HOSES

!VIEWA!
Refer to "Vehicle Emission Control Information"

label for routing of EVAP canister hoses.
BRACKET
INTAKE MANIFOLD
NS 15268
Figure C3-4 EVAP Canister Purge Solenoid Valve

Service
EVAP Canister Purge Solenoid

Valve Bolt 5.8 Nm (52 lb. in.)
THROTTLE BODY
SOLENOID VALVE (NORMALLY CLOSED)
EVAP EMISSION CANISTER
EVAP EMISSION PRESSURE CONTROL

VALVE WITH INTERNAL ORIFICE
FLOATING ROLL-OVER VALVE

FUELTANK
FUEL TANK VENT VALVE (PRESSURENACUUM
RELIEF)REMOTE MOUNTED
Figure C3-5 - Evaporative Emissions (EVAP) Control System Schematic
11-17-92
NS 15659
BLANK
TO EVAP
PRESSURE
CONTROL
VALVE
:r._____
MANIFOLD
VACUUM
-----l..1.1
PCM
EVAP CANISTER
PURGE SOLENOID
VALVE CONTROL
EVAP CANISTER
PURGE
SOLENOID
VALVE
'------------------~428DKGRN/WHT
TO OTHER CIRCUITS
TO EGR SOLENOID
F
#6 (U/H)
VALVE,REVERSE-..___,.,___-<,K--- 54 1 BRN ~ 3000RN - T o
INHIBIT SOLENOID,
c 100
10 AMP
IGNITION
SKIP SHIFT SOLENOID
AND H02S HEATERS
(U/H)
= LOCATED IN UNDER HOOD ELECTRICAL CENTER
6-30-93
PS 17940
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE CHECK
EVAP canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the EVAP
canister when energized. The PCM supplies a ground to energize the solenoid valve.
If the "output/field service enable" terminal is grounded with the engine stopped and ignitiof "ON," or the
following conditions are met with the engine running, the EVAP canister purge solenoid valve will be energized
~purge "ON").
e Engine coolant temperature above 60C (140F).
Vehicle speed above 2 mph.
Throttle off idle, above 4.3%.

1. Checks to see if the solenoid valve is opened or
closed. The solenoid valve is normally closed and
should open when actuated by Tech 1 or the
"output/field service enable" terminal is grounded.
2. This should energize the solenoid valve and allow
the vacuum to drop (purge "ON").
Diagnostic Aids: Normal operation of the EVAP

canister purge solenoid valve is described as follows:
With the ignition "ON," engin,e "OFF,"
"output/field service enable" terminal gro~nded, the
EVAP canister purge solenoid valve ihould be
energized.
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE
SOLENOID VALVE CHECK
;,
IF PCM OTC 2615 SET, REFER TO OTC 26 CHART FIRST.

WITH ENGINE RUNNING AT 2000 RPM, DISCONNECT THROTTLE BODY
SIDE OF EVAP VACUUM HOSE AT SOLENOID VALVE.
INSTALL A VACUUM GAGE AND CHECK FOR VACUUM SUPPLY TO
SOLENOID VALVE.
VACUUM SHOULD BE AT LEAST 25 kPa (7" Hg) AT 2000 RPM.
ISIT?
IGNITION "OFF."
REINSTALL VACUUM HOSE FROM
THROTTLE BODY TO SOLENOID VALVE.
DISCONNECT VACUUM HOSE TO EVAP
SOLENOID FROM CANISTER.
lNSTALL HAND-HELD VACUUM PUMP TO
SOLENOID VALVE.
APPLY 34 kPa (10" Hg) OF VACUUM.
VACUUM SHOULD HOLD.
DOES IT?
WITH VACUUM STILL APPLIED AT 34 kPa (10" Hg).

USING A TECH 1 "MISCTEST" ACTIVATE SOLENOID VALVE.
VACUUM SHOULD DROP.
DOES IT?
SOLENOID VALVE OPERA TING PROPERLY.
LEAKING OR RESTRICTED VACUUM

SUPPLY LINE TO EVAP SOLENOID VALVE.
'1f.C.
FAULTY SOLENOID VALVE.
FAULTY SOLENOID VALVE.
6-16-93
PS 17366
SECTION C4
DISTRIBUTOR IGNITION (DI) SYSTEM

CONTENTS
General Description
~urpose
Description
Operation
.. ............... .
-
(4-1
(4-1
(4-1
(4-2

Diagnosis
On-Vehicle Service
(4-2
(4-2
(4-2
(4-2
GENERAL DESCRIPTION
PURPOSE
The distributor ignition system controls fuel
combustion by providing a spark to ignite the
compressed air/fuel mixture at the correct time. To
provide improved engine performance, fuel economy,
and control of exhaust emissions, the PCM controls
distributor spark advance (timing) with an Ignition
Control (IC) system.
Only the IC system will be described here.
Additional information on the system is found in
SECTION 60.
To properly control ignition/combustion timing the
PCM needs to know:
Camshaft position.
Engine speed (RPM).
Engine load (manifold pressure or vacuum).
Atmospheric (barometric) pressure.
Engine coolant temperature.
The amount of detonation.
IGNITION COIL WIRE
IGNITION COIL MODULE
IGNITION COIL
DESCRIPTION
DISTRIBUTOR
The distributor ignition system is a net build

distributor (no timing adjustment) that provides angle
based timing information to the PCM for individual
cylinder spark timing. The ignition module is capable
of providing both 4X and 360X timing pulses each
crankshaft revolution. Using these timirig pulses, the
PCM processes ignition spark timing and sends an IC
signal to the ignition coil module to activate the
secondary ignition system.
The PCM provides power, ground, and two 5 volt
reference voltages to the ignition control module. As
the camshaft turns (during crank or run), a slotted
two-track timing disk is rotated inside the ignition
control module. Each time a slot in either track of the
disk is properly aligned, the ignition control module
will pulse one of the 5 volt reference voltages to
ground.
NS 15346
Figure C4-1 - Distributor Ignition System
A reference signal is generated each time the PCM

detects that the reference voltages have been grounded
by the ignition control module. When the PCM detects
reference signals, ignition timing can be processed.
The PCM will also compare the 4X and the 360X
signals to each other to determine the location of the
number one cylinder and top dead center. In addition,
if only one signal is being received by the PCM a
Diagnostic Trouble Code (DTC) will be set. DTC 16
will be set if the 4X signal is missing and DTC 36 will
be set if the 360X signal is missing. The vehicle will
not run if the 4X (REFERENCE) signal is not
available at the PCM for processing.

OPERATION
The Ignition Control (IC) system consists. of the
camshaft position sensor, ignition coil, ignition coil
module, and PCM. The connector terminals are
lettered as shown in CHART C-4.
These circuits performthe following functions:
Low resolution signal reference (CKT 453). This provides the PCM with reference signals,
firing order, and camshaft position
information. If the low resolution signal
circuit becomes open or grounded, the engine
will not run because the PCM will not operate
the ignition coil module, fuel pump, or the fuel
injectors. A OTC 16 will set if the PCM
receives high resolution signal references
without the low resolution signals. If engine
cranks but will not start refer to CHART A-3.
High resolution signal reference (CKT 430). This provides the PCM with detailed reference
signals and crankshaft position information.
If this circuit becomes open or grounded a OTC
36 will set and the engine will still run.
System ground (CKT 631). - This circuit is
grounded at the PCM and provides ground for
the distributor to generate low and high
resolution signal reference signals. ~~this
circuit becomes open, the engine will not run
since there will be no reference information.
IC (CKT 423). - This circuit controls the
ignition coil "ON" and "OFF" time. It signals
the ignition coil module to begin primary coil
dwell current when the IC is high. The
ignition coil module shuts "OFF" ignition coil
current when the signal goes low. If this
circuit becomes open, shorted to voltage, or
grounded, the engine will not start and a OTC
41 or 42 will set.

An open IC circuit will set a OTC 41. A grounded
IC circuit will set a OTC 42. An open or grounded IC
circuit will result in a engine cranks but will not n,m.
An open or ground in the low resolution signal
circuit will set a OTC 16 and the engine will not start.
If the high resolution signal circuit becomes open or
grounded a DTC 36 would set. This will cause reduced
performance and poor fuel economy.
NOTICE: An inoperative distributor vent system

may cause premature distributor failure. To check
system operation, ,with engine idling, connect a
vacuum gage to the air inlet filter. Vacuum should
be present. If not, check for clogged inlet filter,
damaged/pinched hoses, a poor seal between the
cap and distributor, or a plugged vacuum source.
The PCM uses information from the MAP and
engine coolant temperature sensor in addition to RPM
to calculate spark advance as follows:
Cold engine = More spark advance.
Engine under minimum load based on RPM
and low amount of air flow - More spark
advance.
Hot engine = Less spark advance.
Engine under heavy load based on RPM and
high amount of air flow - Less spark advance.
DIAGNOSIS
The description, operation and repair procedures of
the distributor ignition system components are found
in SECTION 60 of this manual. For misfire or
ignition control check, refer to CHART C-4 at the end
of this section.
ON-VEHICLE SERVICE
For removal and replacement of the distributor
ignition system components, refer to SECTION 604,
"Ignition System."
Distributor Mounting
Bolts 11 N m (8 lb. ft.)
Ignition Coil Mounting
Fasteners 2.8 Nm (25 lb. in.)
Ignition Coil Module
Fasteners 1.6 Nm (14 lb. in.)
~,}
BLAN!<
PCM
IGNITION SYSTEM
TEST CONNECTOR
. . . - - - - - - - - - - - 632 PNK/BLK
1---------- 632 PNK/BLK
. . . - - - - - - - - - - - - 631 RED
- - - - - - - - - - 631 RED
, - - - - - - - - - - 430 PPL/WHT
- - - - - - - - 430 PPL/WHT
. . - - - - - - - - 453 RED/BLK
1---------- 453 RED/BLK
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTIOIII
SIGNAL
1lr-- 450BLK
ENGINE
GROUND
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
CONNECTOR
239 PNK
--------\ B
IGNITION
COIL
II
423WHT
~~B
1846PNK/BLK
1
I
I
I
I
I
I
IGNITION
COIL
MODULE
I
I
I
I
I
I
I
I
I
I
I
IGNITION CONTROL
GRAY
CONNECTORS
A
1847 WHT/BLK
---------/.J A
BLACK
CONNECTOR
6-25-93
MS 12328
CHARTC-4A
(Page 1 of 2)
DISTRIBUTOR IGNITION (DI) SYSTEM CHECK

The battery should be fully charged prior to any
tests.
1. Checks for proper output from the distributor
ignition system. The spark tester requires a
minimum of 25,000 volts to fire. This check can be
used in case of an ignition miss, because the
system may provide enough voltage to run the
engine but not enough to fire a spark plug under
heavy load.
2. This test will separate the distributor cap, rotor
and ignition wires from the ignition coil to help
identify a secondary ignition system problem.
3. This will determine if the proper available voltage

exists in the primary ignition circuit.
4. This check will begin to determine if the PCM is
providing a signal to the ignition coil module or
not. If the PCM is not providing a signal to the
ignition coil module, the problem exists between
the distributor and PCM.
5. A grounded coil circuit will cause the ignition fuse
to open, and a no-start condition will occur.
Diagnostic Aids: An ignition coil wire that is open

or shorted to ground can cause a no start condition.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-C4-5
CHARTC-4A
(Page 1 of 2)
DISTRIBUTOR IGNITION (DI) SYSTEM CHECK

PERFORM ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK BEFORE PROCEEDING WITH THIS
TEST. (DISCONNECT TACHOMETER (IF EQUIPPED) BEFORE PROCEEDING WITH THE TEST.)
CHECK SPARK AT PLUG WITH SPARK TESTER J 26792 (ST-125) WHILE CRANKING (IF NO SPARK
ON ONE WIRE, CHECK A S.ECOND WIRE) A FEW SPARKS AND THEN NOTHING IS CONSIDERED
NO SPARK.
I
I
NOSPARK
SPARK
I
CHECK FOR SPARK AT IGNITION COIL WIRE WITH TESTER
WHILE CRANKING. (LEAVE SPARK TESTER CONNECTED TO
IGNITION COIL WIRE FOR STEPS 3-6.)
CHECK FUEL, SPARK PLUGS,

ETC. SEE 6E3-B "SYMPTOMS."
I
I
NO SPARK
SPARK
DISCONNECT IGNITION COIL MODULE CONNECTOR.

IGNITION "ON."
WITH DVM,CHECKVOLTAGE FROM HARNESS
TERMINALS" A" AND "D" TO GROUND.
INSPECT CAP FOR CRACKS, SECONDARY WIRES FOR OPENS;

SHORTS; OR POOR CONNECTIONS.
IF OK, REPLACE DISTRIBUTOR.
.11,n,v
--'"'
I
I
BOTH TERMINALS 10 VOL TS OR MORE
WITH DVM ON AC SCALE, CONNECTED

FROM IGNITION COIL MODULE
CONNECTOR TERMINAL "B" TO
GROUND, CRANK ENGINE AND
OIJSi!RVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4
VOLTS?
BOTH TERMINALS UNDER 10 VOLTS
G)
EITHER TERMINAL
UNDER 10VOLTS
rv
FAUL
IGNITION FEED Cll~CUIT TO
IGNITION COIL
OR
GROUNDED EXTERNAL COIL CIRCUIT
OR
FAUL TV IGNITION COIL.
FAUL TV CIRCUIT FROM

TERMINAL TO COIL
OR
FAULTY COIL CONNECTION
OR
FAUL TV COIL.
...
------,
: TO CHART C-4
1 2 OF2.
PROBE IGNITION COIL MODULE CONNECTOR

TERMINAL "C" WITH TEST LIGHT TO B +.
ISLIGHT ON?
I
I
I
L---------..J
~
OPEN IGNITION COIL MODULE GROUND CIRCUIT.
FAUL TV IGNITION COIL MODULE CONNECTION

OR
FAUL TV IGNITION COIL MODULE.
"AFTER REPAIRS.'' CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
6-29-92
MS 10860
PCM
IGNITION SYSTEM
TEST CONNECTOR
1---------- 632 PNK/BLK
. - - - - - - - - - - - 632 PNK/BLK
1----~-----~631RED
, - - ; . - - - - - - - - - 631 RED
. - - - - - - - - . 430 PPLJWHT
. . - - - - - - - - - 453 RED/BLK
1--------- 430 PPLJWHT

1---------- 453 RED/BLK
111---
ENGINE
GROUND
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
450BLK
10AMP
TO~
IGNITION
#11 (U/H)
BLACK
IGNITION
COIL
MODULE
239 PNK
~~~~E_C!~~ \
423WHT
~B
l :~:
IGNITION CONTROL
1846 PNG::~K
IGNITION
COIL
I
I
I
II
I
I
I
CONNECTORS
I
I
1847 WHT/BLK
-------. -/.J A
BLACK
CONNECTOR
(U/H)
6-25-93
MS 12328
= LOCATED IN UNDERHOOD ELECTRICAL CEN'Tt!R
CHARTC-4A
(Page 2 of 2) ,
DISTRIBUTOR IGNITION (DI) SYSTEM CH ECK

1. If the PCM is detecting low resolution signal
pulses and no IC signal was available at the
ignition coil module, a problem exists with the
PCM or the circuit to the ignition coil module.
2.
If the PCM does not detect low resolution signal

pulses the distributor or distributt>r to PCM
circuitry is most likely the problem. The
remaining tests will determine if the proper
signals are being sent and received from both the
distributor and PCM.
----+-----,
r
: FROM CH~RT C-4 :
11 OF2.
I
L-
---------.J
CRANK ENGINE WHILE OBSERVING LQl,/V

RESOLUTION SIGNAL ON TECH 1.
IS LOW RESOLUTION SIGNAL INDICATED?
CHARTC-4A
(Page 2 of 2)
DISTRIBUTOR IGNITION (D') SYSTEM CHECK

IGNITION "OFF."
DISCONNECT DISTRIBUTOR
IGNITION "ON."
PROBE TERMINAL"(" WITH
A TEST LIGHT TO GROUND.
ISIT?
FAULTY IGNITION CONTROL CONNECTION AT PCM

OR
OPEN IGNITION CONTROL CIRCUIT
OR
FAULTY PCM.
CHECK FOR CONTINUITY BETWEEN DISTRIBUTOR

CONNECTOR TERMINAL "D" AND GROUND.
CIRCUIT SHOULD HAVE CONTINUITY.
DOESIT?

OR
OPEN IGNITION FEED CIRCUIT FROM DISTRIBUTOR TO PCM
OR
FAULT~l?CM.
USING A DVM ON DC SCALE, MEASURE VOLTAGE

AT DISTRIBUTOR CONNECTOR TERMINAL" A".
VOLTAGESHOULDBEABOUTSVOLTS.
ISIT?

OR
OPEN GROUND CIRCUIT FROM DISTRIBUTOR TO PCM
OR
FAULTY PCM.
MEASURE VOLTAGE AT DISTRIBUTOR

CONNECTOR TERMINAL "B".
VOLTAGE SHOULD BE ABOUT 5 VOLTS.
ISIT?

OR
FAULTY LOW RESOLUTION SIGNAL
CIRCUIT FROM DISTRIBUTOR TO PCM
OR
FAULTY PCM.
FAULTY DISTRIBUTOR CONNECTION

OR
FAUL TY DISTRIBUTOR.

OR
FAULTY HIGH RESOLUTION SIGNAL
CIRCUIT FROM DISTRIBUTOR TO PCM
OR
FAULTY PCM.
3-19-93
MS 10861
6E3C4-8 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS

PCM
IGNITION SYSTEM
TEST CONNECTOR
, - - - - - - - - - - 632 PNK/BLK
- - - - - - - - - 632 PNK/BLK
. - - - - - - - - - - - 631 RED
- - - - - - - - - - 631 RED
. - - - - - - - - - - 430 PPLJWHT
1---------- 430 PPLJWHT
. . . . . - - - - - - - - 453 RED/BLK
A - - - - - - - - - 453 RED/BLK
ENGINE I
GROUND
lj.--- 450 BLK

10AMP
1GN1~o~
BLACK
~~~~E_C!
~H)
9! \
IGNITION
COIL
MODULE
239 PNK
423WHT
B
: ~ v -1846PNK/BLK
:B
IGNITION
COIL
DISTRIBUTOR
REFERENCE LOW
SIGNAL
DISTRIBUTOR
IGNITION FEED
HIGH RESOLUTION
SIGNAL
LOW RESOLUTION
SIGNAL
II
: :
I
I
I
I
I
I
I
I
IGNITION CONTROL
GRAY
CONNECTORS
A
1847 WHT/BLK
---------/.J A
BLACK
CONNECTOR
6-25-93
MS 12328
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENT R!.
CHARTC-48
MISFIRE CHECK
11

1. By performing CHART C-2A first all injectors
must be operating OK at this point. This chart
covers ignition system related misfire only.
2. A thorough visual/physical check of the engine
components which typically may cause a misfire
may eliminate the need for further diagnostics.
Use fuel pressure gage J 34730-1. Check fuel
pressure. Pressure after ignition "ON" should be
(283-325 kPa) 41-47 psi. If fuel pressure is not
within spec, perform "Fuel System Check,"
CHARTA-7.
3. A spark tester such as a ST-125 must be used
because it is essential to verify adequate available
secondary voltage at the spark plug. (25,000
volts.) This simulates a "load" condition.
4.
With engine running, try to induce theLmisfire by

moving related harness connectors. This may help
locate an intermittent connection.
5. If spark plugs check OK a mechanical engine
problem may be causing misfire (ie. worn
camshaft, bent pushrod, low compression, etc.);
Refer to SECTION 6A.
Diagnostic Aids: The distributor vent system

should also be checked. A blocked air supply to the
distributor will cause vacuum to build within the
distributor causing misfire. Refer to the beginning of
this section for distributor vent system check
procedure.
THIS CHART ASSUMES THAT THE

INJECTORS ARE OPERATING. CHART
C2A MUST BE PERFORMED BEFORE
PROCEEDING WITH THIS
DIAGNOSIS.
CHARTC-48
MISFIRE CHECK
IF ANY DTCs ARE SET USE THOSE CHARTS BEFORE PROCEEDING WITH THIS DIAGNOSTIC CHART.
VISUALLY/PHYSICALLY INSPECT THE FOLLOWING ITEMS:
SECONDARY IGNITION WIRES FOR CRACKING, HARDNESS, SHORTED TO GROUND, PROPER ROUTING AND CARBON
TRACKING.
INJECTOR HARNESS ROUTING (ACCORDING TO FIRING ORDER).
INJECTOR HARNESS WIRING FOR PROPER CONNECTIONS, PINCHES AND BEING BARE.
PCM GROUNDS FOR BEING CLEAN, TIGHT AND IN THEIR PROPER LOCATIONS.
CHECK FOR VACUUM LEAKS.
CHECK FUEL PRESSURE REFER TO FUEL SYSTEM DIAGNOSIS CHART A-7.
WAS A PROBLEM FOUND IN ANY OF THE ABOVE ITEMS?
DISCONNECT COIL WIRE FROM

DISTRIBUTOR AND INSTALL SPARK TESTER
(ST125).
CRANK ENGINE, SPARK SHOULD JUMP
TESTER GAP.
DOESIT?
REPAIR
OR
REPLACE ANY FAUL TY ITEMS FOUND.
RECONNECT COIL WIRE.

USING TECH 1 MISC TESTS, SELECT INJECTOR BALANCE
TEST.
DISABLE INJECTORS ONE AT A TIME AND RECORD RPM
DROP.
DID AN RPM DROP OCCUR FOR EACH CYLINDER?
CHECK RESISTANCE OF COIL WIRE.

REPLACE COIL WIRE IF RESISTANCE IS
MORE THAN 30K. IF RESISTANCE IS
LESS THAN 30K REPLACE IGNITION
COIL.
INSTALL SPARK TESTER (ST125) J 26792 ON IGNITION

WIRE FOR CYLINDER THAT HAS FAULT AND CLIP TO
GROUND.
START ENGINE, SPARK. SHOULD JUMP TESTER GAP .
DOESIT?
PROBLEM INTERMITTENT, PERFORM

CHECK LIST IN CUTSOUT, MISSES,
AND ROUGH, UNSTABLE OR
INCORRECT IDLE, STALLING IN
"SYMPTOMS" SECTION 6E3-B.
CHECK RESISTANCE OF IGNITION WIRE OF

FAULTY CYLINDER, IT SHOULD BE LESS THAN
30K OHMS AND NOT GROUNDED.
IGNITION WIRE OK?
CHECK FOR:
FAULTY, CRACKED OR
WORN SPARK PLUG.
FOULED SPARK PLUG
POSSIBLE MECHANICAL PROBLEM.
CHECK ALL IGNITION SYSTEM WIRING FOR POOR

CONNECTIONS.
IF ALL CONNECTIONS ARE OK, REPLACE DISTRIBUTOR.
6-15-93
PS 17365
6E,3-C440 5. 7l (VIN P) DRIVEABIUTY AND EMISSI.ONS
BLANK
DRIVEABILITYAND EMISSIONS 5.7L (VIN P) 6E3-cs~1
SECTION CS
KNOCK SENSOR (KS) SYSTEM

CONTENTS
General Description
Purpose
Operation
Diagnosis
CS-1
CS-1
CS-1
CS-1
. . . . .. . . .. . .. . .
On-Vehicle Service
Knock Sensor
Knock Sensor Module
~
CS-1
CS-1
CS-2
CS-2
GENERAL DESCRIPTION
PURPOSE
Varying octane levels in today's gasoline can cause
detonation in high performance engines. Detonation
is sometimes called spark knock.
To control spark knock, a Knock Sensor (KS)
system is used. This system is designed to retard
spark timing up to 20 to reduce spark knock in the
engine. This allows the engine to use maximum spark
advance to improve driveability and fuel economy.
KNOCK SENSOR (KS)
35 0023-6E
OPERATION
Figure CS-1 Knock Sensor
The knock sensor system is used to detect engine

detonation. The PCM will retard the spark timing
based on signals from the KS module. The knock
sensors produce an AC voltage which is sent to the KS
module. The amount of AC voltage produced by the
sensor is determined by the amount of knock. This
signal voltage is input to the PCM. The PCM then
adjusts the Ignition Control (IC) to reduce spark
knocking.
DIAGNOSIS
The Tech 1 has several positions to check for
diagnosing KS circuit. "Knock signal" is used to
monitor the input signal from the knock sensor. This
position should display "YES" to indicate when a
knock is being detected. "Knock retard" is the
indication of how much the PCM is retarding the
spark.
OTC 43 is designed to diagnose the knock sensor
circuit. Problems encountered with this circuit should
set DTC 43. However, ifno DTC 43 was set but the KS
system is suspected, refer to CHART C-5.
''PIEZO
CR)'.STAL
LS 8461-6E
Figure CS2. l<nock Sensor Cut~way View
3.
4.
CAUTION: Engine coolant may be hot.

The knock sensor is mounted in the
engine block cooling passage. Engine
coolant in the block will drain when the
knock sensor is removed.
ON-VEHICLE SERVICE
KNOCK SENSOR

1.
2.

Drain coolant, refer to SECTION 6B.
Raise vehicle.
Knock sensor wiring harness connector from
knock sensor.
5.
Knock sensor from engine block.
6E3-CS-2 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS

NOTICE: Do not apply thread sealant to sensor
threads. Sensor is coated at factory and applying
additional sealant will affect the sensor's ability to
detect detonation.
1.
Knock sensor into engine block. Be sure threads

are clean.
l~I Tighten
2.
3.
4.
5.
Sensor to 19 Nm (14 lb. ft.).

KS wiring harness connector to the knock sensor.
Lower vehicle.
Refill coolant. Refer to SECTION 6B.
Knock Sensor Module

1.
2.
3.
4.

PCM from mounting bracket (refer to "PCM
Removal" in "Powertrain Control Module (PCM)
and Sensors/' Section "6E3-Cl").
Knock sensor module access cover.
Knock sensor module.

NOTICE: To prevent possible electrostatic
discharge damage to the PCM and KS module, Do
Not touch the connector pins or soldered
components on the circuit board.
1. Knock sensor module.
2. Access cover.
3. PCM to mounting bracket (refer to "PCM
Installation" in "Powertrain Control Module
(PCM) and Sensors," Section "6E3-Cl").
Knock Sensor
. .. . . . ...
19 Nm (14 lb. ft.)
APPLY PRESSURE IN
DIRECTION OF ARROWS
PS 17477
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-CS-3
BLANK
PCM
KS
SIGNAL
SVOLTS
~ - - - - - 496 DK BLU
KNOCK
SENSOR
(KS)
6-26-93
NS 15347
CHART C-5
5.7L (VINP) "F" CARLINE (SFI)
The knock sensor system is used to detect engine detonation. The PCM will retard the spark timing based on
signals from the KS module. The knock sensor produces an AC voltage which is sent to the KS module. The
amount of AC voltage produced by the sensor is determined by the amount of knock. The circuitry within the
knock sensor causes the PCM's 5 volts to be ,pulled down so that under a no knock condition, CKT 496 would
r1easure about 2.5 volts.
i

l. With engine idling, there should not be a knock
signal present at the PCM, because detonation is
not likely under a no load condition.
2. Tapping on the engines right side exhaust
manifold should simulate a knock signal to
determine if the sensor is capable of detecting
detonation. If no knock is detected, try tapping on
engine block closer to the sensor before replacing
the sensor.
3. If the engine has an internal problem which is
creating a knock, the knock sensor may be
responding to the internal failure.
4. This test determines if a knock sensor is faulty or if

the problem is elsewhere in the circuit.
5. Replace KS module with a known good module. If
the malfunction is not corrected, install a new
PCM with the original KS module.
Diagnostic Aids: While observing knock signal on

the Tech 1, there should be an indication that knock is
present when detonation can be heard. Detonation is
most likely to occur under high engine load conditions.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-(5.,.5
CHART(.. 5
G)
IF OTC 43 IS SET, USE THE OTC CHART.

ENGINE MUST BE IDLING AT NORMAL OPERATING
TEMPERATURE.
USE SCAN TOOL TO OBSERVE KNOCK SIGNAL.

IS KNOCK INDICATED?
IF AN ENGINE KNOCK CAN BE HEARD, REPAIR THE
TAP ON RIGHT EXHAUST MANIFOLD WHILE

OBSERVING KNOCK SIGNAL.
SCAN TOOL SHOULD INDICATE KNOCK WHILE
HEARD,FOLLOWTHE STEPS:
TAPPING ON MANIFOLD.
DOESIT?
PROBE KNOCK SENSOR WITH A DVM TO

GROUND.
BASIC ENGINE PROBLEM. IF NO AUDIBLE KNOCK IS
SET VOLTMETER ON 2 VOLT AC SCALE.

IS A SIGNAL INDICATED ON VOLTMETER?

PROBE KNOCK SENSOR WITH A
DVM TO GROUND.
SYSTEM IS OPERATING
PROPERLY. REFER TO
SET VOLTMETER ON 2 VOLT AC
ON FACING PAGE.
"DIAGNOSTIC AIDS"
CHECK CKT 491; FOR BEING

NEAR AN IGNITION WIRE
REPLACE KNOCK
SENSOR.
OR
FAULTY KS MODULE
SCALE.
OR
TAP ON ENGINE BLOCK NEAR
A FAUL TY PCM CONNECTION
KNOCK SENSOR.
IS A SIGNAL INDICATED ON
OR
FAULTY PCM.
VOLTMETER WHILE TAPPING

ON ENGINE BLOCK?
FAUL TY KS MODULE
REPLACE KNOCK SENSOR.
OR
OR
FAULTY PCM.
'"'AFTER REPAIRS, CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
5-17-93
PS 17939
BLANK
SECTION C6
SECONDARY AIR INJECTION (AIR) SYSTEM

CONTENTS
General Description
Purpose
Operation of System Components
Operation

Diagnosis
Operational Checks
AIR Pump
Hoses and Pipes
. . . . . . . .. . . . . .
C6-1
C6-1
C6-1
C6-1
C6-2
C6-2
C6-2
C6-2
C6-3
.. . . . . . . . . . .. . . .
.. .. . . . . . . . .. . . .
Check Valve
On-Vehicle Service
AIR Pump
AIR Check Valve/AIR Pipes
Left Side
Right Side
AIR Cross Under Pipe
C6-3
C6-3
CG-3
CG-3
CG-3
C6-4
C6-4
C6-4
GENERAL DESCRIPTION
PURPOSE
The Secondary Air Injection (AIR) system helps

reduce Hydrocarbon (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx) exhaust emissions. It also
heats up the oxidation catalytic converter quickly on
engine startup so conversion of exhaust gases can
occur sooner.
OPERATION OF SYSTEM COMPONENTS

The system (Figure C6-1) includes:
AIR Pump. - The AIR pump is mounted to the
lower left front of the engine and supplies the
air to the AIR system. The electric air pump
pressurizes air from the engine air cleaner and
pumps it to the check valves near the exhaust
manifolds.
The AIR pump is controlled by the PCM.
Battery voltage to the AIR pump is controlled
by the AIR pump relay. An integral stop valve
prevents air flow through the pump during
"OFF" periods. When the PCM provides a
ground circuit for the secondary AIR pump
relay, battery voltage is allowed to power up
the AIR pump and integral stop valve.
Check Valves. - The check valves prevent back
flow of exhaust gases into the pump in the
event of an exhaust backfire.
Necessary Plumbing. - As shown in Figure
C6-4.
CHECK VALVES
2
3
AIR INJECTION PIPES
TO AIR CLEANER ASSEMBLY
AIR TO EXHAUST PORTS

(PCM CONTROLLED)
EXHAUST MANIFOLD
INT AKE MANIFOLD
4-5-93
PS 17368
Figure C6-1 -AIR System Operation
OPERATION
The AIR pump with integral stop valve is
controlled by the PCM. The PCM will turn "ON" the
AIR pump by providing the ground to complete the
circuit which energizes the AIR pump relay. When air
to the exhaust ports is desired, the PCM turns "ON"
both the integral stop valve and AIR pump.
6E3-C6-2 5. 7L {VIN P) DRIVEABILITY AND EMISSIONS

2
SECONDARY AIR INJECTION (AIR) RIGHT SIDE PIPE AND CHECK VALVE
2
CLAMP
SECONDARY AIR INJECTION (AIR) CROSS UNDER PIPE
SECONDARY AIR INJECTION (AIR) PIPE
SECONDARY AIR 11\fJKTION (AIR) LEFT SIDE PIPE AND CHECK VALVE
.. ,;:\'~
PS 17017
Figure C6-2 - AIR System {Typical)
The PCM turns "ON" the AIR pump after startup any
time engine coolant temperature is above 15C (59F).
The AIR pump will operate for a maximum of 240
seconds, or until the system enters "Closed Loop"
operation. At the same time the PCM turns the AIR
pump "OFF," it also de-energizes the integral stop
valve solenoid so no air is directed to the exhaust ports.
The air system will be disabled un~er the following
conditions:
When the PCM recognizes a problem and sets a
diagnostic trouble code.
When the fuel system is operating in "Closed

Loop."
The AIR pump has been "ON" for 240 seconds.
RPM is greater than 2825.
MAP is greater than 96 kPa with VSS over 60
mph.
MAP is less than 20 kPa.
ECT less than 15C (59F).
Oxidation catalytic converter over
temperature detected.
Short and long term fuel trim are not in their
normal ranges.
Engine RPM below 400 RPM.
Power enrichment is detected.

If no air (oxygen) flow enters the exhaust stream at
the exhaust ports, HC and CO emission levels will be
too high.
Air flowing to the exhaust ports at all times could
increase temperature of the oxidation catalytic
converter.
DIAGNOSIS
The diagnosis of the AIR system is covered in
CHART C-6 at the end of this section.
OPERATIONAL CHECKS
AIR Pump
The AIR pump is a regenerative turbine type
which is permanently lubricated and requires no
periodic maintenance.
The engine should be at normal operating
temperature in neutral at idle. Using the scan tool
select "Miscellaneous Test" then "Output Test." Select
"AIR System" in "Output Test" directory. Select
H02S voltages for both Bank 1 and Bank 2 H02S.

Enable the "Output Test" for the AIR system. The
"Output Test" will energize the AIR pump for only 5
seconds. When the "Output Test" is enabled, the
H02S voltages for both sensors should remain under
300 m V because air is being directed to the exhaust
ports. If the H02S voltages remain low during the
"Output Test," the AIR pump and integral stop valve
are operating satisfactorily.
If the H02S voltage does not remain low when the
"Output Test" is commanded "ON," proceed as follows.
!LI Inspect
1.
2.
3.
4.
If a leak is suspected on the pressure side of the

system or if a hose or pipe has been disconnected
on the pressure side, the connections should be
checked for leaks with a soapy water solution.
With the AIR pump running, bubbles will form if a
leak exists.
Check Valve
!LI Inspect
1.
For a seized AIR pump (refer to CHART C-6).

Hoses, tubes and all connections for leaks and
proper routing.
For air flow going to the exhaust ports.
AIR pump for proper mounting.
Hoses and Pipes
ILI Inspect
1.
2.
3.
4.
Hose or pipe for deterioration or holes.

All hoses or pipe connections, and clamp tightness:
Hose or pipe routing. Interference may cause
wear.
A check valve should be inspected whenever the

hose is disconnected from a check valve or
whenever check valve failure is suspected. (An
AIR pump that had become inoperative and had
shown indications of having exhaust gases in the
outlet port would indicate check valve failure.)
2. Blow through the check valve (toward the cylinder
head) then attempt to suck back through the check
valve. Flow should only be in one direction
(toward the exhaust manifold). Replace valve
which does not operate properly.
ON-VEHICLE SERVICE
AIR PlJJVIP
Figure C6-3

1.
2.
3.
4.

Electrical connector from AIR pump.
Outlet and inlet hoses.
Air pump mounting bolts (3) from bracket.

1. AIR pump to bracket.
2. Mounting bolts (3).
l~I
3.
4.
5.
6.
EXHAUST MANIFOLD
Left Side
PS 17018
Figure C6-3 - AIR Pump Service
Bolts to 5.6 Nm (50 lb. in.).

Outlet and inlet hoses to pump.
Electric connector to AIR pump.
Check AIR system for proper operation (refer to
CHARTC-6).
AIR CHECK VALVE/AIR PIPES

Figure C6-2
MOUNTING BOLTS
2
Tighten
l++I
1.
2.
3.
4.
Check valve clamp.

Hose from check valve.
Left check valve pipe.
Unscrew check valve from AIR pipe.

1.
l~I Tighten
l~I Tighten
2.
3.
4.
Check valve to AIR pipe 23 N m (17 lb. ft.).

Air pipe to exhaust manifold.
Air hose to check valve.
Check valve clamp.
Clamp and air hoses from AIR system right pipe.

Right check valve pipe.
Unscrew check valve from AIR pipe.

1.
Clamp and air hose to check valve, both sides, from

cross under pipe.
2. Clamp and air hose to air pump, from cross under
pipe.
3. Raise vehicle.
4. Fasteners from air cross under pipe bracket, both
sides.
5. Cut cross under pipe near center of oil pan to aid in
removal.
6. Cross under pipe.
1.

1.
AIR CROSS UNDER PIPE
Right Side
2.
3.
Check valves 23 Nm (17 lb. ft.).

2. Right check valve pipe.
3. Hose and clamp to check valve.
4. Check AIR system for proper operation (see
CHARTC-6).

1.
2.
3.
4.
5.
6.
7.
Cross under pipe. New cross under pipe must be

cut similarly to old pipe before installation.
Use appropriate length of 5/8 heater hose to join
both halves of cross under pipe. Clamp both ends
of hose securely with stainless steel clamps.
Fasteners to AIR cross under pipe bracket, both
sides.
Lower vehicle.
Clamp and AIR hose from AIR pump to cross under
pipe.
Clamp and AIR hose from check valve, both sides,
to cross under pipe.
Check AIR system for proper operation (see
CHARTC-6).
AIR HOSE TO CHECK VALVE
2
AIR CROSSUNDER PIPE
AIRPUMP
AIR HOSE TO AIR CLEANER ASSEMBLY
AIR HOSE TO CROSSUNDER PIPE

PS 17367
Figure C6-4 AIR Pipes and Hoses
Check Valves
AIRPump
Right Side AIR Pipe
to Exhaust Manifold
Cross Under AIR Pipe
Mounting Fasteners
Left Side Air Pipe to
Exhaust Manifold
23 Nm (17 lb. ft.)

5.6Nm(50lb.in.)
24 Nm (18 lb. ft.)
5.6 Nm (50 lb. in.)
24 Nm (18 lb. ft.)
COOLANT FAN :l;ELAY,

PRIMAAY (DRIV-R SIDE)
AIR PUMP
RELAY
AIC COMPRESSOR
RELAY
ABSREL.C.Y
w
1NJECTOR
EARLY PRODUCTION
NJ ECTOR
00
00
IGNi-lON
:l.1C-CRUISE
'
COOLANT FAN
PONTIAC
IL _______
ONLY
...JI
UNDERHOOD ELECTRICAL
CENTER
AIR PUMP
COOLANT FAN
RE Ly
A
?:ELAY#1
weo <IV,
woo
00 re---ji
E
ABS!GN
.:i.BSBAT
FAI\S1ACTR
;OG LTS
'
~I
DV,D
c
5
<I Va bll
<]
DV,D
AIRPUMP
~~
'
RHDLPDR
_ D
~ ]
t}:~:',f[>.
~w-USED
'
I
tn
L rlDLP DR
u
PONTIAC
ONLY
_______
'
~
V,
bll
DUD
COOLANTFol.N
RELAY #2
=1
D~CJ
G[J
4
ASRfTCS RELAY
~ ~
to
1 H[>.
5
FOG LIGHTS
RELAY
INJECTOR
A1
[::u
bll ~
~
INJECTOR
D~CJ
~ ~
r.,o
<] Va
5
CJV,D
-'
AJC COMPRESSOR
RELAY
ABSRELM
#2
LATE PRODUCTION
RELAY
~ ~
~I
HIGH BLOWER.RELAY
FOG LIGHTS
(f>ASSENGER SIDE)
.,
LOW COO~ANT
RELM
RELAY .SECOtJDARY
CJ~D
~ ~
,C;
[>.
COOLANT FAN
RELAY #3
00
w
'GNITION
:l./C CRU!SE
JI
NS 15660
Figure CG~s Air Pump Relay Location
PCM
FROM
AIR
CLEANER _.....
ASSEMBLY
TO
EXHAUST
PORTS
.....__ _ 150BLK
---,11

(AIR) PUMP RELAY
E
t - - - - < ~ 436 BRN
78RED
B+
78RED
502RED - - - -_ _ _ _ __......._..
AIR PUMP
RELAY CONTROL
C100
82
#7 (U/H)
TO ....t-----<11~,<1~,----- 300 ORN ~ 441 BRN - - - - '
IGNITION
C200
20 AMP
(U/H)
6-10-93
PS 17941
CHARTC-6
SECONDARY AIR INJECTION (AIR) SYSTEM CHECK
5.7L (VIN P) "F'' CARLINE (SFI)
During cold starts, above 15C (59F), the PCM completes the ground circuit to the air pump relay which
enables the air pump and integral stop valve. Air is directed to the exhaust ports whenever the engine is started.
Whenever the fuel system goes to "Closed Loop," or the air pump has been "ON" for greater than 240 seconds, the
PCM opens the ground circuit to the air pump relay, and the air pump is de-energized and the integral stop valve
closes.

1. The PCM should energize the air pump when
engine coolant temperature is greater than 15C
(59F) and fuel system not in "Closed Loop." If any
Diagnostic Trouble Codes (DTCs) are present the
PCM will not energize the AIR pump.
The fuel system must be operating in "Open Loop"
to perform this test. If the system goes to "Closed
Loop," stop the engine and allow some time to cool
down then restart.
2. Air pump relay is located in the underhood
electrical center.
3. The PCM should de-energize the air pump relay

when engine speed exceeds 2825 RPM.
4. Selecting "Miscellaneous Test" then outputs and
then AIR system on the Tech 1 should enable the
AIR pump and integral stop valve.
There is a possibility that the AIR pump motor will
be operating, but no air is being distributed to the AIR
system. A restriction in the AIR hoses or pipes may be
the cause or the integral stop valve may not be
opening. The integral stop valve is part of the AIR
pump.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-C67
CHARTC-6
CORRECT ANY PCM DTC(s) BEFORE ENTERING THIS DIAGNOSTIC PROCEDURE.

ENGINE COOLANT TEMPERATURE GREATER THAN 15C (59F).
ENGINE IDLING IN "OPEN LOOP" FUELING.
IS AIR PUMP WORKING'?
G)
ENGINE "OFF"
REMOVE AIR PUMP RELAY.
PROBE TERMINAL "E1" OF
AIR PUMP RELAY HARNESS
WITH A TEST LIGHT
IS LIGHT "ON"'?
IGNITION "OFF."
JUMPER TERMINAL "E4" TO
TERMINAL "E 1" OF AIR PUMP
RELAY HARNESS USING A
FUSED JUMPER.
IS AIR PUMP ON'?
DISCONNECT AIR PUMP

CONNECTOR.
WITH TERMINALS "E1" AND "E4"
STILLJUMPERED, PROBE
TERMINALS "A" AND "B" WITH A
IS LIGHT ON'?
OPEN
BATTERY
FEED
CIRCUIT.
SECONDARY AIR
INJECTION (AIR) SYSTEM
CHECK
11
5. 7L (VIN P) F"
CARLINE (SFI)
ENGINE STILL OPERATING IN "OPEN LOOP."

RUN ENGINE TO 2850 RPM.
AIR PUMP SHOULD TURN "OFF."
DOES IT'?
DISCONNECT OUTLET
HOSE AT AIR PUMP.
START ENGINE.
USING A TECH 1, ENABLE
AIR PUMP.
IS AIR PRESENT AT AIR
PUMP OUTLET'?
DISCONNECT AIR PUMP

RELAY.
DOES AIR PUMP STOP'?
FAULTY AIR
PUMP
RELAY.
RECONNECT HOSE AT AIR

PUMP OUTLET.
START ENGINE.
FUEL SYSTEM OPERATING
IN "CLOSED LOOP."
USING A TECH 1, ENABLE
AIR PUMP AND OBSERVE
H02S VOLTAGES.
DO BOTH H02S
VOLTAGES GO BELOW
300 mV FOR 3 SECONDS'?
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
FAUL TY AIR PIPE TO

EXHAUST PORTS.
CHECK AIR PIPES
FOR BLOCKAGE OR
LEAKS. CHECK FOR
FAUL TY CHECK
VALVES STUCK
CLOSED ON THE
SIDE THAT DID NOT
GO BELOW 300 mV.
NO
TROUBLE
FOUND.
CKT(s) 78
SHORTED TO
VOLTAGE.
DISCONNECT
CONNECTOR AT AIR
PUMP.
PROBE TERMINAL
"B" AT AIR PUMP
ELECTRICAL
HARNESS
CONNECTOR WITH
A TEST LIGHT
CONNECTED TO
GROUND.
DOES TEST LIGHT
ILLUMINATE'?
PUMP
ELECTRICAL
CONNECTION
OR FAULTY
AIR PUMP.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO Mil (SERVICE ENGINE SOON).
6-29-93
PS 17942
BLANK
SECTION C7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

CONTENTS
General Description
Purpose
Operation
EG R Control
Negative Backpressure EGR Valve
EGR Valve Identification
C7-1
C7-1
C7-1
C7-1
C7-1
C7-2
C7-2
GENERAL DESCRIPTION
Diagnosis
On-Vehicle Service
EGR Valve
EGR Manifold Passage

EGR Vacuum Control Signal
Solenoid Valve
C7-2
C7-2
C7-2
C7-2
C7-3
C7-3
For this reason, very little exhaust gas is allowed to

pass through the EGR valve. The EGR valve is
usually open during warm engine operation when the
vehicle is above idle speed.
PURPOSE
The Exhaust Gas Recirculation (EGR) system is
used to lower NOx (Oxides of Nitrogen) emission levels
caused by high combustion temperature and excessive
oxygen. It does this by decreasing combustion
temperature and displacing oxygen.
The main element of the system is the EGR valve
mounted on the intake manifold and operated by
vacuum.
The EGR valve feeds small amounts of exhaust gas
back into the combustion chamber as shown in (Figure
C7-1).
EGRCONTROL
The EGR vacuum control has a vacuum solenoid
valve that is controlled by pulse width modulation.
This means the PCM turns the solenoid valve "ON"
and "OFF" many times a second and varies the
amount of "ON" time ("pulse width") to vary the
amount of vacuum applied to the EGR valve.
The PCM uses RPM and information from the
following sensors to regulate the EGR solenoid valve:
Intake Air Temperature (IAT) sensor.
Manifold Absolute Pressure (MAP) sensor.
Park/Neutral Position (PNP) switch.
Grounding the DLC output/field service enable
terminal, with the ignition "ON" and the engine not
running, will energize the solenoid valve and allow
vacuum to the EGR valve.
NEGATIVE BACKPRESSURE EGR VALVE
EGR VALVE
INTAKE AIR
EXHAUST GAS
PORTED VACUUM
4S0001-6E
Figure C7-1 - Exhaust Gas Recirculation
OPERATION
The EGR valve is opened by vacuum to let exhaust
gas flow into the intake manifold. The exhaust gas
then moves with the air/fuel mixture into the
combustion chamber. If too much exhaust gas enters,
combustion will not occur.
The EGR valve used on this engine is a negative

backpressure valve. It varies the amount of exhaust
gas flow into the manifold depending on manifold
vacuum and variations in exhaust backpressure.
The diaphragm on this EGR valve (shown in
Figure C7-2) has an internal vacuum bleed hole which
is held closed by a small spring when there is no
exhaust backpressure. The amount of vacuum to the
valve is controlled by an PCM controlled solenoid
valve.
Engine vacuum opens the EGR valve against the
pressure of a large spring. When vacuum combines
with negative exhaust backpressure, the vacuum
bleed hole opens and the EGR valve closes.

When replacing an EGR valve, always check for
correct part number in the parts catalog or
supplemental bulletin.

Too much EGR flow dilutes the fresh intake
air/fuel mixture, causing the engine to run roughly or
stall. With too much EGR flow (at idle, cruise, or cold
operation) tends to weaken combustion and may result
in any of the following conditions:
Engine stops after cold start.
Engine stops at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
Too little or no EGR flow allows combustion
temperatures to get too high during acceleration and
load conditions. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
EGRVALVE
EXHAUST GAS
SMALL SPRING
INTAKE AIR
LARGE SPRING
VACUUM PORT
DIAPHRAGM
AIR BLEED HOLE
4S0113-6E
Figure C7-2 - Negative Backpressure EGR Valve
DIAGNOSIS
Diagnosis of the EGR system is covered in CHART
C-7 at the end of this section, if DTC 27 or 32 was not
set.
ON-VEHICLE SERVICE
EGR VALVE
ASSEMBLY
!+-+I Remove or Disconnect

1.
2.
3.
4.
Negativebatterycable.
Vacuum line.
Retaining nuts.
EGR valve.
EGR Manifold Passage

TYPE OF VALVE:
P = POSITIVE BACKPRESSURE
N =NEGATIVE BACKPRESSURE
BLANK= PORTED VALVE
!L'l'I Inspect
LP 1203-AS
Figure C7-3 - EGR Valve Identification
EGR VALVE IDENTIFICATION
Negative backpressure EGR valves will have a

"N" stamped on the top side of the valve after the
part number.
Positive backpressure EGR valves will have a "P''
stamped on the top side of the valve, after the part
number.
Port EGR valves have no identification stamped
after the part number.
If EGR passages in the inlet manifold indicate

excessive build-up of deposits, the passages should
be cleaned. Care should be taken to ensure that all
loose particles are completely removed to prevent
them from clogging the EGR valve or from being
ingested into the engine.
~ Clean
With a wire wheel, buff the exhaust deposits from
the mounting surface and around the valve.
2. Look for exhaust deposits in the valve outlet.
Remove deposit build-up with a screwdriver.
3. Clean mounting surfaces of intake manifold and
valve assembly.
1.
EGR VALVE
2
GASKET
INTAKE MANI.FOLD
NS 15267
Figure C7-4 - EGR Valve Service

l~I Tighten
1.
EGR valve on intake manifold usifig new'gasket.
Bolts to.22 Nm (16 lb. ft.).

2. Vacuum hose to valve.
EGR VACUUM CONTROL SIGNAL SOLENOID

VALVE

2. Electrical connector at solenoid valve.
3. Vacuum hoses.
4. Nut and solenoid valve.
1.

1. Solenoid and bracket.
l~I Tighten
Nut to 34 Nm (25 lb. ft.).
2. Vacuum hoses.
INTAKE MANIFOLD
EGR VACUUM CONTROL SIGNAL SOLENOID VALVE
EGR
VACUUM HOSE HARNESS
NS.15266
Figure C7-5 - EGR Vacuum Control Signal Solenoid

Valve
EGR Valve Bolts to
Intake Manifold
Solenoid Valve and Bracket,
Nut to Intake Manifold
22 Nm (16 lb. ft.)

34 Nm (25 lb. ft.)
6E3-C7,.4 5.7L (VIN P) DRIVEABILITY.AND EMISSIONS
TO
IGNITION
#6
EXHAUST GAS
RECIRCULATION
(EGR)VACUUM
CONTROL SIGNAL
SOLENOID VALVE
PCM
10 AMP
(U/H)
EGRVACUUM
CONTROL SIGNAL
SOLENOID V"'LVE
CONTROL
F
541 BRN
~---
C100
CIRCUITS
(U/H)

6-29-93
PS17926
CHARTC-7
{Page 1 of 2)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK
11
The Exhaust Gas Recirculation (EGR) valve is controlled by a normally closed solenoid valve. The PCM
turns the solenoid valve "ON" to allow vacuum tp pass to the EGR, and turns the solenoid valve "OFF" to prevent
EGR operation.
' '
The duty cycle is calculated by the PCM based on information from the ECT, IAT, TP sensor, and MAP
sensors. Also, engine RPM and the PNP switch input affect EGR. There should be no EGR when in park or
neutral, TP sensor below a calibrated value (manual transmission), or TP sensor indicating WOT.
With the ignition "ON" and engine "OFF," the EGR solenoid valve is de-energized. The solenoid valve,
however, should be energized, if the output/field service enable terminal is grounded with the ignition "ON" and
engine "OFF."

1. Intake Passage: Shut "OFF" engine and
remove the EGR valve from the manifold. Plug
the exhaust side hole with a shop rag or suitable
stopper. Leaving the intake 'Side hole open,
attempt to start the engine. If the engine runs at a
very high idle (up to 3000 RPM is possible) or
starts and stalls, the EGR passages are not
restricted. If the engine starts and idles normally,
the EGR intake side passage in the intake
manifold is restricted.
Exhaust Passage: With EGR valve still
removed, plug the intake side hole with a suitable
stopper. With the exhaust side hole open, check for
the presence of exhaust gas. If no exhaust gas is
present, the EGR exhaust side passage in the
intake manifold is restricted.
2. The vacuum at the gage may or may not slowly
bleed off. It is important that the gage is able to
read the amount of vacuum being applied.
3. When the output/field service enable terminal is

grounded, or Tech 1 is used, the vacuum gage
should bleed off through a vent in the solenoid
valve. The pump gage may or may not bleed off
but this does not indicate a problem.
Diagnostic Aids: Vacuum lines should be

thoroughly checked for proper routing. Refer to
Suction from shop exhaust hoses can alter
backpressure and may affect the functional check of
the EGR valve.
When we transmission enables TCC, the EGR will
be in a reduced duty cycle.
CHARTC-7
{Page 1 of 2)
BEFORE USING THIS CHART, CHECK FOR MANIFOLD VACUUM TO
EGR SOLENOID VALVE, ALSO CHECK HOSES FOR LEAKS OR
RESTRICTIONS. SHOULD BE AT LEAST 7" Hg VACUUM AT 2000 RPM.
EXHAUST GAS RECIRCULATION

(EGR) SYSTEM CHECK
5.7L (VIN P) 11 F11 CARLINE (SFI)
IF OTC 27 IS SET, USE THAT CHART FIRST.

WITH ENGINE AT IDLE AND AT NORMAL OPERATING
TEMPERATURE, MANUALLY LIFT EGR VALVE DIAPHRAGM.
RPM SHOULD DECREASE OR ENGINE SHOULD STALL. DOES IT?
DISCONNECT EGRVACUUM HARNESS AT SOLENOID VALVE. INSTALL A

VACUUM GAGE TO MANIFOLD SIDE OF HARNESS AND CHECK FOR
VACUUM SUPPLY TO SOLENOID VALVE.
VACUUM SHOULD BE AT LEAST 25 kPa (7" Hg} OF VACUUM AT 2000 RPM.
IS IT?
ROTATE VACUUM HARNESS AND REINSTALL ONLY THE EGR VALVE-SIDE, TO THE
SOLENOID VALVE.
INSTALL A VACUUM GAGE IN PLACE OF EGR VALVE.
INSTALL A HAND HELD VACUUM PUMP TO MANIFOLD SIDE OF EGR SOLENOID VALVE.
IGNITION "ON," ENGINE STOPPED.
USING TECH 1 SELECT "FIELD SERVICE" MODE.
APPLY 34 kPa (10" Hg} VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP. DOES IT?
USING TECH 1, EXIT "FIELD SERVICE" MODE.

VACUUM SHOULD BLEED OFF COMPLETELY
AT GAGE.
DOESIT?
L----------.J
DISCONNECT SOLENOID VALVE

DOES VACUUM BLEED OFF
RAPIDLY AT GAGE?
PCM DRIVER
CIRCUIT OPEN
OR
FAULTY PCM.
CHECK FOR PLUGGED

EGR PASSAGES.
PLUGGED VACUUM PORT

AT INTAKE MANIFOLD.
LEAKING OR RESTRICTED
VACUUM SUPPLY LINE
TO EGR SOLENOID
VALVE.
CONNECT VACUUM PUMP TO EGR VALVE SIDE OF HARNESS.

APPLY VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP.
DOESIT?
--------,
: REFER TO EGR
:
I CHART (2 OF 2). 1
FAUL TY SOLENOID
VALVE
CONNECTION
OR
FAUL TY SOLENOID
VALVE.
FAULTY
VACUUM
SUPPLY LINE
TO EGR VALVE.
REPLACE
SOLENOID
VALVE.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO Mil (SERVICE ENGINE SOON}.
1-28-93
MS 9329-6E
TO
IGNITION
EXHAUST GAS
RECIRCULATION
(EGR) VACUUM
CONTROL SIGNAL
SOLENOID VALVE
PCM
EGRVACUUM
CONTROL SIGNAL
SOLENOID VALVE
CONTROL
541 BRN
--4--C100
CIRCUITS
6-29-93
PS 17926
CHARTC-7
(Page 2 of 2)

The Exhaust Gas Recirculation (EGR) valve is controlled by a normally closed solenoid valve. The PCM
turns the solenoid valve "ON" to allow vacuum to pass to the EGR, and turns the solenoid valve "OFF" to prevent
EGR operation.
The duty cycle is calculated by the PCM based on information from the TP sensor, ECT, IAT, and MAP
sensors. Also, engine RPM and the PNP switch input affect EGR. There should be no EGR when in park or
neutral, TP sensor below a calibrated value (manual transmission), or TP sensor indicating WOT.
With the ignition "ON" and engine "OFF," the EGR solenoid valve is de-energized. The solenoid valve,
l;iowever, should be energized, if the output/field service enable terminal is grounded with the ignition "ON" and
~ngine "OFF."

1 The remaining test checks the ability of the EGR
valve to int.eract with the exhaust system. This
system uses a negative backpressure EGR valve
which should hold vacuum with engine "OFF."
2. When engine is started, exhaust backpressure at
the base of the EGR valve should open the valve's
internal bleed and vent the applied vacuum
allowing the valve to seat.
Diagnostic Aids: Suction from shop exhaust hoses

can alter backpressure and may affect the functional
check of the EGR valve.
During normal EGR valve operation, the
movement of the EGR pintle is small. It is important
to determine whether the valve pintle moves and not
how much it moves.
When the transmission enables TCC the EGR will
be in a reduced duty cycle.
CHARTC-7
(Page 2 of 2)

,--------------,
: CONTINUED FROM :
I EGRCHART
I
:{10F2).
L-
-----------'
IGNITION "OFF."
CONNECT A VACUUM PUMP TO EGR VALVE.
OBSERVE EGR DIAPHRAGM WHILE APPLYING VACUUM.
DIAPHRAGM SHOULD MOVE FREELY AND HOLD VACUUM
FOR AT LEAST 20 SECONDS.
DOESIT?
APPLY 34 kPa (10" Hg) VACUUM TO EGR VALVE.

START ENGINE AND IMMEDIATELY OBSERVE GAGE ON VACUUM PUMP.
EGRVALVE DIAPHRAGM SHOULD MOVE TO SEATED POSITION AND
VACUUM SHOULD DROP FROM PUMP GAGE WHILE STARTING ENGINE.
DOESIT?
REMOVE EGR VALVE.

CHECK FOR PLUGGED OR RESTRICTED EXHAUST PASSAGES.
EGR CIRCUIT IS OPERA TING PROPERLY. REFER

TO SYMPTOMS {SECTION 6E3-B).
PASSAGES NOT OK
REPLACE EGR VALVE.
CLEAN PASSAGES.
RE-CHECK EGR VALVE.
10-9-90
MS 10854
BLANK
SECTION
ca
AUTOMATIC TRANSMISSION CONTROL SYSTEM

CONTENTS
General Description
Input Information

Transmission Fluid Temperatur~ (TFT)
Sensor
C8-1
C8-1
C8-1
C8-1
C8-1

Switch Assembly
Brake Switch
Output Information
C8-2
C8-2
C8-4
C8-4
GENERAL DESCRIPTION
PCM ~(CLEAR) ACCESS COVER~(BLUE)
~:::::::::::::::::ID
~
.................
...................
'
A
(RED)
C8-5
C8-5
C8-5
C8-5
The Powertrain Control Module (PCM) is an

electronic device which monitors various inputs to
control various transmission functions including shift
quality and transmission diagnostics. The PCM
receives various input information from sensors,
switches, and components to process for use within its
control program. Based on this input information, the
PCM controls various transmission output functions
and devices.
KNOCK SENSOR MODULE
C8-4
C8-4
C8-4
C8-5
INPUT INFORMATION

(PCM)
figure CB-1
1-2 Shift Solenoid

2-3 Shift Solenoid

Solenoid
On-Vehicle Service
Internal Transmission
Components
[:,::::::::::::::::.~
...............~~
f.l.++
~,
B
(BLACK)
PS 17345
Figure CS-1 - Powertrain Control Module
The PCM uses the following information sensors to

gather data for electronically controlling transmission
functions.
Transmission Fluid Temperature (TFT) sensor.
Transmission Range (TR) pressure switch
assembly.
Brake switch.

Sensor
temperature) used to indicate transmission fluid
input to determine the fqllowing:
Shift quality.
control valve body within the transmission.

Assembly
Figure CB-3
This device is a set of five pressure switches (two
normally closed and three normally open), that detect
fluid pressure within the valve body passages. The
five pressure switches are connected to three signal
circuits referred to as range signals A, B, C.

A
Park
Rev
Neutral
D4
D3
D2
D1
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
Illegal
Illegal
ON
ON
OFF
ON
ON
ON
Range Signal
ARROW
N
p
C B
The combination of pressure switch states determine

the voltage signal (B + or 0) on each range signal to
the PCM. These three range signals are then
interpreted by the PCM to indicate the transmission
range selected. The transmission range fluid pressure
switch assembly contains the trans fluid temperature
sensor and attached to the control valve body within
the transmission.
(INTERNAL)
ARROW
CAVITY

Figure CB-4
FUNCTION
PRESSURE CONTROL SOLENOID (HIGH)
PRESSURE CONTROL SOLENOID (LOW)
BOTH SHIFT SOLENOIDS, TCC SOLENOID,

AND 3-2 CONTROL SOLENOID IGNITION
(B +) FEED CKT
TRANSMISSION FLUID TEMP'ERA TURE

(TFT) SIGNAL CKT

(TFT) SENSOR GROUND CKT
RANGE SIGNAL "A" CKT
RANGE SIGNAL "C" CKT
RANGE SIGNAL "B" CKT
3-2 CONTROL SOLENOID CONTROL CKT
TCC SOLENOID CONTROL CKT

3-27-93
MS 13631
Figure CS-2 - Harness Connector
This device contains a permanent magnet

surrounded by a coil of wire producing a magnetic field
which is interrupted by rotor teeth pressed on an
output shaft. As the rotor interrupts the magnetic
field, an AC voltage is generated in the circuit. This
device is used to provide an output shaft speed signal
to the control module. The control module uses the
vehicle speed sensor signal input to:
Calculate vehicle speed, trans output speed,
TCC slip speed.
Control shift quality.
The VSS is attached to the output shaft housing.
8 8
BOTTOM
MS 13676
Figure CS-3 - Transmission Range (TR) Pressure Switch Assembly
CHART
Gear
1-2 Shift
Solenoid
2-3 Shift
Solenoid
ON
ON
OFF
ON
OFF
OFF
ON
OFF
Brake Switch
This electrical switch is used to indicate brake
pedal status. This switch is normally closed when the
brake pedal is not applied. When the brake pedal is
applied the switch will open, changing the signal to
the PCM. The PCM uses this signal to de-energize the
TCC solenoid when brake pedal is applied. The brake
switch is located on the brake pedal mounting bracket.
OUTPUT INFORMATION
Based on input information, the PCM controls
various transmission output functions and devices.
1-2 Shift Solenoid.
2-3 Shift Solenoid.
3-2 Control Solenoid.
Pressure Control Solenoid (PCS).
Torque Converter Clutch (TCC) Solenoid.
1-2 SHIFT SOLENOID

2
2-3 SHIFT SOLENOID
MS 13675-7A
Figure CS-5 - 12 Shift Solenoid or 2-3 Shift Solenoid
1-2 Shift Solenoid

Figure CB-5
acting on the 1-2 and 3-4 shift valves. The solenoid is a
2-3 Shift Solenoid

Figure CB-5
acting on the 2-3 shift valves. The solenoid is a
MS 13678-7A
Figure CS-6 32 Control Solenoid

Figure CB-6
acting on the 3-2 shift valve, which then controls the 24 band apply rate and 3-4 clutch release rate. It is a
pulse width modulated solenoid that operates on a
negative duty cycle. This solenoid controls the 3-2
downshift feel and is attached to the control valve body
:q,
PRESSURE CONTROL
SOLENOID
ELECTRICAL CONNECTORS
MS 10090-7A
Figure CS-7 Pressure Control Solenoid (PCS)

Figure CB-7
This electrical device is used to control fluid line
pressure by controlling actuator feed limit fluid flow
acting on an internal spool valve and spring pressure.
The solenoid is a normally closed solenoid valve that
controls fluid pressure when operating on a duty cycle.
The solenoid is attached to the control valve body
Refer to SECTION 7 of the appropriate service

manual for Vehicle Speed Sensor (VSS) service. The
VSS is located on the transmission.

Solenoid
Figure CB-8
This electrical device is used to control fluid acting
on the TCC converter clutch valve, which then controls
TCC apply and release. This solenoid is attached to
the transmission case assembly extending into the
pump cover.
ON-VEHICLE SERVICE
INTERNAL TRANSMISSION COMPONENTS
The following list of components will be serviced in
SECTION 7 A14A of the appropriate service manual.
3 - 2 control solenoid.
Pressure control solenoid.
TCC solenoid with internal wiring harness.
Any service that requires removal of the pan.
MS 13679-7A
Figure CS-8 Torque Converter Clutch (TCC)

Solenoid
WIRING HARNESS ASSEMBLY
3-2 CONTROL SOLENOID
TORQUE CONVERTER CLUTCH SOLENOID
1-2 SHIFT SOLENOID
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY
2-3 SHIFT SOLENOID
TRANSMISSION FLUID TEMPERATURE SENSOR

(PART OF TR PRESSURE SWITCH ASSEMBLY )
MS 13680
Figure CS-9 - Electrical Components
TRANSMISSION ELECTRICAL CONNECTOR

THE TRANSMISSION WIRING CONNECTOR IS A VERY IMPORTANT PART OF THE
TRANSMISSION OPERATING SYSTEM. ANY INTERFERENCE WITH THE
ELECTRICAL CONNECTION CAN CAUSE THE TRANSMISSION TO SET DIAGNOSTIC
TROUBLE CODES (DTC)s AND/OR AFFECT PROPER OPERATION.
THE FOLLOWING ITEMS CAN AFFECT THE ELECTRICAL CONNECTION:
-
BENT PINS IN THE CONNECTOR FROM ROUGH HANDLING DURING

CONNECTION AND DISCONNECTION.
WIRES BACKING AWAY FROM THE PINS OR COMING UNCRIMPED (IN

EITHER INTERNAL OR EXTERNAL WIRING HARNESS).
DIRT CONTAMINATION
DISCONNECTED.
PINS IN THE INTERNAL WIRING CONNECTOR BACKING OUT OF THE

CONNECTOR OR PUSHED OUT DURING RECONNECTION.
ENTERING THE
VEHICLE HARNESS
CONNECTOR WHEN
EXCESSIVE TRANSMISSION FLUID LEAKING INTO THE CONNECTOR,

WICKING UP INTO THE EXTERNAL WIRING HARNESS, AND DEGRADING
OF THE WIRE INSULATION. *
-
WATER/MOISTURE INTRUSION IN THE CONNECTOR.
LOW PIN,RETENTION IN THE EXTERNAL CONNECTOR FROM EXCESSIVE

CONNECTION AND DISCONNECTION OF THE WIRING CONNECTOR
ASSEMBLY.
PIN CORROSION FROM CONTAMINATION.
THE PRESENCE OF TRANSMISSION FLUID IN THE TRANSMISSION

CONNECTOR IS NOT HARMFUL IN ITSELF. THE FLUID ONLY AFFECTS THE
EXTERNAL HARNESS WIRING INSULATION IF THE FLUID WICKS UP TO THE
HARNESS.
SQUEEZE
HERE
POINTS TO...BEMEMBER WHEN WORKING WITH THE TRANSMISSION 1/VIRING

CONNECTOR ASSEMBLY:
-
TO REMOVE THE CONNECTOR, SQUEEZE THE TWO TABS TOWARDS EACH

OTHER AND PULL STRAIGHT UP (REFER TO THE ILLUSTRATION).
CAREFULLY LIMIT TWISTING OR WIGGLING THE CONNECTOR DURING
REMOVAL. BENT PINS CAN OCCUR.
- 00 NOT PRY
THE CONNECTOR OFF WITH A SCREWDRIVER OR OTHER
TRANSMISSION
CONNECTOR
TOOL
TO REINSTALL THE EXTERNAL WIRING CONNECTOR, FIRST ORIENT THE
PINS BY LINING UP THE ARROWS ON EACH HALF OF THE CONNECTOR.
PUSH THE CONNECTOR STRAIGHT DOWN INTO THE TRANSMISSION
WITHOUT TWISTING OR ANGLING THE MATING PARTS.
-
THE CONNECTOR SHOULD CLICK INTO PLACE WITH A POSITIVE FEEL

AND/OR NOISE.
WHENEVER THE TRANSMISSION EXTERNAL WIRING CONNECTOR IS

DISCONNECTED FROM THE INTERNAL HARNESS AND THE ENGINE IS
OPERATING DTC(s) WILL SET. CLEAR THESE DTC(s) AFTER
RECONNECTING THE EXTERNAL CONNECTOR.
Figure CS-10 Transmission Electrical Connector
1-6-93
NS 15891
4L60E TRANSMISSION FLUID CHECKING PROCEDURE

1.
Warm the transmission to normal operatin& temperature by driving the vehicle about 15 miles (24 km).
Operating temperature is 180-200F (82-94 C).
2. Park vehicle on a level surface, place shift lever in "P" park and apply the parking brake.
3. Check fluid level on the dipstick (read the lower level).
4. If fluid level is low, add only enough DEXRON-IIE to bring the fluid level into the hot area.
* It is important to check fluid level when the transmission has reached operating temperature. The hot range
is calibrated correspond to the correct fluid level range for fluid between 180 and 200F(82-94C).
lcoLo
11i1;11:i I
HOT CHECK RANGE (180-200F, 82-92C)

CHECK FLUID COLOR I
$
1GJ
CHECK FLUID LEVEL
HIGH
REMOVE
EXCESS
FLUID.
LOW
ADD FLUID TO
OBTAIN PROPER
LEVEL.
NON TRANSPARENT PINK
LIGHT BROWN
I
NOTICE: TRANSMISSION
FLUID MAY TURN DARK
WITH NORMAL USE AND
DOES
NOT
ALWAYS
INDICATE CONTAMINATION
OR OXIDATION.
REPLACE COOLER.
I FOAM
CONTAMINANTS
IN FLUID
FLUID
LEVEL
HIGH
DRAIN FLUID TO
DETERMINE IF
THERE IS
CONTAMINATION.
I
CHECK FOR EXTERNAL
LEAKS. REFER TO
"LEAK INSPECTION
POINTS" SECTION
7 A 14A FOR POSSIBLE
LEAK.
CORRECT LEAK
CONDITION. REFER
TO "ON-VEHICLE
SERVICE" #FLUID
LEAK DIAGNOSIS
AND REPAIR
SECTION 7A14A.
DRAIN FLUID TO
DETERMINE
SOURCE OF
CONTAMINATION.
NOTICE: A VERY SMALL

AMOUNT OF MATERIAL IN THE
BOTTOM OF THE PAN IS A
NORMAL CONDITION.
CHANGE FLUID
ANO FILTER,
"ON-VEHICLE
SERVICE"
SECTION 7A14A.
REMOVE
EXCESS
FLUID.
TRANSMISSION
OVERHAUL(OR
SRTA) REQUIRED
(REFER TO
SECTION 7A14B.)
I
ADDNEWFLUID
LARGE PIECES OF
METAL OR OTHER
MATERIAL IN THE
BOTTOM PAN.
I
TRANSMISSION
OVERHAUL (OR
SRTA) REQUIRED
(REFER TO
SECTION 7 A 148.)
ADD NEW FLUID

CHECK FLUID LEVEL
IF "ON-BOARD DIAGNOSTIC" (OBD) SYSTEM CHECK HAS BEEN

PERFORMED CONTINUE WITH DIAGNOSIS, OTHERWISE PERFORM
OBD SYSTEM CHECK.
IF DIAGNOSTIC TROUBLE CODES ARE NOT STORED, REFER TO
"FUNCTIONAL TEST PROCEDURE" SECTION 7A 14A.
Figure CS-11 - 4L60E Transmission Fluid Checking Procedure
CHECK FLUID LEVEL
5-11-93
NS15874
BLANK

PCM
TRANSMISSION RANGE
B+
- - - - - - - - - 1224PNK
...,__ _ _ _ _ _ _ 1225 DK BLU
B+
B+
1226 RED
I
I
TRANSMISSION
:.__ CONNECTOR
- - - - - - - 1227 BLK/YEL
TRANSMISSION FLUID
TEMPERATURE (TFT)
SENSOR (INTERNAL)
- - - - - - - - - 470 BLK
67-93
PS18401
CHARTC-8A
TRANSMISSION RANGE (TR) PRESSURE SWITCH ASSEMBLY CIRCUIT CHECK
The Transmission Range (TR) switch assembly consists of five pressure switches (two normally closed and
three normally open), and a TFT sensor combined into one unit and mounted on the valve body. The PCM
supplies battery voltage to each range signal. By grounding one or more of these circuits t.q.rough various
combinations of the pressure switches, the PCM detects what manual valve position has been selected by the
vehicle operator. With ignition "ON" and engine "OFF," PIN will be indicated. When the transmission electrical
connector is disconnected, the ground potential for the three range signals to the PCM will be removed, and with
ignition "ON," D2 will be indicated.
~hart Test Description: Number(s) below refer to

manual valve position actually selected.
3. This test checks a short to ground or an open in
any one of the three circuits.
A
Neutral
D4
D3
D2
D1
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
Illegal
Illegal
ON
ON
OFF
ON
ON
ON
Range Signal
Park
Rev
Expected Readings
Diagnostic Aids: Refer to accompanying chart for

various NB/C range combinations. Check all wiring
connectors for proper terminal tension.
Check" or "Functional Test Procedure" irr SECTION
7A14A of the appropriate service manual for further
information.
CHARTC-8A
TRANSMISSION RANGE (TR) PRESSURE SWITCH
ASSEMBLY CIRCUIT CHECK


DOES EACH SELECTED TRANSMISSION RANGE MATCH THE SCAN TOOL nTRANS RANGE SW" DISPLAY?
IGNITION "OFF."
INSTAUJ 39775-JUMPER HARNESS/PROBE KIT ON THE
IGNITION "ON," ENGINE nOFF."
DOESJ39200 DISPLAY B + AT ALL THREECIRCUITS?
ONcCIRCUIT(S) THAT DID NOT INDICATE B +, CHECK FORAN

OP,fN OR SHORT TO GROUND. IF OK, CHECK CONTROL
MODULE CO.NNECTOR TERMINAL TENSION ON THESE
VERIFY THAT CKT(s) 1224, 1225, OR 1226 ARE NOT

CHECK" SECTION 7A14A (4L60E) OR 7A17A
4-27-93
PS 17065
PERFO'RMANCE/TRACTION
PCM
__... TO INTERIOR LIGHTS
(DIMMING)
PERFORMANCE
MODE SWITCH
SIGNAL
451
BLK/WHT
ELECTRONIC
BRAKE/TRACTION
CONTROl
MODULE
8 2
LTBLU
TCS/ASR
ACTIVE SIGNAL
PERFORMANCE
MODE
INDICATOR
LAMP CONTROL
TOIGN
SWITCH
PERFORMANCE
MODE
INDICATOR
LAMP FEEDBACK
(1/P)
= INSTRUMENT ~ANEL FUSE BLOCK
7-9-93
PS 17832
CHART C-88
PERFORMANCE MODE SWITCH INDICATOR LAMP CONTROL CIRCUITCHECK
~ircuit Description:
' The performance mode switch enables the operator to select a more aggressive shift pattern within the
midrange throttle position (40%-100%). When performance mode is selected, the B+ performance mode input
signal is momentarily toggled to zero volts. The PCM enters performance mode and turns on the performance
mode indicator lamp (within the switch). While in performance mode, shifts will be firmer and delayed 1-3 mph
(upshifts) or advanced 1-3 mph downshifts). Normal mode operation is obtained by toggling the performance
mode switch again, or when the ignition switch is cycled "OFF" then "ON."

1. This step checks the entire performance mode
switch circuit for a malfunction.
correctly.
Diagnostic Aids: If, during performance mode,

increase performance is not perceived, use snapshot
mode on scan tool. Record data in normal mode then in
performance mode. When reviewing data observe mph
and pressure control solenoid duty cycle for differences
during upshifts and downshifts.
A malfunction within the performance mode
switch circuit will result in normal mode operation
only.
CHARTC-88
PERFORMANCE MODE SWITCH INDICATOR
LAMP CONTROL CIRCUIT CHECK
INSTALL SCAN TOOL

PRESS THE PERFORMANCE MODE SWITCH AND OBSERVE
THE INDICATOR LAMP WITHIN THE SWITCH.
IS IT "ON" WHEN PERFORMANCE MODE IS SELECTED?

OBSERVE "PERFORMANCE MODE SWITCH" ON SCAN TOOL
DISPLAY WHILE PRESSING THE PERFORMANCE MODE
SWITCH TWICE.
IS "CLOSED" DISPLAYED WHEN THE PERFORMANCE MODE
SWITCH IS PRESSED, AND "OPEN" DISPLAYED WHEN
RELEASED?
PERFORMANCE MODE SWITCH

INDICATOR LAMP CONTROL CIRCUIT
CHECK OKAY. REFER TO
"DIAGNOSTIC AIDS .
IGNITION "OFF," DISCONNECT PERFORMANCE MODE

SWITCH CONNECTOR, IGNITION "ON."
WITH TEST LIGHT TO GROUND PROBE IGNITION VOLTAGE
CIRCUIT TO SWITCH.
IS TEST LIGHT "ON"?
REFER TO "PERFORMANCE MODE

SWITCJi SIGNAL CIRCUIT CHECK"
FOR DIAGNOSIS.
WITH TEST LIGHT, JUMPER IGNITION VOLTAGE CIRCUIT TO

PERFORMANCE MODE INDICATOR LAMP CONTROL CIRCUIT
AT CONNECTOR.
WITH FUSED WIRE JUMPER TO GROUND PROBE 2ND GEAR
START SWITCH SIGNAL CIRCUIT SEVERAL TIMES.
DOES TEST LIGHT FLASH "ON" AND "OFF"?
REPAIR IGNITION VOLTAGE CIRCUIT

TO SWITCH.
REPLACE FAULTY
PERFORMANCE MODE SWITCH.
REPAIR OPEN OR SHORT IN

INDICATOR LAMP CONTROL CIRCUIT
TO PCM.
6-15-93
PS 18645
PERFORMANCE/TRACTION
PCM
___.. TO INTERIOR LIGHTS
(DIMMING)
451
BLK/WHT
PERFORMANCE
MODE SWITCH
SIGNAL
B+
ELECTRONIC
BRAKE/TRACTION
CONTROL
MODULE
B+
TCS/ASR
ACTIVE SIGNAL
PERFORMANCE
MODE
INDICATOR
LAMP CONTROL
TOIGN
SWITCH
PERFORMANCE
MODE
INDICATOR
LAMP FEEDBACK
(1/P) = INSTRUMENT PANEL FUSE BLOCK
7-9-93
PS 17832
CHARTC-8C
PERFORMANCE MODE SWITCH SIGNAL CIRCUIT CH ECK
The performance mode switch enables the operator to select a more aggressive shift pattern within the
midrange throttle position (40%-100%). When performance mode is selected, the B+ performance mode input
signal is momentarily toggled to zero volts. The PCM enters performance mode and turns on the performance
mode indicator lamp (within the switch). While in performance mode, shifts will be firmer and delayed 1-3 mph
(upshifts) or advanced 1-3 mph downshifts). Normal mode operation is obtained by toggling the performance
mode switch again, or when the ignition switch is cycled "OFF" then "ON."

1. This step checks the entire performance mode
switch circuit for a malfunction.
correctly.
Diagnostic Aids: If, during performance mode,

inci:ease performance is not perceived, use snapshot
mode on scan tool. Record data in normal mode then in
performance mode. When reviewing data observe mph
and pressure control solenoid duty cycle for differences
during upshifts and downshifts.
A malfunction within the performance mode
switch circuit will result in normal mode operation
only.
DRIVEABILITYAND EMISSIONS 5.7L (VIN P) 6E3-C8-15
CHARTC-8C
PERFORMANCE MODE SWITCH SIGNAL CIRCUIT
CHECK
r.j\
\..:..)
INSTALL SCAN TOOL.

OBSERVE "PERFORMANCE MODE SWITCH" ON SCAN TOOL DISPLAY, WHILE
PRESSING THE PERFORMANCE MODE SWITCH TWICE.
IS "CLOSED" DISPLAYED WHEN PERFORMANCE MODE SWITCH IS PRESSED,
AND "OPEN" DISPLAYED WHEN RELEASED?
IGNITION "OFF."
DISCONNECT THE PERFORMANCE MODE SWITCH
CONNECTOR.
IGNITION "ON."
WITH TEST LIGHT TO GROUND, PROBE THE PERFORMANCE
MODE SWITCH SIGNAL CIRCUIT AT CONNECTOR WHILE
OBSERVING "PERFORMANCE MODE SWITCH" ON SCAN
TOOL DISPLAY.
IS "CLOSED" DISPLAYED DURING PROBE AND "OPEN"
DISPLAYED WHEN REMOVED?

SIGNAL CIRCUIT CH ECK OKAY.
WITH TEST LIGHT TO B + PROBE THE GROUND CIRCUIT AT

CONNECTOR.
IS TEST LIGHT "ON"?
REPAIR OPEN OR SHORTED

SIGNAL CIRCUIT TO THE PCM.
REPLACE PERFORMANCE
MODE SWITCH.
6-15-93
PS 18646
BLANK
SECTION C10
A/C CLUTCH CIRCUIT DIAGNOSIS

CONTENTS
General Description
Operation
Diagnosis
On-Vehicle Service
Cl0-1
Cl 0-1
Cl0-1
Cl 0-1
GENERAL DESCRIPTION
In order to improve engine operation, the A/C
compressor operation is controlled by the PCM.
OPERATION
This system consists of a HV AC control assembly,
an NC refrigerant pressure sensor, an NC evaporator
temperature sensor, a control relay, the compressor
clutch and the PCM.
When the HV AC control assembly is placed in the
NC mode, a request signal is sent to the PCM. The
PCM will then energize the NC clutch relay, unless
abnormally high or low NC pressure is detected by the
A/C refrigerant pressure sensor. The PCM also
monitors the NC evaporator temperature sensor to
cycle the NC clutch "ON" and "OFF." If the PCM
detects an NC evaporator temperature less than 2C
(36F), the NC clutch will be prohibited from being
enabled. The PCM will also energize the cooling fans
"ON" when A/C is requested. Refer to "Electric
Cooling Fan," Section "6E3-Cl2". The A/C control
relay is controlled by the PCM so that the PCM can
increase idle speed before turning "ON" the clutch or
disable the clutch when high engine coolant
temperature is detected or high engine RPM is
detected.
DIAGNOSIS
The PCM will energize the NC clutch whenever
the engine is running less than 4100 RPM and NC has
been requested, unless any of the following conditions
are met:
NC head pressure greater than 414 psi (2854
kPa) or less than 38 psi (262 kPa) (as
determined by the NC refrigerant pressure
sensor).
A/C evaporator temperature less than 2C
(36F).
A/C Relay
A/C Evaporator Temperature
Sensor
Cl0-1
Cl 0-1
Cl0-1
Low ignition voltage.

Engine speed greater than 4700 RPM for 6
seconds.
ECT greater than 125C (257F).
CHART C-10 should be used for diagnosing the
electrical portion of the NC circuit. SECTION lB of
the service manual should be used for diagnosing the
refrigerant portion of the system.
The Tech 1 will be used in diagnosing the system,
as it has the ability to read the NC request input to
the .PCM, A/C compressor status, NC system pressure,
NC evaporator temperature, as well as displaying
when the PCM has commanded the NC clutch "ON."
ON-VEHICLE SERVICE
A/C RELAY

2. Cover from underhood electrical center.
3. Relay from underhood electrical center.

1. Relay to underhood electrical center.
2. Cover to underhood electrical center.
A/C Evaporator Temperature Sensor

For removal and replacement procedures, refer to
SECTION lB of the service manual.

3. Carefully back out A/C refrigerant pressure
sensor.
6E3-C10-2 5.7t (VIN P) DRIVEABILITY.AND EMISSIONS
AIR PUMP
RELAY
COOLANT FAN ~ELAY,

PRIMARY (ORfVi:'R SIDE)
ABS RELAY
AJC COMPRESSOR
RELAY
M
M
00
INJECTOR
EARLY PRODUCTION
INJECTOR
w
tGNl"':ION
AICCRUISE
CENTER
'
PONTIAC
ONL'f.
COOLANT FAN
LOW COOLANT
RELAY, SECOtlDARY
(PASSENGER SIDE)
RELAY
FOG LIGHTS
RELAY
HIGH BLOWER RELAY
L-------...1
AIR PUMP
COOLANT FAN
RELAY
RELAY #1
ABS RELAY
AJC COMPRESSOR
RELAY
co
INJECTOR
~
INJECTOR
LA TE PRODUCTION
00
w
'GNITION
A.IC-CRUISE
'
PONTIAC
ONLY
COOLANT FAN
RELAY#2
ASRFTCS RELAY
FOG LIGHTS
COOLANTFAN
RELAY
RELAY#3
L-------..J
Figure C10-1 -A/C Clutch Control Relay Location

A/C refrigerant pressure sensor to NC refrigerant
line.
3. Negativebatterycable.
components, refer to SECTION lB of the service
manual.
1.
NS 15660
BLANK

#12 (U/H)
. - - - - - - - 1 3 9 P N K ~ 3PNK
20AMP
~ - - - - - TO OTHER A/C CRUISE
FUSE CIRCUITS
A/C
RELAY
- - - i. .
TOIGNITION
PCM
-1
#3 (1/P)
TO IGNITION- 300 ORN
25AMP
TO REAR
DEFOG SYSTEM
-----a)I,
TO HVAC
~ 66 LT GRN
BLOWER SWITCH
HVAC
CONTROL
ASSEMBLY
139
PNK
C100
241
BRN
F
762 DK GRN/WHT ~
,___ _--;.~~IE--~1-----------459DKGRN/WHT
I
59 DK GRN
CI
-+((-~:---------7--w---
DK GRN - - - - - - - - - - - - - '
450 BLK
A/C
COMPRESSOR
l
-
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR

A/CCLUTCH
CONTROL
A/CCLUTCH
STATUS
TO OTHER
452 CIRCUITS
l-----e'---452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
A/C REQUEST SIGNAL
2~
I
Bl
I~
I
380 RED/BLK
416 GRY
416GRY
- - - - - 7 3 2 DK BLU
TO OTHER
452 CIRCUITS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29-93
PS 16541
CHART C-10 (Page 1 of 3)

The NC clutch control relay is PCM controlled to delay NC clutch engagement after the NC is turned "ON."
This allows the PCM to adjust engine RPM before the NC clutch engages.
The PCM will engage the NC clutch any time NC has been requested unless any of the following conditions
exist:
Low battery voltage.

High NC system pressure.
High engine RPM.
Low NC system pressure.
Low evaporator temperature.
When the HVAC control assembly is placed in the NC mode, A 12 volt signal is sent to the PCM. When the
PCM receives this signal the PCM will ground CKT 459 to energize the NC relay. This will be displayed on the
Tech 1 as NC request "YES." A 3-wire NC refrigerant pressure sensor is used to monitor NC system pressure.
If the NC refrigerant pressure is greater than 414 psi or lower than 38 psi, the NC clutch will not engage.
The NC refrigerant pressure sensor uses OTCs 66 and 67. If the NC refrigerant pressure sensor signal wire
becomes open, shorted to ground or shorted to voltage, OTC 66 will set. If the NC clutch engages and no pressure
change is detected, a OTC 67 will set.
The PCM also monitors NC evaporator temperature. The PCM utilizes this information to cycle the NC
clutch. If NC evaporator temperature is out of range (high or low), the PCM will disable the NC clutch relay.
The NC evaporator temperature sensor uses OTC 71. If the NC evaporator temperature sensor circuits
becomes open, shorted to ground or shorted to voltage, OTC 71 will set.
When a request for NC has been detected by the PCM, the PCM will ground the NC clutch control relay
driver circuit, the relay contacts will close, and current will flow through the relay to the NC compressor clutch.
When NC niquest has been detected by the PCM, the cooling fan(s) will be turned "ON" unless vehicle speed
is too high.
Diagnostic Aids: Before using CHART C-10, be
sure no OTC(s) are stored. The PCM will not activate
the NC clutch with a stored OTC.
1. Checks the PCM's ability to control the NC clutch
control relay.
2. Before replacing C60 A/C control components,
refer to SECTION lB for further diagnostics.
3. Checks for grounded CKT 459 to PCM.
DRIVEABIUTY AND EMISSIONS 5.7L (VIN P) 6E:3-C10-5
CHART C-10
(Page 1 of :3)

11
CHECK" A/C" FUSES.

ENGINE COOLANT AT NORMAL OPERATING TEMPERATURE.
CORRECT ANY PCM DIAGNOSTIC TROUBLE CODES.
A/C REFRIGERANT PRESSURE AND A/C EVAPORATOR HMPERA TURE NORMAL.
ENGINE IDLING.
A/C "OFF."
IS A/C CLUTCH ENGAGED?
WITH ENGINE IDLING AT NORMAL OPE~A TING

TEMPERATURE, TURN A/C "ON" AND "OFF."
DOES A/C CLUTCH CYCLE "ON" AND "OFF"?
;:;:;&~~~~~~~~~~~~~~~-r-
PLACE A/C CONTROL IN A/C MODE.

TECH 1 SHOULD DISPLAY A/C REQUEST "YES."
DOESIT?
----,
: REFER TO :
I CHART(-
: 10(PAGE :
......_.~~~~~~~~~~~~~~~~,30F3).
/, L - - - - - - . J
ENGINE STILL RUNNING.

TECH 1 SHOULD DISPLAY A/C REQUEST "NO."
DOESIT?
DISCONNECT A/C RELAY.

PROBE CKT 459 WITH A
TEST LIGHT TO B +.
IS TEST LIGHT "ON"?
CKT762
SHORTED TO
VOLTAGE
OR FAULTY HVAC
CONTROL
ASSEMBLY OR
FAULTY PCM.
IGNITION "OFF."
DISCONNECT HVAC CONTROL
ASSEMBLY.
IGNITION "ON."
PROBE TERMINAL "C" OF HVAC
CONTROL ASSEMBLY HARNESS WITH A
TEST LIGHT CONNECTED TO GROUND.
TEST LIGHT SHOULD ILLUMINATE.
DOESIT?
USING A FUSED JUMPER WIRE, JUMPER

TERMINAL "C" TO "A" AT HVAC HARNESS
CONNECTOR.
TECH 1 SHOULD INDICATE A/C REQUEST "YES."
DOESIT?
FAULTY HVACCONTROLASSEMBLY CONNECTION OR

FAULTY HVAC CONTROL ASSEMBLY.
OPEN IN IGNITION FEED CIRCUIT TO

HVAC CONTROL ASSEMBLY.
CKT762 OPEN
OR
FAULTY PCM
CONNECTION
OR
FAULTY PCM.
6-29-93
NS 15559
6E3-C10-.6 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS
#12 (U/H)
, - - - - - - 1 3 9 P N K ~ 3PNK - T O IGNITION
20AMP
...--------i~ TO, OTHER A/C CRUISE
FUSE CIRCU.ITS
A/C
RELAY
PCM
#3 (1/P)
TOIGNITIQN.+,- 3000RN
~
25AMP
TOHVAC
~66LTGRN
BLOWER SWITCH
241
BRN
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
139
PNK
C100
A/C REQUEST SIGNAL
I
I ~BI
I
A/CCLUTCH
CONTROL
59 DK GRN
CI
-f<( :
~DKGRN
450BLKl
A/C
COMPRESSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
TO.OTHER
452 CIRCUITS
452 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/CCLUTCH
STATUS
380 RED/BLK
416 GRY
416 GRY
732 DKBLU
452 BLK
(UIH) = LOCATED IN UNDERHOOD ELECTRICAL CENTER

(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BL(\~ ..
TO OTHER
452 CIRCUITS
SENSOR GROUND
A/CREFRIGERANT PRESS.
SENSOR SIGNAL
+ S VOLT REFERENCE
A/CEVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29-93
PS 16541
CHART C-10
(Page 2 of 3)

The A/C clutch control relay is PCM controlled to delay A/C clutch engagement after the A/C is turned "ON."
This allows the PCM to adjust engine R.PM before the NC clutch engages.
;The PCM will engage the A/C clutch any time NC has been requested unless any of the following ~onditions
exist:
High engine RPM.
Low evaporator temperature
When the HV AC control assembly is placed in the A/C mode, a 12 volt signal is sent to the PCM. When the
Tech 1 as NC request "YES." A 3-wire AJC refrigerant pressure sensor is used to monitor NC system pressure.
If the A/C refrigerant pressure is greater than 414 psi or lower than 38 psi, the A/C clutch will not engage.
The A/C refrigerant pressure sensor uses OTCs 66 and 67. If the A/C refrigerant pressure sensor signal wire
becomes open, shorted to ground or shorted to voltage, OTC 66 will set. If the NC clutch engages and no pressure
change is detected, a DTC 67 will set.
The PCM also monitors A/C evaporator temperature. The PCM utilizes this information to cycle the NC
clutch. If NC evaporator temperature is out of range (high or low), the PCM will disable the A/C clutch relay.
The A/C evaporator temperature sensor uses DTC 71. If the A/C evaporator temperature sensor circuits
becomes open, shorted to ground or shorted to voltage, OTC 71 will set.
When a request for A/C has been detected by tae PCM, the PCM will ground the NC clutch control relay
Wh~n A/C request has been detected by the PCM, the cooling fan(s) will be turned "ON" unless vehicle speed
is too high.
DRIVEABILtTY AND EMISSIONS 5.7L (VIN P) 6E3-C10-7
CHART C-10
(Page 2 of 3)

,--------------,
___________
: FROMCHARTC-10 :
I
PAGE 1 OF 3
.....
...,,1
INSTALL A/C MANIFOLD GAGE SET. REFER TO SECTION 18.

IGNITION "ON."
USING TECH 1, COMPARE A/C GAGE SET PRESSURE TO TECH 1 PRESSURE.
IS TECH 1 PRESSURE WITHIN 20 psi OF HIGH SIDE OF PRESSURE?
ENGINE IDLING, A/C "ON."

USING A TECH 1, MONITOR A/C
EVAPORATOR TEMPERATURE.
IS A/C EVAPORATOR TEMPERATURE
GREATER THAN 2C (36F).
IGNITION "OFF.''
JUMPER PRESSURE SENSOR CONNECTOR TERMINALS "B" AND "C".
IGNITION "ON."
DOES TECH 1 INDICATE PRESSURE SENSOR VOLTAGE ABOVE 4.8 VOLTS?
DISCONNECT A/C
EVAPORATOR
TEMPERATURE SENSOR.
DOES A/C EVAPORATOR
TEMPERATURE
INDICATE-7C(19F)?
us1NG DVM MEASURfvoLTAGE

FROM PRESSURE SENSOR
.CONNECTOR "B" TO GROUND.
DOES DVM MEASURE ABOUT 5
VOLTS?
FAULTY A/C
EVAPORATOR
TEMPERATURE
SENSOR.
HIGH RESISTANCE
IN CIRCUIT 732
OR
FAULTY PCM.
FAULTY PCM 5
VOLT REFERENCE
CONNECTION OR
OPEN OR
GROUNDED5
VOLT REFERENCE
CIRCUIT OR
FAULTY PCM.
FAULTY PCM
SIGNAL CIRCUIT
CONNECTION OR
OPEN OR
GROUNDED
PRESSURE SENSOR
SIGNAL WIRE OR
FAULTY PCM.-
WITH A TEST LIGHT TO B +,

PROBE A/C REFRIGERANT
PRESSURE SENSOR
CONNECTOR TERMINAL "A".
IS TEST LIGHT "ON"?
OPEN
PRESSURE
SENSOR
GROUND
CIRCUIT.
FAULTY
SENSOR
CONNECTION
OR FAULTY
SENSOR.
6-29-93
NS 15570
#12 (U/H)
, - - - - - - 1 3 9 PNK ~ 3PNK ___.. TO IGNITION
20AMP
.----e--- TO OTHER A/C CRUISE
FUSE CIRCUITS
PCM
#3 (1/P)
TOIGNITION.._ 3000RN
~
25AMP
TOHVAC
.._.66LTGRN
BLOWER SWITCH
C100
I
I
59 DKGRN
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
139
PNK
241
BRN
A/C REQUEST SIGNAL
BI
-f<(-~:~--------7-----
DK GRN - - - - - - - - - - - ~
A/C
COMPRESSOR
450 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
A/CCLUTCH
CONTROL
CI
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/CCLUTCH
STATUS
TO OTHER
452 CIRCUITS
l-----e<'--452 BLK
380 RED/BLK
416 GRY
416 GRY
1 - - - - - - 7 3 2 DK BLU

(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLQ~
TO OTHER
452 CIRCUITS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
6-29-93
PS 16541
CHART C-10
(Page 3 of 3)

The NC clutch control relay is PCM controlled to delay NC clutch engagement after the NC is turned "ON."
This allows the PCM to adjust engine RPM before the NC clutch engages.
The PCM will engage the NC clutch any time NC has been requested unless any of the following conditions
exist:
High NC system pressure.
Low evaporator temperature.
High engine RPM.
When the HVAC control assembly is placed in the NC mode, a 12 volt signal is sent to the PCM. When the
Tech 1 as NC request "YES." A 3-wire NC refrigerant pressure sensor is used to monitor NC system pressure.
If the NC refrigerant pressure is greater than 414 psi or lower than 38 psi, the NC clutch will not engage.
The NC refrigerant pressure sensor uses DTCs 66 and 67. If the NC refrigerant pressure sensor signal wire
becomes open, shorted to ground or shorted to voltage, DTC 66 will set. If the NC clutch engages and no pressure
change is detected, a DTC 67 will set.
The PCM also monitors A/C evaporator temperature. The PCM utilizes this information to cycle the NC
clutch. If NC evaporator temperature is out of range (high or low), the PCM will disable the NC clutch relay.
The NC evaporator temperature sensor uses DTC 71. If the NC evaporator temperature sensor circuits
becomes open, shorted to ground or shorted to voltage, DTC 71 will set.
When a request for NC has been detected by the PCM, the PCM will ground the NC clutch control relay
When NC request has been detected by the PCM, the cooling fan(s) will be turned "ON" unless vehicle speed
is too high .
.Chart Test Description: Number(s) below refer to
This would cause NC clutch to be engaged at all times
when NC is requested.
1. If 5 volt reference is not present at the A/C
evaporator temperature sensor, the A/C
evaporator temperature would be at a fixed value.
CHARTC-10
(Page 3 of 3)

5.7L {VIN P) "F" CARLINE (SFI)
r------------,
: FROMCHARTC-10 :
I PAGE 1 OF 3.
1
L
G)
----------.l
IGNITION "OFF."
DISCONNECT A/C EVAPORATOR TEMPERATURE SENSOR.
IGNITION "ON."
USING A DVM (J 39200) MEASURE VOLTAGE AT TERMINAL
"A" OF A/C EVAPORATOR TEMPERATURE SENSOR
HARNESS.
IS 5 VOL TS INDICATED ON DVM?
NO TROUBLE FOUND, A/C

CLUTCH CIRCUIT OK.
5 VOLTS REFERENCE
CIRCUIT OPEN.
OR
SHORTED TO GROUND.
10-30-92
NS 16198
BLANK
SECTION C12
ELECTRIC COOLING FAN(S)

CONTENTS
General Description
Operation
Non A/C and Early Production A/C
C12-1
C12-1
C12-1
GENERAL DESCRIPTION
The electric cooling fan(s) are used to cool engine
coolant flowing through the radiator. They are also
used to cool the refrigerant (R134a) flowing through
the NC condenser.
Vehicles without NC use a single electric cooling
fan. Vehicles with A/C will have either an early
production or late production system both using dual
electric cooling fans. The two systems have completely
different operating strategies.
OPERATION - NON A/C AND

EARLY PRODUCTION A/C
The electric cooling fan(s) are controlled by the
PCM. The PCM controls the ground path for the
cooling fan relay(s).
The relay(s) are used to control the high current
flow to power the cooling fan motor(s). The PCM
determines operation of the independent fans based on
various sensor inputs.
Primary Cooling Fan (Fan 1)

The primary cooling fan is controlled by the PCM
based on inputs from the NC system, Engine Coolant
Temperature (ECT) sensor, Vehicle Speed Sensor
(VSS).
The PCM will turn the primary cooling fan "ON"
when any of the following conditions exist at idle.
Certain PCM Diagnostic Trouble Codes (DTCs)
set.
ECT above 108C (226F).
AJC head pressure above 248 psi.
If the primary fan has been turned "ON" by the
Engine Coolant Temperature (ECT) sensor, the PCM
will turn the fan "OFF" when that temperature has
dropped about 3C (5F). If the primary cooling fan has
been turned "ON" by high NC head pressure, the PCM
will turn the fan "OFF" when the pressure has dropped
to 208 psi. The minimum "ON" time for the primary
cooling fan is 50 seconds.
Late Production A/C

On-Vehicle Service
Cooling Fan Relay
(12-1
(12-3
(12-3
Secondary Cooling Fan (Fan 2) (With AJC)

The secondary cooling fan is controlled by the PCM
based on inputs from the NC system, Engine Coolant
Temperature (ECT) sensor, Vehicle Speed Sensor
(VSS).
The PCM will turn the secondary cooling fan "ON"
when any of the following conditions exist at idle:
Certain Diagnostic Trouble Codes (DTCs) set.
ECT above l 13C (235F).
NC head pressure above 248 psi.
Once the secondary fan has been turned "ON" by
the ECT, the PCM will turn the fan "OFF" when that
temperature has dropped about 3C (5F). If the
sec~ary cooling fan has been turned "ON" by high
NC'''t&ad pressure, the PCM will turn the fan "OFF''
when the pressure has dropped to 208 psi. The
minimum "ON" time for the secondary cooling fan is
30 seconds.
OPERATION- LATE PRODUCTION A/C

The electric cooling fans are controlled by the
PCM. The PCM controls the ground path for the three
cooling fan relays. The relays are used to control the
high current flow to power the cooling fan motors.
Both fans operate together. When minimum cooling is
required, the PCM energizes cooling fan relay #1 and
both fans operate at low speed, since the fan are
connected in series through cooling fan relay #3, and
cooling fan relay #2 is open. When maximum cooling
is required, the PCM energizes all three cooling fan
relays. The left fan is still powered through cooling
fan relay #1, but is now grounded through cooling fan
relay #3. The right fan is now powered directly
through cooling fan relay #2 and both fans operate at
high speed.
Low Speed Fans

The cooling fans are controlled by the PCM based
on inputs from the A/C system, Engine Coolant
Temperature (ECT) sensor and Vehicle Speed Sensor
(VSS).
PRIMARY COOLING FAN MOTOR
RADIATOR
SECONDARY COOLING FAN MOTOR
LOWER RADIATOR SUPPORT
NS 15383
Figure C12-1 - Cooling Fan Configurations
AIR PUMP
RELAY
COOLANT FAN RELAY,

PRIMARY (DRIVER SIDE)
ABS REL.C..Y
AJC COMPRESSOR
RELAY
"
INJECTOR
00
EARLY PRODUCTION
w
w
INJECTOR
lGNnON
AJC.CRUISE
'
u
PONTIAC
I
ONL'r
I
L _______ ..J
CENTER
COOLANT FAN
RELAY, SECOtlDARY
FOG LIGHTS
RELAY
RELAY
(PASSENGERSIDEi
.3.!RPUMP
RELAY
"
LOW COOLANT
COOLANT FAN
RELAY #1
ABS RELAl'
HIGH BLO WERRELA
AJC COMPRESSOR
RELAY
"
INJECTOR
w
w
INJECTOR
LATE PRODUCTION
IGNITION
AJC-CRUISE
I
:
U
PONTIAC
I
ONLY
L
_______
COOLANTFAN
RELAY #i
ASRfTCSRElAY
FOG LIGHTS
RELAY
COOLANTFAN
RELAY #l
..J
NS 15660
Figure C12-2 - Cooling Fan Relay Location
DRIVEABILITY AND EMISSIONS 5.7L (VIN P} 6E3-C12-3

The PCM will command low speed fans "ON" when
Engine Coolant Temperature (ECT) is above 108C
(226F). The PCM will turn the fans "OFF" when the
temperature drops about 3C (5F). The minimum
"ON" time for low speed fans is 50 seconds.
High Speed Fans

The PCM will command high speed fans "ON"
when any of the following conditions exist at idle.
Certain Diagnostic Trouble Codes (DTCs) set.
ECT above ll3C (235F).
NC head pressure above 248 psi.
If the high speed fans were turned "ON" by the
ECT, the PCM will switch the fans back to low speed
when the temperature drops about 3C (5F).
Minimum "ON" time for HI speed fans is 30 seconds.
ON-VEHICLE SERVICE
COOLING FAN RELAY

2. Cover from underhood electrical center.
3. Relay from underhood electrical center.

1. Relay to underhood electrical center.
2. Cover to underhood electrical center.
Cooling system component replacement can be
found in SECTION 6B.
components, refer to SECTION lB.
6E3-C12-4 5.7L (VIN P) DRIVEABILITY AND EMlSSIONS
PCM
J
. - - - - - - 3 3 5 DK GRN - - - - - - J ~ ' # K - - - - - 3 3 5 DK GRN
C100
PRIMARY COOLING
FAN RELAY CONJ"ROL
~ - - 4 0 9 LT BLU
_r-150BLK
402 RED ~ B + JUNCTION
(FAN 2)
SECONDARY
COOLING
FAN
504BRN
r150BLK
SECONDARY COOLING
FAN RELAY (W/C60)
' - - - - - - - - 4 7 3 DK BLU
- - - - - - - c ~....
K - - - - 4 7 3 DK BLU
C100
(U/H)
SECONDARY COOLING
FAN RELAY CONTROL
CHART C-12A
6-5-93
MS 12084
(Page 1 of 2>
ELECTRIC COOLING FAN CONTROL CIRCUIT DIAGNOSIS

(NON A/C AND EARLY PRODUCTION A/C)

The cooling fans are controlled by the PCM based on various inputs. Battery voltage is supplied to the
primary fan relay on terminal "01" and on "F4" of the secondary fan relay. Ignition voltage is supplied to
terminal "05" of the primary fan relay and "F2" of the secondary fan relay. Grounding CKT 335 (relay terminal
"02") will energize the primary cooling fan relay (Fan 1) and supply battery voltage to the primary cooling fan
motor. Grounding CKT 473 (relay terminal "F5") will energize the secondary cooling fan relay (Fan 2) and
supply battery voltage to the secondary fan motor.
When certain Diagnostic Trouble Codes (DTCs) are set, the PCM will enable the cooling fans.
1. With the output/field service enable terminal
complaint was due to an actual boil over, or the
grounded, the cooling fan control driver(s) will
warning indicator light, or engine coolant temperature
close, which should energize the fan control
gage indicated overheating.
The gage accuracy can also be checked by
relay(s).
If vehicle is equipped with one cooling fan (non
comparing the Engine Coolant Temperature (ECT)
sensor reading using a Tech 1 and comparing its
A/C) and cooling fan operation is OK, refer to
diagnostic aids below for further diagnosis of
reading with the gage reading.
cooling system.
If the engine is actually overheating and the gage
2. Engine coolant temperature must be below 100C
indicated overheating, but the cooling fan is not
(212F) to perform this step. The cooling fans
coming "ON," the Engine Coolant Temperature (ECT)
should come "ON" anytime A/C system is
sensor has probably shifted out of calibration and
operating.
should be replaced.
3. Comparing Tech 1 pressure and manifold gage set
If the engine is overheating and the cooling fans
pressure will determine if the A/C refrigerant
are "ON," the cooling system should be checked, refer
pressure sensor is out of range. An out of range
to SECTION 68.
AJC refrigerant pressure sensor can cause the
The PCM will command fan 1 "ON" at l08C
cooling fans to operate at the wrong times.
(226F) and "OFF" at 105C (221 F) and, fan 2 "ON" at
113C (235F) and "OFF" at l l0C (230F).
DRIVEABILITYANDEMISSIONS 5.7L (VIN P) 6E3-C12~5
CHARTC-12A
(Page 1 of 2)
IF ANY PCM DTC(s) ARE SET REFER TO DTC (s) CHART FIRST.
BE SURE COOLING SYSTEM AND BEL TS ARE OK.
ENGINE COOLANT TEMPERATURE BELOW 100C (212F).
IGNITION "ON," ENGINE "OFF.," A/C "OFF."
ARE COOLING FAN(s) "OF.F"?
ELECTRIC COOLING FAN

(NONA/CANO
EARLY PRODUCTION A/C)
5.7L (VIN P) "F" C:ARLINE (SFI)
START ENGINE, A/C "OFF."

ARE FAN(S) "ON"?
: REFERTO
:
: PAGE 2 OF 2. :
A/C REQUEST CIRCUIT

SHORTED TO VOLTAGE
OR
FAULTY HVAC
CONTROL ASSEMBLY.
OR
FAULTY PCM.
INSTALL A/C MANIFOLD GAGE SET.

IGNITION "ON." ENGINE "OFF."
USING TECH 1 COMPARE MANIFOLD
GAGE SET PRESSURE TO TECH 1
PRESSURE READING.
IS TECH 1 PRESSURE READING WITHIN
20 psi OF HIGH SIDE PRESSURE?
DISCONNECT FAN RELAY FOR COOLING

FAN THAT IS OPERA TING.
DID THE FAN STOP?
IGNITION "ON."
PROBE FAN RELAY CONTROL
CIRCUIT TERMINAL IN THE
HARNESS CONNECTOR WITH A
TEST LIGHT TO B +.
IS TEST LIGHT ON?
CIRCUIT(s) FROM RELAY

TO FAN IS SHORTED TO
VOLTAGE.
PfUMARY FAN (FAN 1)
SECONDARY FAN (FAN 2)
PRIMARY COOLING FAN RELAY

CONTROL CIRCUIT SHORTED TO
GROUND
OR
FAULTY PCM.
SECONDARY COOLING
FAN RELAY CONTROL
CIRCUIT SHORTED TO
GROUND
OR
FAULTY PCM.
: REFER TO SECTION
: C-10 FOR FURTHER
I DIAGNOSIS OF THE
: A/C CIRCUIT.
:
:
I
ENGINE IDLING, A/C "ON."


"DIAGNOSTIC AIDS" ON FACING
PAGE.
6-11-93
PS 17258
6E3-C12-6 5.7L (VIN P) PRIVEABILITY AND EMISSIONS
PCM
J
....-------335 DK GRN ------.~rt1(('-------335 DK GRN
C100
PRIMARY COOLING
FAN RELAY CONTROL
~ - - 409 LT BLU
.r150BLK
402 RED ~ B + JUNCTION
504BRN
_r--150BLK
SECONDARY COOLING
FAN RELAY (W/C60)
(FAN 2)
SECONDARY
COOLING
FAN
' - - - - ' - - - - 4 7 3 DK BLU - - - ~ - - < ( ( - - - - - 4 7 3 DK BLU

C100
(U/H)
SECONDARY COOLING
FAN RELAY CONTROL
6-5-93
MS 12084
CHARTC-12A
(Page 2 of 2)

(NON A/C AND EARLY PRODUCTION A/C)

The cooling fans are controlled by the PCM based on various inputs. Battery voltage is supplied to the
primary fan relay on terminals "Dl" and "F4" of the secondary fan relay. Ignition voltage is supplied to terminal
"D5" of the primary fan relay and "F2" of the secondary fan relay. Grounding CKT 335 (relay terminal "D2") will
energize the primary cooling fan relay (Fan 1) and supply battery voltage to the primary cooling fan motor.
Grounding CKT 473 (relay terminal "F5") will energize the secondary cooling fan relay (Fan 2) and supply
battery voltage to the secondary fan motor.
The PCM will enable the cooling fans, when certain Diagnostic Trouble Codes (DTCs) are set.
overheating prol)lem, it must be determined if the
complaint was due to an actual boil over, the warning
indicator light, or engine coolant temperature gage
indicated overheating.
The gage accuracy can also be checked by
comparing the Engine Coolant Temperature (ECT)
sensor reading using a Tech 1 and comparing its
reading with the gage reading.
If the engine is actually overheating and the gage

indicated overheating, but the cooling fan is not
coming "ON," the Engine Coolant Temperature (ECT)
sensor has probably shifted out of calibration and
should be replaced.
to SECTION 6B.
The PCM will command fan 1 "ON" at l08C
(226F) and "OFF" at 105C (221 F) and an 2 "ON" at
113C (235F) and "OFF" at 110C (230F).
CHART C-12A (Page 2 of 2>
,---------,
I
: FROM
I
I CHART C-12 1
I
: (1 OF 2)
I
ELECTRIC COOLING FAN

L--.-----..J
I
PRIMARY
SECONDARY
IGNITION "OFF."
DISCONNECT PRIMARY COOLING FAN RELAY
IGNITION "ON."
PROBE FAN RELAY HARNESS TERMINALS "01" ANO
"05" WITH A TEST LIGHT CONNECTED TO GROUND.
I
I
LIGHT "ON" BOTH
USING TECH 1 ACTIVATE

"FAN CTRL PCM A 11."
PROBE HARNESS TERMINAL
"02" WITH A TEST LIGHT
CONNECTED TO B +.
IS TEST LIGHT "ON"?
USING A FUSED JUMPER

WIRE, JUMPER FAN RELAY
HARNESS TERMINALS "01"
AND "04" TOGETHER.
DOES FAN OPERATE?
IGNITION "OFF."
DISCONNECT PRIMARY COOLING
FAN ELECTRICAL CONNECTOR
IGNITION "ON."
JUMPER WIRE STILL INSTALLED
AT RELAY HARNESS.
CONNECT A TEST LIGHT ACROSS
COOLING FAN ELECTRICAL
CONNECTOR TERMINALS.
IS TEST LIGHT "ON."
.
LIGHT "OFF"
ONE OR BOTH
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
LIGHT "OFF"
'ONE OR BOTH
USiNG TECH 1 ACTIVATE

"FAN CTRL PCM A 10."
PROBE HARNESS TERMINAL
"F5" WITH A TEST LIGHT
CONNECTED TO B +.
IS TEST LIGHT "ON"?
REPAIR OPEN OR
SHORT TO
GROUND IN
CIRCUIT THAT DID
NOT LIGHT.
REPAIR OPEN OR
SHORTTO VOLTAGE
INCKT 335.
PR
FAULTY PCM
CONNECTION OR
FAULTY PCM.
~
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
s
REPAIR OPEN OR
SHORTTO VOLTAGE
IN CKT473.
OR
FAULTY PCM
CONNECTION OR
FAULTY PCM.
USING A FUSED JUMPER

WIRE.JUMPER FAN RELAY
HARNESS TERMINALS "F1"
AND "F4" TOGETHER.
DOES FAN OPERA TE?
[]
IGNITION "OFF."
DISCONNECT SECONDARY COOLING
FAN ELECTRICAL CONNECTOR
IGNITION "ON."
JUMPER WIRE STILL INSTALLED AT
RELAY HARNESS.
CONNECT A TEST LIGHT ACROSS
COOLING FAN ELECTRICAL
CONNECTOR TERMINALS.
IS TEST LIGHT "ON."
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY .
.
LIGHT "ON" BOTH
I S.7L (VIN P) "F" CARLINE (SFI)
IGNITION "OFF."
DISCONNECT SECONDARY COOLING FAN RELAY
IGNITION "ON."
PROBE FAN RELAY HARNESS TERMINALS "F2" ANO
"F4" WITH A TEST LIGHT CONNECTED TO GROUND.
~NONA/CANO
EARL PRODUCTION A/C)
PROBE COOLING FAN MOTOR

HARNESS CONNECTOR
TERMINAL "B" WITH A TEST
LIGHT CONNECTED TO GROUND.
IS TEST LIGHT "ON"?
[$]
FAUL TY FAN MOTOR
CONNECTION
OR
CIRCUIT 150 OPEN.
~
FAUL TY CONNECTION
AT FAN MOTOR
OR
FAULTY FAN MOTOR.
s
OPEN IN CIRCUIT 409
BETWEEN RELAY
AND COOLING FAN
MOTOR.
PROBE COOLING FAN MOTOR

HARNESS CONNECTOR
TERMINAL "B" WITH A TEST
LIGHT CONNECTED TO GROUND.
IS TEST LIGHT "ON"?
I
s
FAUL TY FAN MOTOR
CONNECTION
OR
CIRCUIT 150 OPEN.
FAULTY CONNECTION
AT FAN MOTOR
OR
FAULTY FAN MOTOR.
s
OPEN IN CIRCUIT 504
BETWEEN RELAY AND
COOLING FAN
MOTOR.
6-29-93
PS 18475
6E3-C12-8 5.7L (VIN P) ORIVEABILITY AND EMISSIONS
PCM
TO
IGNITION
!~~
FUS LINK
1--~
#6
402 RED
(U/H)
------541
BRN
COOLING FAN
(LEFT SIDE)
532 BLK
J2
541 BRN
J3
504 BRN
J1
150 BLK
l
-=-

402 RED
F1
335
DKGRN
504 BRN
-----t
150BLK
COO
..L-IN_.G._F_A,_N_R_E-LA""'Y._#_2.,.(WH)
473
DKrU
. ,,w'"
1
-
COOLING FAN
(RIGHT SIDE)
C100
rH,
.__ _ _ _ _ _ _ _ _ _ _ _ _ _...,l~cK'----"-1- - - 4 7 3 DKBLU
~---------------------K~1---335DKGRN
LJ...J

&#3CONTROL
CONTROL
7.9.93
PS 18466
CHART C-128 (Page 1 of 4)

(LATE PRODUCTION A/C)
5. 7 (VIN P)
11
F" CARLINE (SFI)
The cooling fans are controlled by the PCM based on various inputs. Ignition voltage is supplied to all three
cooling fan relay coils on CKT 541. The PCM controls cooling fan relay #1 by providing the ground path through
CKT 335. The PCM controls cooling fan relays #2 .and #3 together by providing the ground path through CKT
473. When cooling fan relay #1 is energized the cooling fans are connected in series and operate together at low
speed. When all three relays are energized the fans are connected in parallel and operate together at high speed.
When certain DTCs are set, the PCM will enable cooling fans.
1. The cooling fans should come "ON" anytime NC
.
system is operating.
2. Comparing Tech 1 pressure and manifold gage set
pressure will determine if the A/C refrigerant
to SECTION 6B.
pressure sensor is out of range. An out of range
The PCM .will command low speed fans "ON" at
NC refrigerant pressure sensor can cause the
108C (226F) and "OFF" at 105 C (221 F) and, high
. cooling.fans _to operate at the wrong times.
speed fans "ON" at l 13C (235F) and "OFF" at l 10C
D1agnost1c Aids: If the owner complained of an
(230F).
CHARTC-128
IF ANY DTCs ARE SET PERFORM THOSE CHARTS FIRST.

CHECK COOLING SYSTEM.
COOLANT BELOW 100C (212F).
IGNITION "ON," ENGINE "OFF," A/C "OFF."
FANS SHOULD BE "OFF."
ARE THEY?
(Page 1 of 4)
ELECTRIC COOLING FAN CONTROL

CIRCUIT DIAGNOSIS
(LATE PRODUCTION AJC)
11
USING TECH 1 ACTIVATE FAN CTRL PCM A 11 ".

DO BOTH FANS TURN "ON"?
,--1'---~~~~~~~~-,r

"FAN CTRL PCM A10".
DO BOTH FANS SWITCH TO
HIGH SPEED?
---------~
,......IL-~~~~~~~~~-,
: REFER TO PAGE :
1 2 OF4.
1
'-----------..J
DISCONNECT FAN RELAY #3.

FANS SHOULD BE "OFF."
ARE THEY?
WITH TEST LIGHT TO B +,

PROBE FAN RELAY #1
CONNECTOR TERMINAL
TERMINAL "02".
IS THE LIGHT "ON"?
IGNITION "OFF."
WITH LIGHT STILL
CONNECTED,
DISCONNECT PCM
CONNECTOR "A".
IGNITION "ON."
IS LIGHT "ON"?
,......IL-~~~~~~~~~r
USING TECH 1 EXIT OUTPUTS : REFER TO

:
START ENGINE, A/C "OF.F."
PAGE 4 OF 4. 1
1
ARE FANS "ON"?
L.--------~
,___~~~~~~~~~~
WITH TEST LIGHT TO B +

PROBE FAN RELAY #3 .
CONNECTOR TERMINAL "FS".
IS THE LIGHT ON?
A/C
REQUEST CIRCUIT
SHORTED
TO.VOLTAGE
OR
.,__ _ _ _ _ _ _ _ _..,. FAULTY
PCM.
INSTALL A/C MANIFOLD

GAGE SET. REFER TO
SECTION 18.
IGNITION "ON." ENGINE
"OFF."
USING TECH 1 COMPARE
MANIFOLD GAGE SET
PRESSURE TO TECH 1
PRESSURE READING.
IS TECH 1 PRESSURE
READING WITHIN 20 psi OF
HIGH SIDE PRESSURE?
FAULTY
FAN
RELAY #1
WITH LIGHT STILL

CONNECTED,
DISCONNECT
PCM CONNECTOR
"A".
IS LIGHT "ON"?
DOESTECH.1
DISPLAY A/C
REQUEST "YES"?
r-
-----------.,
: REFER TO SECTION
I C-10 FOR FURTHER
: DIAGNOSIS OF THE
I A/C CIRCUIT.
:
I
:
1
L-------------..1
ENGINEIDLING,A/C"ON."
FAUL TY A/C REFRIGERANT PRESSURE SENSOR.

7-9-93
MS 12489
PCM
TO
IGNITION
~~"4
FUSE LINK
---1- ~
#6
402 RED
(U/H)
.----541
BRN
COOLING FAN
(LEFT SIDE)
532 BLK
541 BRN
.------11
J2
J3
504BRN
J1
150 BLK
=!--
402RED
504 BRN
335
DKGRN
-----1 B
150
BLK
iiiO
~
COOLING FAN
(RIGHT SIDE)
aoo
r,
- H
~~
~~K,-----1 --~473DKBLU
1
~--------------~
'----------------------H!KE--f-1---335DKGRN
LJ...J

&#3CONTROL
CONTROL
7.9.93
PS18466
CHART C 128 (Page 2 of 4)

5.7 (VIN P)
11
F" CARLINE (SFI)
CKT 335. The PCM controls cooling fan relays #2 and #3 together by providing the ground path through CKT
473. When cooling fan relay #1 is energerized the cooling fans are connected in series and operate together at low
The PCM will command low speed fans "ON" at
108C (226F) and "OFF" at 105 c (221 F) and, high
speed fans "ON" at 113C (235F) and "OFF" at 110C
(230F).
to SECTION 68.
CHART C-128
(Page 2 of 4)
...

CIRCUIT DIAGNOSIS
------------,
: FROM CHARTC-12 :
1 1 OF4.
1
L-.-----------.J
010 EITHER FAN
TURN "ON"?
11
5. 7L (VIN P)
F" CARLINE (SFI)
EJ
~
TECH 1 ACTIVATE "FAN CTRL PCM A 11 " .
USING
DISCONNECT FAN RELAV #1
WITH
TEST LIGHT TO B +, PROBE RELAV
CONNECTOR
TERMINAL "02".
USING TECH 1 ACTIVATE "FAN CTRL PCM A 11 " .

DISCONNECT THE FAN WHICH IS NOT OPERATING .
DID THE OTHER FAN TURN "OFF"?
IS LIGHT "ON"?
:]
~f]
WITH TEST LIGHT TO

GROUND PROBE FAN
RELAY CONNECTOR
TERMINALS "05" AND
"01."
LIGHT SHOULD BE "ON"
FOR BOTH CIRCUITS.
ISIT?
RELAY
CONTROL
CIRCUIT OPEN
OR SHORTED
TOB+ .
REPAIR OPEN
OR5HORTTO
GROUND ON
CIRCUIT THAT
DID NOT LIGHT.
8J
] :]
TEST LIGHT STILL

CONNECTED.
IGNITION "OFF."
DISCONNECT PCM
CONNECTOR "A".
PROBE PCM HARNESS
CONNECTOR TERMINAL
"A 11" WITH FUSED
JUMPER TO GROUND.
IS LIGHT "ON"?
DISCONNECT THE LEFT FAN .

WITH A TEST LIGHT TO GROUND, PROBE
FAN HARNESS CONNECTOR TERMINAL "B".
15 THE LIGHT "ON"?
~
CIRCUIT 532 SHORTED
TO GROUND.
FAN RE LAV #1 FAUL TV
[]
CONNECTASECONDFUSED
JUMPER WIRE BETWEEN FAN
15 THE RIGHT FAN "ON"?
USING A TEST LIGHT TO GROUND. PROBE FAN RELAY #3

HARNESS CONNECTOR TERMINAL" J4."
IS THE LIGHT "ON"?
.~
CONTINUED ON PAGE 3 OF 4.
L------------------J
r
CONNECT A JUMPER BETWEEN FAN

RELAY CONNECTOR TERMINALS "D1"
AND "04". LEAVE THIS JUMPER IN PLACE
FOR THE REMAINDER OF THIS CHART.
DO THE FANS COME "ON"?
~
LEFT FAN .
RECONNECT
OISCONNECTFAN RELAY #3
RELAY #2 FAULTY.
FAULTY PCM
CONNECTIONS
OR
FAULTY PCM.
THE FAN WHICH

WAS NOT
OPERA TING IS
FAULTY .
@]
DISCONNECT FAN
RELAY #2.
DID THE FAN TURN
"OFF"?
--------------,
OPEN CIRCUIT 409.
]
FAULTY LEFT FAN MOTOR CONNECTIONS
OR
FAULTY LEFT FAN MOTOR.
~
OPEN CIRCUIT 532.
6-30-93
NS 15382
PCM
TO
IGNITION
~~4
FUSE LINK
1-I-~
#6
402 RED
(U/H)
.-----..541
BRN
COOLING FAN
(LEFT SIDE)
532 BLK
J2
541 BRN
J3
504 BRN
J1
150 BLK
COOLING FAN RELAY #3(U/H)
_______
402 RED
_.
F1
335
DKGRN
-=-
504 BRN

473
~~
-----1
150BLK
COOLING FAN
(RIGHT SIDE)
C100
- r,
H
~<<IK:--'--1- - - 4 7 3 DK BLU
, __ _ _ _ _ _ _ _ _ _ _ _ _ __._..I
'-----------~---~-------M!~K~1e---~3350KGRN
LJ.J
(U/H)

& #3 CONTROL
.
CONTROL
7-9-93
PS18466
CHART C-128
(Page 3 of4)

5. 7 (VIN P) ''F" CARLINE (SFI)

473. When cooling fan relay #1 is energerized the cooling fans are connected in series and operate together at low

to SECTION 68.
The PCM will command low speed fans "ON" at

108C (226F) and "OFF" at 105 c (221 F) and, high
speed fans "ON" at 113C (235F) and "OFF" at l 10C
(230F).
CHART C-128
(Page 3 of 4)

CIRCUIT DIAGNOSIS
r-------------------,
CONTINUED FROM PAGE 2 OF 41

L
-----------------~
USING THE SECOND JUMPER WIRE,

CONNECT FAN RELAY #3 HARNESS
CONNECTOR TERMINALS "J4" AND "J3."
DO THE FANS COME ''.ON"?
RECONNECT FAN RELAY #3.

DISCONNECT RIGHT FAN.
FAN HARNESS CONNECTOR TERMINAL "B".
IS THE LIGHT "ON"?
CONNECT THE SECOND JUMPER WIRE BETWEEN

FAN HARNESS CONNECTOR TERMINALS.
IS THE LEFT FAN "ON"?
FAULTY RIGHT FAN MOTOR CONNECTIONS

OR
FAULTY RIGHT FAN MOTOR.
6-30-93
PS 18463
6E3-C12-14 5.7L {VIN P) DRIVEABILITY AND EMISSIONS
PCM
TO
IGNITION
~~4
#6
{U/H)
FUSE LINK
11----,
10
AMP
402 RED
,----541
BRN
______
.......04
__.
409 LT BLU
COOLING FAN
(LEFT SIDE)
541 BRN COOLING FAN RELAY #1 {U/H)

532 BLK
541 BRN
~-...., J2
J3
J1
504 BRN
150 BLK
=!--
402 RED
504 BRN - - - - - .
150BLK
335
DKGRN
COOLING FAN RELAY #2 {U/H)
COOLING FAN
(RIGHT SIDE)
aoo
r,
-
DKBLU
~ - - - - - - - - - - - - - -.........
l~mK~'--~473DKBLU
~--------------------+<K~l---335DKGRN
LJ.J
{U/H)

&#3CONTROL
CONTROL
7-9-93
PS 18466
CHART C-128 {Page4of4)

{LATE PRODUCTION A/C)
5.7 {VIN P)
11
F" CARLINE {SFI)
473. When cooling fan relay #1 is energized the cooling fans are connected in series and operate together at low
1. It may be necessary to raise the vehicle and
observe the cooling fans from underneath during
this test. Both fans should operate at low speed
when "FAN CTRL PCM All" is activated. Both
fans should operate at high speed when "FAN
t' t d
to SECTION 68.
CTRL PCM Alo " isac
iva e
The PCM w1'11 command 1ow spee d 1ans
r
"ON" at
108C (226F) and "OFF" at 105 C (221 F) and, high
speed fans "ON" at 113C (235F) and "OFF" at 110C
<230F).
DRIVEABILITY AND EMISSIONS 5. 7L {VIN P) 6E3-C12-15
CHARTC-128
r------------,
: FROM CHART C-12 :

11 OF4.
I
{Page 4 of 4)
... ,-----------'
CDf:
I
USING TECH 1 ACTIVATE "FAN CTRL PCM A11".

WHILE OBSERVING FANS, ACTIVATE "FAN CTRL PCM A10".

CIRCUIT DIAGNOSIS
{LATE PRODUCTION A/C)
11
5.7L (VIN P)
BOTH FANS OPERATE (NO CHANGE).,
LEFT FAN STOPS OPERATING.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "A".
JUMPER RELAY HARNESS CONNECTOR
TERMINAL "D1" TO "D4".
IGNITION "ON."
PROBE PCM HARNESS CONNECTOR
TERMINAL" A 10" WITH A FUSED
JUMPER TO GROUND.
DO THE FANS SWITCH FROM LOW TO
HIGH SPEED?
~
CKT473 OPEN
OR
SHORTED TO B +.
RIGHT FAN STOPS OPERA TING.,

PROBE RELAY HARNESS
CONNECTOR TERMINAL" J2"
WITH A TEST LIGHT TO B +.
USING TECH 1 ACTIVATE "FAN
CTRL PCM A10".
IS THE LIGHT "ON"?
I
~
PROBE FAN
RELAY #3
HARNESS
CONNECTOR
TERMINAL" J1"
WITHA TEST
LIGHTTOB+.
IS THE LIGHT
"ON"?
FAULTY PCM
CONNECTIONS
OR
FAULTY PCM.
PROBE FAN
RELAY #3
HARNESS
CONNECTOR
TERMINAL
"J5"WITHA
TEST LIGHT TO
GROUND.
IS THE LIGHT
"ON"?
[$
CIRCUIT 473
OPEN
BETWEEN FAN
RELAY #3
AND SPLICE.
[!_]
CKT 150
OPEN.
FAN RELAY #31

FAULTY.
PROBE FAN
RELAY #2
HARNESS
CONNECTOR
TERMINAL "F2"
WITH A TEST
LIGHT TO
GROUND.
ISTHE LIGHT
"ON"?
CONNECTOR
TERMINAL "F4"
WITH A TEST
LIGHT TO
GROUND.
IS THE LIGHT
"ON"?
~
CIRCUIT 541
OPEN TO FAN
RELAY #3.
CIRCUIT473
OPEN
BETWEEN
FAN
RELAY #2
AND
SPLICE.
_]
~
PROBE
RELAY
CIRCUIT402
#2 HARNESS OPEN
BETWEEN
JUMPER
RELAY #2
HARNESS
CONNECTOR
TERMINAL
"F4"TO "F1 ".
ISTHE RIGHT
FAN "ON"?
~
FAN
RELAY #2
FAULTY.
6-30-93
PS17946
[$]
DISCONNECT FAN RELAY #2 .

PROBE RELAY HARNESS
CONNECTOR TERMINAL
"F5" WITH A TEST LIGHT TO
B+ .
"FAN CTRL PCM A10"
IS THE LIGHT "ON"?
F" CARLINE (SFI)
RELAY #2AND
FUSELINK.
]
CKT541 OPEN
TO FAN RELAY
#2.
[]
CIRCUIT 504
OPEN BETWEEN
FAN
RELAY #2 AND
SPLICE.
BLANK
SECTION C13
CRANKCASE VENTILATION SYSTEM

CONTENTS
General Description
Operation
Diagnosis
C13-1
C13-1
C13-1
C13-1
GENERAL DESCRIPTION
A "closed" crankcase ventilation system is used to
provide a more complete scavenging of crankcase
vapors. Fresh air from the air cleaner is supplied to
the crankcase, mixed with blow-by gases and then
passed through a crankcase ventilation valve into the
intake manifold (Figure Cl3-1).
Functional Check of Crankcase Ventilation

Valve ,
Functional Check of Crankcase
Ventilation Valve System
On-Vehicle Service
(13-1
C13-2
C13-2
OPERATION
The primary control is through the crankcase
ventilation valve (Figure Cl3-2) which meters the flow
at a rate depending on manifold vacuum.
To maintain idle quality, the crankcase
ventilation valve restricts the flow when intake
manifold vacuum is high. If abnormal operating
conditions arise, the system is designed to allow
excessive amounts of blow-by gases to back flow
through the crankcase vent tube into the engine air
inlet to be consumed by normal combustion.

A plugged valve or hose may cause:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Sludge in engine.
A leaking valve or hose would cause:
Rough idle.
Stalling.
High idle speed.
DIAGNOSIS
VENTILATION VALVE
c::> CLEAN AIR
-+
VOLATILE OIL FUMES
----- MIXTURE OF AIR AND FUMES
If an engine is idling rough, check for a clogged

crankcase ventilation valve or plugged hose. Replace
as required. Use the following procedure:
1. Remove crankcase ventilation valve from
rocker arm cover.
2. Run the engine at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at the valve
check for plugged hoses or manifold port,
crankcase ventilation valve. Replace plugged
or deteriorated hoses.
4. Turn "OFF" the engine and remove crankcase
ventilation valve. Shake valve and listen
the rattle of check needle inside the valve. If
valve does not rattle, replace valve.
oi'

2
TO THROTTLE BODY
3
4
CRANKCASE VENT HOSE

CRANKCASE VENTILATION VALVE HOSE
TO INTAKE MANIFOLD
SS 1725-6E
Figure C13-1 - Crankcase Ventilation Valve Flow

(Typical)
fo;
CHECK VALVE
45 0068-6E
Figure C13-2- Crankcase Ventilation Valve Cross

Section
With this system, any blow-by in excess of the

system capacity (from a badly-worn engine, sustained
heavy load, etc.) is exhausted into the intake manifold
and is drawn into the engine. Proper operation of the
crankcase ventilation system is dependent upon a
sealed engine. If oil sludging or dilution is noted, and
the crankcase ventilation system is functioning
properly, check engine for possible cause and correct to
ensure that system will function as intended.

VENTILATION VALVE SYSTEM
1.
2. Engine at normal operating temperature.

3. Block off crankcase ventilation system fresh air
. intake passage.
4. Remove engine oil dipstick and install a vacuum
gage on dipstick tube.
5. Run engine at 1500 RPM for 30 seconds then read
vacuum gage while at 1500 RPM.
If vacuum is present the crankcase ventilation
system is functioning properly. No vacuum
indicated the engine may not be sealed and/or is
drawing in outside air. Check valve cover, oil pan
gasket for leaks. If the vacuum gage registers a
pressure or the vacuum gage is pushed out of the
dipstick tube, check for the correct crankcase
ventilation valve, a plugged hose or excessive
engine blow-by.
ON-VEHICLE. SERVICE
An engine which is operated without any
crankcase ventilation can be damaged. Therefore, it is
important to replace the crankcase ventilation valve
at intervals shown in SECTION OB.
Periodically, inspect the hoses and clamps and
replace any showing signs of deterioration.
Check crankcase ventilation valve for correct

application.
5
6
!VIEWS!
2
3
4
5
6
7
CONNECTOR
GROMMET
INTAKE MANIFOLD
CRANKCASE VENTILATION PIPE ASSEMBLY
CRANKCASE VENTILATION HOSE
THROTTLE BODY
PS 17339
Figure C13-3 - Crankcase Ventilation System
SECTION C14
AIR INTAKE SYSTEM

CONTENTS
General Description
Air Intake System
On-Vehicle Service
. .... . . . . . . .. .
~
. , ..........
(14-1
(14-1
(14-1
Air Filter Element/Air Cleaner
Assembly
(14-1
GENERAL DESCRIPTION
AIR INTAKE SYSTEM
Outside air is drawn through the air filter
element. The air cleaner is remotely mounted (refer to
Figure C14-1). The air passes through the Mass Air
Flow (MAF) sensor, and the intake duct to the throttle
body. The air then flows into the intake manifold,
through the cylinder heads and into the cylinder.
ON-VEHICLE SERVICE
AIR FILTER ELEMENT/AIR CLEANER

ASSEMBLY

1. Loosen clamp at air intake duct at throttle body.
2. IAT and MAF electrical connectors.
3. Retainer from upper radiator support.
4. Hose from air intake duct.
5. Disconnect air intake duct from throttle body.
6. Slide air cleaner housing up and air intake duct as
a whole assembly.
7. Release latches from air cleaner housing.
8. Air filter element.

1.
2.
3.
4.
5.
6.
7.
Air filter element into air cleaner housing.

Snap air cleaner latches into place.
Slide air cleaner assembly into retainers.
Air intake duct to throttle body and tighten clamp.
IAT and MAF electrical connectors.
Retainer to upper radiator support:
Hose to air intake duct.
2
3
RETAINER
AIR CLEANER ASSEMBLY
5
6
FRONT AIR INTAKE DUCT

UPPER RADIATOR MOUNTING PANEL
PS 17794
Figure C14-1 -Air Intake Components
rn
Important
If the Mass Air Flow (MAF) sensor is installed

backwards, the system will go rich. An arrow
cast into the plastic portion of the sensor
indicates proper air flow direction. The arrow
must point toward the engine.
AIR CLEANER OUTLET DUCT (WITHIAT SENSOR)
PS17795
Figure C142 Air Intake Components
DRIVEABILITY AND EMISSIONS 5.7t (VIN P) INOEX-1
PAGE
SECTION
SECTION
PAGE
Chart C-5:
Chart C-6:
Secondary Air Injection
System Check _
Chart C-7:
Exhaust Gas Recirculation (EGR)
.. .... .
Acceleration Mode
C2-2
A/C Clutch Circuit
General Description .
Cl0-1
Cl0-1
Diagnosis
On-Vehicle Service
Cl0-1
Cl0-4
Chart C-10 .,.
A/C Request Signal
General Description
Cl-7
Diagnosis _.,'. _,, . C1-9
C14~1
Air Cleaner .
C14-1
Air Intake System
C8-1
... .. . ... . ... . .. .. . . .
Backfire
Before Starting
8-16
C2-2
B-2
c
ChartA~1:
No Malfunction Indicator Lamp
(MIL)

ChartA-2:
Output/Field Service Enable Circuit
ChartA-3:
ChartA-5
Fuel Pump Relay Circuit
Chart A-7:
Chart B-1:
Restricted Exhaust System Check ,
Chart C-1A:
Park/Neutral Position Signal
Diagnosis
Chart C-1D:
Map Output Check
Chart C-2A:
Injector Balance Test
Chart C-2C:
Idle Air Control (IAC) Valve Check
Chart C-3:
EVAP Canister Purge Valve Check
Chart C-4A:
Distributor Ignition (DI)
System Check
Chart C-48:
Misfire Check
.........
. ..
Check
Chuggle
A-24
A-26
A-30
A-30
, ~
ChartC-8A:
Assembly Circuit Check
Chart C~8B:
Performance Mode Switch Indicator Lamp
Control Circuit Check
Chart C-8C:
Performance Mode Switch Signal
Circuit Check
ChartC-10:
A/C Clutch Circuit Diagnosis
Chart C-12A:
Electric Cooling Fan Contro.l Circuit
Chart ~-128:
Ele4tric Cooling Fan Control
Cir::<uit Diagnosis
Clear Flood Mode

''Closed Loop"
Component Location
General Description
Diagnosis
Service .
Cuts Out
... . . . . . . . . . .. .. . . . . .
CS-4
CG-6
C7-4
C8-10
(8-12
(8-14
Cl0-4
C12-4
C12~8
B-6
C2-1
C2-2
A-3
C13-1
C13-1
C13-2
8-10
A-32
D
8-17
C1-16
Cl-18
C2-l7
C2-24
C3-6
C4-4cb
C4-8
. ..... ...
Data Link Connector.(DLC)

Deceleration Mode
Detonation
Diagnosis Procedure
Dieseling
Distributor Ignition (DI) System
Operation
Diagnosis
DTC 41
DTC 42
ChartC-4A
Chart C-48
Setting Timing
. .. . . . . . . . . . . . . . . .
. . . . . . . . . ... . . . . ...
. . . . . . .. . . . . . . . . . . .
. .. . . . . . . . . . . . .
A-4
C2-2
B-8
6E2-3
B-15
C4-1
C4-2
C4-2
A-84
A-86
C4-4
C4-8
C4-2
(4-2
2-INDEX 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

SECTION
Distributor Reference Signal
General Description
Diagnosis
DTC 11
DTC 13
DTC14
DTC15
DTC16
DTC18
DTC21
DTC22
DTC23
DTC24
DTC25
DTC26
DTC27
DTC28
DTC29
DTC32
DTC33
DTC34
DTC36
DTC37
DTC38
DTC41
DTC42
DTC43
DTC44
DTC45
DTC46
DTC47
DTC48
DTCSO
DTC51
DTC53
OTC SS
DTC58
DTC59
DTC61
DTC63
DTC64
DTC65
DTC66
DTC67
DTC68
DTC69
DTC70
DTC71
DTC72
...
.... . . . . ..
. . . .. . . . . .
... ..
........
........ ..
...
........
.. .
....
.. . . . . . . . . .
. ..
. . ... ..
...
..........
....
....
.......... . .........
...................
....
...... ... . . ......
. . . . . . . .. . . . . . . .
..........
...... ..
.. .
..........
..........
......... .
.. .
.. .
..............
...
.......... ......
........... . ..
PAGE
C1-7
C1-9
A-40
A-42
A-44
A-46
A-48
A-50
A-52
A-54
A-56
A-58
A-60
A-62
A-64
A-66
A-68
A-70
A-74
A-76
A-78
A-80
A-82
A-84
A-86
A-88
A-90
A-92
A-94
A-96
A-98
A-100
A-103
A-104
A-106
A-108
A-110
A-112
A-114
A-116
A-118
A-120
A-122
A-124
A-126
A-128
A-130
A-132
SECTION
PAGE
DTC73
DTC74
DTC75
DTC77
DTC79
DTC80
DTC81
DTC82
DTC83
DTC84
DTC84
DTC85
DTC90
DTC91
DTC97
DTC99
A-134
A-136
A-138
A-140
A-142
A-144
A-146
A-148
A-150
A-152
A-154
A-156
A-158
A-160
A-162
A-164
. . ... . . . . . . . . . . . .
....
. ....
.....
E
EEPROM
General Decription
On-Vehicle Service
Functional Check
DTC51
Electric Cooling Fan System
General Description
Operation
Diagnosis
On-Vehicle Service
Engine Component Locations
Connector Terminal End View
OnNehicle Service
Wiring Diagram
Engine Coolant Temperature Sensor
General Description
Diagnosis

On-Vehicle Service
DTC 14
DTC 15
EVAP Canister Hoses
EVAP Canister Purge Valve Check
Evaporative Emission Control System
General Description
Diagnosis
Chart C-3
On-Vehicle Service
Exhaust Emissions Excessive (Odors)
...
C1-2
Cl-10
C1-12
A-103
C12-1
C12-1
C12-4
C12-1
A-3
A-12, 15
Cl-10
A4-A9
Cl-3
Cl-8
Cl-10
A-44
A-46
A-30
C3-3
C3-2
C3-6
C3-1
C3-2
C3-6
C3-2
B-14
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) INDEX-3

SECTION
PAGE
Exhaust Gas Recirculation (EGR) System
General Description
EGR Valve Identification
Diagnosis
EGRCheck
DTC32
Chart C-7
On-Vehicle Service
Exhaust System Check (Restricted)
. . . . . . .. . . .
C7-1
C7-1
C7-2
C7-2
C7-4
A-70
C7-4
C7-2
B-17
F
Fan, Electric Cooling
Fuel Cutoff Mode
Fuel Injectors
Fuel Meter Body Assy.

Fuel Meter Cover Assy.
General Description
Diagnosis
Chart A-7
On-Vehicle Service

Fuel Pump Relay
Fuel System Pressure Test
C12-1
C2-2
C2-3
C2-11
C2-9
C2-1
C2-5
A-34
C2-6
C2-14
C2-2
C2-5
C2-6
A-34
A-38
6E3-2
H
Hard Start
General Description
Diagnosis
On-Vehicle Service
DTC 13
DTC44
DTC45
Hesitation
PAGE
. ........... .

Diagnosis
On-Vehicle Service
Ignition Control
General Description
Diagnosis
On-Vehicle Service
DTC41
DTC42
Chart C-4
Incorrect Idle
Information Sensors
lntermittents
Introduction
. ...
C2-5
C2-24
C2-13
C4-1
C4-2
C4-2
A-84
A-86
C4-4
8-11
C1-3
8-3
6E3-2
K
Knock Sensor System
Diagnosis
On-Vehicle Service
KS System Check
DTC41
DTC42
DTC43
. . .. . . . . . . . . . . . . . . . .
CS-1
CS-1
CS-1
CS-4
A-84
A-86
A-88
L
Lack of Power
B-7
G
General Description
SECTION
B-5
C1-4
(1-8
C1-13
A-42
A-90
A-92
B-9
Malfunction Indicator Lamp

MAP Sensor
Diagnosis
On-Vehicle Service
DTC 33
DTC34
ChartC1-D
Misses
...
...
.. .
A-26
(1-3
C1-8
C1-12
A-74
A-76
C1-18
B-10
N
Negative 8ackpressure EGR Valve
No Malfunction Indicator Lamp
C7-1
A-26
0
IATSensor
Diagnosis
On-Vehicle Service
DTC23
DTC25
.. . .
C1-4
(1-8
C1-13
A-56
A-60
Odors From Exhaust System

Engine Oil Pressure Indicator Switch
On-Board Diagnostic (OBD) System Check
Open Loop
B-14
(2-6
A-16
C2-2
4-INDEX 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

SECTION
PAGE
PAGE
SECTION
Park/Neutral Position Signal

General Description
Diagnosis
On-Vehicle Service
Chart C-1A
PCM Pin Connector "A"
Symptoms Chart
PCM Pin Connector "B"
Symptoms Chart
PCM Pin Connector "C"
Symptoms Chart
PCM Pin Connector "D"
Symptoms Chart
Personal Automotive Security System
Poor Fuel Economy
Positive Backpressure EGR Valve
General Description
Function
... . . . ... . ..... ...
Diagnosis
C1-7
C1-9
C1-14
C1-16
B-18
8-20
8-22
8-24
A-94
8-13
C7-2
C1-1
C1-2
C1-7
Throttle Body Unit

General Description
Service
Throttle Position Sensor
Diagnosis
On-Vehicle Service
DTC21
DTC22
Transmission Fluid Temperature
(TFT) Sensor
Switch Assembly
Typical Tech 1 Data Definitions
. .. . . . . . . . . . . .. . . . . . .
Unstable Idle
Sag ~
Scan Data
General Description
Diagnosis
On-Vehicle Service
OTC 26
Stumble
Surges
B-11
C1-7
8-17
8-11
C2-2
8-15
Vehicle Speed Sensor

General Description
Diagnosis
B-9
A-18
Wiring Diagrams
DTC 24
C6-1
C6-2
C6-3
A-62
C6-6
C1-3
C4-2
8-7
B-8
B-7
8-11
C2-1
8-9
8-6
(1-6
(1-10
A-58
Chart C-6
Sensor Information
Setting Timing
SI uggish
Spark Knock
Spongy
Stalling
Starting Mode
(8-2
A-20
A-18
Reference Signal
Restricted Exhaust System
Run On
C8-1
Rough Idle
Run Mode
C2-3
C2-6
(1-5,
C2-5
(1-9
C1-14,
C2-12
A-52
A-54
A4,A9
ELECTRICAL DIAGNOSIS SA - CONTENTS
SECTION SA
ELECTRICAL DIAGNOSIS
1994 CHEVROLET, PONTIAC
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section gJ under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR components
or wiring. Failure to follow CAUTIONS could result in possible air bag deple>yment,
personal injury, or otherwise unneed.ed SIR system repairs.
SA
SECTION
1
Chevy
Camaro
Pontiac
l'irebird
INDEX
y
y
INTRODUCTION
SYMBOLS
TROUBLESHOOTING PROCEDURES
REPAIR PROCEDURES
VEHICLE ZONING
POWER DISTRIBUTION
.,
SECTION CONTENT
10
11
FUSE BLOCK DETAILS
14
GROUND DISTRIBUTION
15
RETAINED ACCESSORY POWER (RAP): WITH AU3
20
SEQUENTIAL MUL TIPORT FUEL INJECTION: VG VIN S (3.4L L32)
21
SEQUENTIAL MULTIPORT FUEL INJECTION: VS VIN P (5.7L LT1)
30
STARTER AND CHARGING
31
COOLANT FANS
y
y
y
'
ENGINE COOLANT HEATER (KOS)
33
34
CRUISE CONTROL (K34)
39
ELECTRONIC TRANSMISSION CONTROLS (M30)
40
HORNS
41
BRAKE WARNING SYSTEM
44
ANTILOCK BRAKES/TRACTION CONTROL (NW9)
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
y
y
32
47
50
DATA LINK CONNECTOR (DLC): PIN ASSIGNMENT
60
HEATER (C41)
61
DEFOGGER (C49)
HVAC BLOWER CONTROL (CGO)
HVAC COMPRESSOR CONTROL (CGO)
65
HVAC AIR DELIVERY AND TEMPERATURE CONTROL (REFER TO SECTION 1 B)
76
AUDIBLE WARNINGS: TONE
81
INSTRUMENT CLUSTER: WITH GAGES
89
STEERING WHEEL CONTROLS: RADIO (UK3) (REFER TO SA-150-1)
NIA
y
y
63
64
91
WIPER/WASHER: PULSE
100
HEADLIGHTS AND FOG LIGHTS: WITHOUT DRL {T61)
102
HEADLIGHTS AND FOG LIGHTS: DAYTIME RUNNING LIGHTS (T61)
(CONTINUED ON NEXT PAGE)
SA- CONTENTS ELECTRICAL DIAGNOSIS
(CONTINUED FROM PREVIOUS PAGE)

SA
SECTION
SECTION CONTENT
Chevy
Camaro
Pontiac
Firebird
N/A
y
y
104
HEADLIGHT DOORS
110
EXTERIOR LIGHTS
112
BACKUP LIGHTS
114
INTERIOR LIGHTS
117
INTERIOR LIGHTS DIMMING
120
POWER WiNDOWS (A31)
121
CONVERTIBLE TOP
130
POWER DOOR LOCKS (AU3)
132
KEYLESS ENTRY (AUO)
133
THEFT DETERRENT SYSTEM: PASS-Kevn
135
HATCH RELEASE (A90)
138
BRAKE TRANSMISSION SHIFT INTERLOCK (AUTOMATICTRANSMISSfON)
140
POWER SEAT: DRIVER 6-WAY (AC3)
141
POWERSEATS: ULTIMA(AQ9)
147
150
N/A
POWER MIRRORS (DG7)
RADIO
200
SERVICE PARTS INFORMATION
201
COMPONENT LOCATION VIEWS
202
HARNESS CONNECTOR FACES
203
HARNESS ROUTING VIEWS
ELECTRICAL DIAGNOSIS SA- CONTENTS
BLANK
SA -
1-0
ELECTRICAL DIAGNOSIS .
INDEX
PAGE
ABS Brake Pressure Valve Solenoids
. . . ..
ABS Motor Pack . . . . . . . .

ABS Relay
.......... , ...
Adjuster Assembly .........

Air Conditioning
A/C Clutch Diode (VG VIN S) ...
A/C Clutch Diode (V8 VIN P) ......
A/C Compressor Clutch
A/C Compressor Relay
A/C Evaporator Temperature Sensor
A/C Refrigerant Pressure Sensor ...
Air Pump Relay ..........
Ambient Light Sensor ........
Amplifier (part of UW2 Speaker Option)
Antenna .........
Anti lock Brakes .........

Arming Sensor, Dual Pole ......
Ashtray Lamp ......
Audible Warnings ....
Audio Alarm Module ....
Backup Lights ... ; ...
Backup Lamps .....
Backup Light Switch ...
Blower Motor ......
Blower Resistor
.....
Blower Switch (C41) .....

Blower Switch (CGO) ....
Bose Relay .......
Brake Combo Valve (ABS) .....
Brake Switch Assembly .........
Brake Transmission Shift Interlock ....
Brake Transmission Shift Interrupt Solenoid .
Brake Warning System ..... '..
44-0,
44-2
44-1,
44-2
44-1,
44-3
44-3
64-0
64-1
64-0,
64-1
64-0,
64-1
64-0,
64-1
64-0,
64-1
11-11
102-0,
102-2
150-5
150-0,
150-3,
150-5
44-0
47-1
117-1,
117-3
76-0
76-0
112-0
112-0
112-0
60-0,
63-0
60-0,
63-0
60-0
63-0
150-2
44-0,
44-2
110-1
138-0
138-0
41-0
PAGE
Camshaft Position Sensor (VG VIN S) . . . .
Center High Mounted Stop Light (CHMSL) .
Cigar Lighter . . . . . . . . . . . . . .
Circuit Breaker Details
#12 DEFOG/Seats .........
#15Windows .......
Clutch Anticipate/Cruise Release Switch ..
Clutch Start Switch .......
Component Location Views .........
Console Compartment Lamp ........
Convenience Center ............
Convertible Top Pump Assembly ........
Convertible Top Switch .......
Coolant Fan, Primary .............
Coolant Fan, Left ... ; .........
Coolant Fan, Right ............
Coolant Fan, Secondary ..........
Coolant Fan (VG VIN S) ............
Coolant Fan(s) (V8 VIN P) ..... "! ...
Coolant Level Latching Module ........
Courtesy Lamp, LR .........
Courtesy Lamp, RR .........
Crankshaft Position Sensors (VG VIN S)
Cruise Control ..........
Cruise Control Module ............
Cruise Release Brake switch (all with K34)
Cruise Release Clutch Switch
(V8 Manual with K34, 2 pin) .
Data Link Connector (DLC) ......
Daytime Running Lights (DRL) Module ..
Defogger (C49)
..............
Diagnostic Energy Reserve Module (DERM)

Discriminating Sensor, Forward .......
Discriminating Sensor, Passenger
Compartment ...........
Distributor ........
Dome Lamp .............
Door Illumination Lamps .....
Door Jamb Switches .......
20-1
110-1
114-0,
114-1
11-7
11-9
20-7
30-0
201-0
114-0,
114-1
76-1
121-0
121-0
31-1
31-2
31-2
31-1
31-0
31-1,
31-2
81-3
114-1
114-1
20-1
34-0
34-0,
34-1
34-0
34-0
50-0
102-0,
102-1
61-0,
61-1
47-0,
47-1
47-1
47-1
21-1
114-0
117-1
114-0,
114-1
ELECTRICAL DIAGNOSIS SA -
PAGE
Doer Lock Actuators .....
Electronic Brake Control Module (EBCM)
Electronic Brake/Traction Control
Module (EBTCM) .............
Engine Controls (VG VIN S)

Engine Controls (V8 VIN P)
Engine Coolant Heater (KOS) .
Engine Coolant Level Sensor (V8 VIN P) ..
(VG VIN S) .................
(V8 VIN P) .
Engine Coolant Temperature Gage Sensor
Purge Solenoid Valve (VG VIN S) ......
Purge Solenoid Valve (V8 VIN P) .....
Exhaust Gas Recirculation (EGR) Vacuum
Control Signal Solenoid Valve (VG VIN S)
Contro.1 Signal Solenoid Valve (V8 VIN P)
Express Down Module ...........
Exterior Lights .....
Fog Lights
Fog Lamps ................
FogLamps(T61) ............
Fog Light Relay .........
Fog Light Relay (TG 1) ......
Fog Light Switch .....
Fog Light Switch (TG 1) ....
Forward/Back Motor (AC3 Power Seat)
Front Height Motor (AC3 Power Seat)
Fuel Gage Sender .........
Fuel Injectors (VG VIN S) ...
Fuel Injectors (V8 VIN P) ....
Fuel Pump ..........
Fuel Pump Relay (VG VIN S) ......
Fuel Pump Relay (V8 VIN P) ..
Fuse Block Details .........
#1 Air Bag ............
130-0
44-0,
44-1
44-2,
44-3,
44-4
20-4
21-4,
21-5
32-0
81-3
20-4
21-4
81, 1
20-5
21-5
20-5
21-5
120-0
110:0
100-1
102-4,
102-5
100-1
102-4,
102-5
100-1
102-4,
102-5
140-0
140-0
81-2
20-3
21-3
81-2
20-2
21-2
11-0
11-5
1-1
PAGE
#2 TURN B-U . . . . . . 11-6
#3 HVAC . . . . . 11-6
#4 PCM BAT .. . .. .. .. .. .. .. 11-7
#5 PCM IGN . . . 11-5
. #6 Stop/Hazard . . . . . . . . . . . . . . 11~7
#7PWRACCY ........ 11-8
#8 Courtesy . . . . . . . . . 11-7
#9 Gages . . . . . . . . . . . . 11-5
#10 TAIL LTS . . . . 11-7
#11 Cigar/Horn . . . . . . . . . 11-8
#12 DEFOG/Seats Circuit Breaker 11-7
#131/P Dimmer .. , . . . 11-9
#14 Wiper/Wash . . . . . . 11-9
#15 Windows Circuit Breaker . . . . . 11-9
#16Crank ........... 11-9
#17 Radio ......... 11-9
Fusible Links .. . .. .. .. .. .. .. .. .. 10-0
Gages . . . . . . . . 81-0
Coolant Temperature . . . . .. 81-1
Oil Pressure . . . . . . 81-0
Speedometer . . . . . . 81-0
Tachometer ...... , ; . . 81-q;.\
Voltmeter . . . . . . . . 81-0.
Generator . . . . 30-1
Ground Distribution . . . . 14-0
Harness Connector Faces . . . . 202-0
Harness Routing Views . . . 203-0
Hatch Release (A90) . . . . . . . . . . . 135-0
Hatch Release Actuator . . . . . . . . . . 135-0
Hatch Release Relay . . . . . . . 135-0
Hatch Release Switch . . . . . 135-0
Hazard Flasher . . . . . . . . . . . . 110-0
Headlight Doors . . . . . . . . . . . . . . . 104-0
Headlamp Door Motor Assembly . . . . 104-0
Headlight Doors Module . . . . . . .104-0
Headlight Doors Module . . . . . . . . . . 104-0
Headlights
With (T61) Daytime Running Lights .. 102-0
Without (T61) Daytime Running Lights ... 100-0
Headlight Dimmer Switch (without T61)
100-0,
Headlight Dimmer Switch (with T61)
..
Headlight Switch (without T61) ..

Headlight Switch (with T61) ....
Heated Oxygen Sensor, Bank #1
...
Heated Oxygen Sensor, Bank #2 .....
100-2
102-1,
102-3
100-0
102-1
21-5
21-5
SA -
1 - 2 ELECTRICAL DIAGNOSIS
INDEX
PAGE
PAGE
Heater (C41) .........
HE!aterNent/Air Conditioning (HVAC)
Control Assembly ......
High Blower Relay .....
Horns ..............
Horn Relay ......
Horn Switch ........
Horn # 1 (A note) .....
Horn #2 (F note) .....
HVACSystem
Air Delivery and Temperature Control .
Blower Control (C60) ....
Compressor Control (C60) ..........
Hydraulic Modulator Assembly ......
1/P:Compartment Lamp ........
1/P.Dimmer Switch ........
1/P Fuse Block ............
Idle Air Control (IAC) Valve (V6 VIN S) ...
Idle Air Control (IAC) Valve (VB VIN P)
Ignition Coil Module (VB VIN P) .
Ignition Coil (VB VIN P) ..
Ignition Control Module (V6 VIN S) ....
Ignition Key Lock Cylinder . , ....
Ignition Key Warning Switch .
Ignition Switch .
Indicators
ABS INOP
Air Bag .....
Brake ...
Check Gages ..
Fasten Seat Belts .
High Beam ...
Left Turn .
tow Coolant ...
Low Oil ..........
LOW TRAC .... , .
Right Turn ...
Security .......
Service Engine Soon ......
lnflator Module, Driver .
lnflator Module, Passenger ..
Instrument Cluster ..
(V6 VIN S) ..........
(V8 VIN P) ........
60-0
Interior Lights
63-0
63-0
40-0
40-0
40-0
40-0
40-0
Interior Lights Dimming . . . . . . . . . . . . . .
Sec 1B
63-0
64-0
44-0,
44-1
114-0
117-0
11-0
20-5
21-3
21-1
21-1
20-1
133-1
76-0
10-2,
10-3
81-1
81-3
81-3
81-1
81-3
81-3
81-3
81-3
81-1
81-3
81-3
81-2
81-3
47-1
47-1
81-0
.. .. . . . . .. . . . . . .. .
Introduction . . . . . . . . . . . . . . . . .
Isolation Diode (BTSI) . . . . . . . . . . .
Isolation Diode (RAP) . . . . . . . .
Isolation Diode (Wipers) . . . . . . .
Keyless Entry . . . . . . . . . . . .
Keyless Entry Receiver . . . . . . .
Knock Sensor (V6 VIN S) . . . . . . . . . .

Knock Sensor (VB VIN P) . . . .
License Lamp .....................
Lights (Exterior)
Backup ........
Fog ...............
Front Marker .......... ;.
Headlights ...........
License
Park/Turn ............... .
Rear Marker
Tail/Stop/Turn
Lights (Interior)
Courtesy Lamp, LR . . . . .
Courtesy Lamp, RR . . . . . . . . .
Dome . . . . . . . . . .
Door Illumination . . . . . .
1/PCompartment .. .. .. .. .. .. .. ..
Interior Lights Dimming . . . . . . . . . . .
Rear Compartment Lamp . . . .
(VG VIN S) . . . . . . . . . . . . .
(V8 VIN P) . . . . . . . . . . . . . . . . .
Marker Lamps, Front . . . . . . . . . . .
Marker Lamps, Rear . . . . . . .
20-4
MassAirFlow(MAF)Sensor ...
21-4
114-0,
114-1
117-0,
117-2
2-0
138-0
15-0
91-0
132-0
132-0,
132-1
20-4
21-4
110-4,
110-5
112-0
100-1,
102-4
110-2,
110-3
100-0
110-4,
110-5
110-2,
110-3
110-4,
110-5
110-4,
110-5
114-1
114-1
114-0
117-1
114-0
117-0
114-1
20-4
21-4
110-2,
110-3
110-4,
110-5
21-5
ELECTRICAL DIAGNOSIS SA - 1 - 3
PAGE
Mirror Motor Pack
Modules
Audio Alarm
Coolant Level Latching .........
Cruise Control ....
Daytime Running Lights
Diagnostic Energy Reserve .......
Electronic Brake Control Module
147-0,
147-1
76-0
81-3
34-0,
34-1
102-0,
102-1
47-0,
47-1
44-0,
44-1
Electronic Brake/Traction Control

Module (EBTCM) . . . . . . . . . . . . . . . . . . . . . 44-2,
44-3,
44-4
Express Down ....... 120-0
Headlight Doors ..... 104-0
Ignition Coil ..... 21-1
Ignition Control Module (VG) 20-1
lnflator ............ 47-1
Power Seat Control ...... 141-0
Powertrain Control Module (VG) .... 20-0
Powertrain Control Module (V8) .. 21-0
Retained Accessory Power ..... 15-0
Theft Deterrent ......... 133-1
Windshield/Wiper Motor ...... 91-0
Motors
Blower ... 60-0,
63-0
Headlamp Door .... 104-0
Power Mirror (DG7} ......... 147-0,
147-1
Power Seat (AC3) .... 140-0
Starter .. 30-1
Washer.Pump ... 91-0
Window .... 120-0
Wiper ... 91-0
Multi-Function Lever ..... 34-0
Oi I Level Sensor ... 81-1
81-0
Oil Pressure Sensor
Outside Mirrors ....... 147-0,
147-1
Oxygen Sensors (VG VIN S) .... 20-4
Oxygen Sensors, Heated (V8 VIN P) .. 21-5
Park Brake Switch ........ 41-0
PAGE
Park/Turn Lamps
.......
Performance Switch . . . . . . .
Performance/Traction Control Switch .
Power Distribution .....
Power Door Locks (AU3) ..
Power Door Lock Switch, LH ...
Power.Door Lock Switch, RH .....
Power Mirrors (DG7) ...
Power Mirror Switch
Power Seat (AC3)
Power Seat Actuator Assembly (AC3)
Power Seat Motor (AC3) ...
Power Seat Switch (AC3) ..
Rear Height Motor (AC3) .
Power Seats (AQ9)
Power Seat Control Module
(AQ9 Power Seat) ..
Pi::>wer Seat Switch, Driver (AQ9) .
Power Seat Switch, Passenger (AQ9)
Pump Assembly (AQ9) ....
Solenoid Valve Assembly (AQ9)
Powertrain Ignition Control Module
(VG VINS) .....
Powertrain Control Module (PCM) (VG VIN S)
Powertrain Control Module (PCM) (V8 VIN P)
Power Windows (A31) ...
Power Window Switch, LH .
Power Window Switch, RH .
PRNDL Illumination Lamp (Auto Trans)
Radio ......
Rear Compartment Lamp ....
Rear Defogger ...
Rear Defogger Switch ......
Rear Defogger Switch/Timer ..
Rear Defogger Timer/Relay ..
Rear Dome Light Switch ..
Rearview Mirror .
Relays
A/C Compressor
....................
110-2,
110-3
39-1
39~1,
44-4
10-0
130-0
130-0
130-0
147-0,
147-1
147-0,
147-1
140-0
140-0
140-0
140-0
141-0
141-0
141-t
141-0
141-0,
141-1
20-1
20-3
21-0
120-0
120-0
120-0
117-1
150-0
114-1
61-0,
61-1
61-1
61-0
61-1
114-0
114-0,
114-1
64-0,
64-1
SA -
INDEX
PAGE
PAGE
ABS ..........
Air Pump .........
Bose ..
Coolant Fan #1 .............
Coolant Fan #2 ............
Coolant Fan #3 .....
Coolant Fan, Primary .........
Coolant Fan, Secondary ..........
Fog Lights ..........
Fog Lights (T61) ............
Fuel Pump (V6 VIN S) .
Fuel Pump (VS VIN P) ...
Hatch Release ..
High Blower .........
Horn .............
Theft Deterrent ...........
Repair Procedures .....
B,tained Accessory Power (RAP) Module
Reverse Lockout Solenoid (VS VIN P Manual)
Seat Belt Switch ..........
See:ondary Air Injection Pump Assembly
(V6 VIN S) ..........
Secondary Air Injection Pump Assembly
(VS VIN P) ..........
Selector Switch (C41)
Selector Switch (C60)
Sensors
A/C Evaporator Temperature .......
A/C Refrigerant Pressure
....
Ambient Light ...

Arming, Dual Pole ....
Camshaft Position
Crankshaft Position ...
Discriminating Sensor, Forward .
Discriminating Sensor, Passenger .
Engine Coolant Temperature (V6 VIN S) .
Engine Coolant Temperature (VS VIN P) .
Heated Oxygen Sensor, Bank #1 ...
Heated Oxygen Sensor, Bank #2 ..
Intake Air Temperature (V6 VIN S)
Intake Air Temperature (VS VIN P) ....
44-1,
44-3
11-11
150-2
31-2
31-2
31-2
31-0,
31-1
31-1
100-1,
100-3
102-4,
102-5
20-2
21-2
135-0
63-0
40-0
30-0
5-9
15-0
21-7
76-0
20-5
21-3
60-0
63-0
64-0,
64-1
64-0,
64-1
102-0,
102-2
47-1
20-4
20-4
47-1
47-1
20-4
21-4
21-5
21-5
20-4
21-4
Knock (V6 VIN S) . . . . . . . . .

Knock (V8 VIN P) . . . . . . . .
Manifold Absolute Pressure (V6 VIN S)
Manifold Absolute Pressure (VS VIN P)
MassAirFlow(MAF) ......
Oil Level . . . . . . . .
Oil Pressure . . . . . . . . .
Oxygen (V6 VIN S) . . . . . . . . .
Throttle Position Sensor (V6 VIN S) . .
Throttle Position Sensor (V8 VIN P) . . .
Vehicle Speed . . . . . . . . . . . . . .
Wheel Speed . . . . . . . . . . .
Service Parts Information . . . . . .
SIR Coil Assembly . . . . . . . . .
Solenoids
ABS Brake Pressure Valve . . . . . . . . .
Brake Transmission Shift Interrupt (BTSI)
Canister Purge (V6 VIN S) ... , ,..
Canister Purge (V8 VIN P) . ,,, .
Reverse Lockout . . . . . . . . . . . .
Starter ................. .
Speakers
Left Front (Base - UQO) .... ,....
Left Front Midrange (with UW2 Speakers)
Left Front Tweeter (with UW2 Speakers)
Left Rear (Base - UQO) . . . . .
Left Rear Subwoofer (with UW2 Speakers)
Left Rear (with UW2 Speakers) . . . .
Right Front (Base - UQO) . . . . . . . . . .
Right Front Midrange (with UW2 Speakers)
Right Front Tweeter (with UW2 Speakers)
Right Rear (Base - UQO) . . . . . . . . . .
Right Rear Subwoofer (with UW2 Speakers)
Right Rear (with UW2 Speakers) . .
Speaker/Amp, Left Front (Bose) . .
Speaker/Amp, Rear (Bose) . . . . .
Speaker/Amp, Right Front (Bose) .
Starter and Charging . . . . . . . . . . . .
'
Starter Motor
Starter Solenoid ..........
Steering Wheel Controls, Radio (UK3)
Supplemental Inflatable Restraints .
Switches
Backup Lights ............
Blower (C41) ..........
Blower (C60) ...............
.....................
20-4
21-4
20-4
21-4
21-5
81-1
81-0
20-4
20-4
21-4
33-0
44-1,
44-4
200-0
47-1
44-0,
44~2
138-0
20-5
21-5
21-7
30-1
150-0
150-4
150-4
150-0
150-5
150-5
150-0
150-4
150-4
150-0
150-5
150-5
150-3
150-2
150-3
30-0
30-1
30-l
150-1
47-0
112-0
60-0
63-0
ELECTRICAL DIAGNOSIS 8A -
PAGE
Brake .... ,. . . . . . 41-0
Clutch Anticipate/Cruise Release . . 20-7
Clutch Start . . . . . . 30-0
Convertible Top . . 121-0
Cruise Release Brake . . . . . . . 34-0
Cruise Release Clutch . . 34-0
Door Jamb . . . . . . . , 114-0,
Hatch Release . . . . . .
Headlight ..........
Headlight Dimmer ......
Ignition .. ,.... ,. .....

Ignition Key Warning ..
Park Brake ....
Performance .. ,, ...
Performance/Traction Control .
Seat Belt ...
Traction Control
Transmission Position (for Backup Lights)
Transmission Position (VG VIN S) .
Transmission Position (VS VIN P) ,
Symbols ......
Taillamps .... ~ ..
Tail/Stop/Turn Lamps ..
...............
Theft Deterrent Module

Theft Deterrent Relay . . . . . .
Theft Deterrent System . . . .
Throttle Position (TP) Sensor (VG VIN S) . . .
Throttle Position (TP) Sensor (V8 VIN P) . . .
Traction Control Motor Pack . . . . . .
Traction Control Switch . . . . . . .
Transmission Position Switch
(for Backup Lights) . . . . . . .
Transmission Position Switch (VG VIN S)
Transmission Position Switch (V8 VIN P)
Troubleshooting Procedures . . . . .
Turn Flasher . . . .
Turn/Hazard Switch Assembly . . . .
Underhood Electrical Center Fuse Details
#1 ABS . . . . . . .
'
'
114-1
135-0
100-0,
102-1
100-0,
100-2,
102-1,
102-3
10-2,
10-3
76-0
41-0
39-1
39-1,
44-4
76-0
44-4
112-0
20-6
21-6
3-0
110-4,
110-5
110-4,
110-5
~ 33-1
30-1
133-0
20-4
21-4
44-3
44-4
112-0
20-6
21-6
4-0
110-0
110-0
11-10
1- 5
PAGE
#2 FOG LP ...
#3 R-HDLP DR .......
#4 L-HDLP DR ...........
#SASS IGN
.. ,...
#6 FANS/ACTR . ~ ..........
#7 Air Pump ......
#9 Injector (VG VIN S) .....
#9 Injector (V8 VIN P) .......
#10 Injector (VG VIN S) .......
#10 Injector (VS VIN P) ......
#11 Ignition ........
#12 A/C-CRUISE ....
Underhood Electrical Center Relay Details
A/C Compressor .............
ABS ..........
Air Pump ............
Coolant Fan #1 ..................
Coolant Fan #2 .................
Coolant Fan #3 ................
Coolant Fan, Primary .......
Coolant Fan, Secondary ......
Fog Lights .............
High Blower ........
Vehicle Speed Sensor .......
Vehicle Zoning ... ; .
Wheel Speed Sensors .....
Window Motors ....
Washer Pump Motor ..........
Wiper Motor Module ......
Wiper/Washer Switch .....
Wiper/Washer .... ;
11~10
11-10
11-10
11-11
11-11
11-11
11-14
11-13
11-14
11-13
11-13
11-13
11r 15
11-11
11 11
11-12
11-12
11-12
11-12
11-12
11-tO
63-0 1
33-0
9-0
44-1,
44-4
120-0
91-0
91-0
91-0
91-0
SA - 2 - 0 ELECTRICAL DIAGNOSIS
INTRODUCTION
The Electrical Diagnosis section contains the
following types of diagnostic information (the way in
which the information is arranged may vary from
system to system or vehicle to vehicle):
Electrical Schematics
Component Location Lists
Harness Connector Faces
Troubleshooting Hints
System Checks
System Diagnosis
Circuit Operation Descriptions
Harness Routing Views
Using these elements together will make electrical
troubleshooting faster and easier. Each element is
described below.
The Circuit Schematic shows the electrical current
paths when a circuit is operating properly. It is
essential to understand how a circuit should work
before trying to diagnose a failure.
The Component Location List helps to find where
the components of a system can be located. A brief
statement of the location is given and also a reference
to a drawing that shows. the component and its
connecting wires. These Component Location Views
are in SECTION SA-201.
The Harness Connector Faces show the cavity or
terminal locations in all the 4 pin or larger connectors
shown in the schematic. Together with the wire colors
and terminals given in the schematic, they help locate
test points. The drawings show the connector faces as
seen after the harness connector has been disconnected
from a component or mating connector.
The Troubleshooting Hints offer short-cuts or
checks to help determine the cause of a complaint.
They are not intended to be a rigid procedure for
solving an electrical situation.
Rather,
Troubleshooting Hints represent a common-sense
approach, based on an understanding of the circuit.
The System Check gives a summary of how the
system should be operated and what should happen.
This is especially important when working on a new
system. The System Check will help identify
symptoms, lead to diagnosis and confirm normal
operation of the system after repair.
The System Diagnosis provides a procedure to

follow that will locate the condition in a circuit causing
a malfunction. If your own knowledge of the system
and the Troubleshooting Hints have not produced a
quick fix, follow the System Diagnosis. All procedures
are based on symptoms to assist in locating the
condition as fast as possible.
The Circuit Operation describes the components
and how the circuit works.
Harness Routing Views are found in SECTION
SA-203. These views show the routing of the major
wiring harnesses and the in-line connectors between
the major harnesses.
SECTION/PAGE NUMBER
Sections are organized by sub-systems with most
containing a circuit schematic and the associated text.
This makes the section easy to use, since the page
number will stay the same year after year. For
example, the Cruise Control schematic will always
begin on page SA-34-0. The other information for
Cruise Control follows and is paged SA-34-1, SA-34-2,
etc.
Some sections may have more than one circuit
schematic, such as Power Distribution, Interior Lights
and Air Conditioning. The circuit of interest can
either be located by using the Index or by a quick look
through the related section.
All the engine circuits for a particular engine VIN
type are in the same section. This makes that section
easy to use, since schematics for other engines are not
in your way. The Instrument Panel schematics are
organized similarly. If you are working on a vehicle
with a Digital Cluster, only the schematics that apply
to that vehicle's Digital Cluster will be in the section
you use. Information on the Indicators and Gages
Clusters will be in other sections.
2 -1
HORN
-
1 ORN
-,FUSE
BLOCK
I
I
I
40
5212- -
:I
I
1 ORN
SEE FUSE
BLOCK DETAILS
PAGE8A-11-1
I :
A1 f
~~~~
CONVENIENCE
CENTER
: Q------------------~l~ - :
~--~---------~----~
.35 BLK!28
G
1 DK GRNA29
..--------
C201
G T C101!
1 DK GRN
.8 BLK
28
S139
1 DK Gr!JJRN
29
1 DK GRN
HORN
BRUSH"-
29
- - -....- . . - - - H - 0..
STEERING ..
WHEEL
01]
29
1 DK GRN
I
L
HO=~
-=-
t_J
.8 BLK/YEL
CAPACITOR
152,- -
--4
SEE GROUND
DISTRIBUTION
PAGE8A-14-1
----2101
Figure 1 - Typical Horn Schematic
SCHEMATICS
Schematics break the entire electrical system
down into individual circuits. Wiring which is not part
of the circuit of interest is referenced to another page,
where the circuit is shown complete.
rn
Important:
It is important to realize that no attempt is made
on the schematic to represent components and
wiring as they physically appear on the vehicle.
For example, a 4-foot length of wire is treated no
differently in a schematic from one which is only
a few inches long. The number of cavities for
each connector is listed in the Component
Location List. Similarly, switches and other
components are shown as simply as possible,
with regard to function only.
When diagnosing a Horn problem, the technician

would reference the Horn section. The schematic in
Figure 1 is a typical example of what would be found in
a Horn section of SECTION 8A, along with the
following text.
Voltage is applied to the Horn Relay at all times.
When the relay coil is grounded by closing the Horn
Switch, the relay contacts close. When the relay
contacts are closed, both the LH and RH Horns are
energized.
8A.,
INTRODUCTION
COMPONENT LOCATIONS
To locate the schematic components on the vehicle,
use the Component Location List, see Figure 2.
Listed in the left hand column are the components,
connectors, grounds and splices shown on the
schematic. To the right of the component is the
location, "Under RH side ofl/P." Reference to LH and
RH is made as though the technician was sitting in the
driver's seat. On the same line, in the next two
columns, are page and figure references for
SECTION SA-201, "Component Location Views." In
this case, you are directed to Figure 4 on page
SA-201-1.
Where connectors are listed, the number of
cavities is provided. This represents the total number
COMPONENT
LOCATION
of cavities in the connector, regardless of how many

are actually used. This information is provided to help
identify connectors on the vehicle. In the far right
column is a page reference where a view of the
connector face may be found. Connectors with 3
cavities or less are not included in SECTION 8A-202,
"Harness Connector Faces."
Grounds are listed next in the table. The location
description for GIOl reads, "Behind LH Composite
Headlamp." You are directed to page SA-201-8,
Figure 14.
Nearly every component, connector, ground or
splice shown on a schematic can be pinpointed visually
by using the Component Location View figures.
201-PG
1
Convenience Center
Under RH side ofl/P ............................ .
Fuse Block . . . . . . . . . . . . . Behind I/P Compartment Door ................... .
0 ....
FIG.
4
CONN
CONNECTORS
CIOO (34 cavities)
C210 (15 cavities)
Mounted to LR Hood Hinge ...................... .

Above Convenience Center, behind
I/P Compartment .............................. .
7 . . . . 11
202-0
18 ...
23
202-2
8 ....
14
15
8
GROUNDS
GIOl . . . . . . . . . . . . . . . . . . . Behind LR Composite Headlamp . . . . . . . . . . . . . . . . . .
SPLICES
8139
8212
Forward Lamp Wiring Harn, behind

RH Composite Headlamp ...................... .
I/P Wiring Harn, behind I/P, above Steering Column
Figure 2- Typical Entries in the Component Location List
12064752
12059472
7-WA Y F METRlPACK MIXED SERIES
6-WA Y F METRlPACK 280 SERIES
BLK
BLK
C406
mIE l lc Is IA
0
G~ H~J~K~L~M~
12065666
12034297
4-WAYWEATHER PACK
12-WAY PC EDGEBOARD
BLK
BLK
CRUISE CONTROL MODULE
Figure 3 Typical Harness Connector Faces

The connectors, see Figure 3, are labeled with the
component they are connected to, or the connector
number. In addition the color of the connector is given
along with the family/series name.
If you need to backprobe a connector while it is on
the component (refer to page SA-4-3 for probing
procedures), the order of the terminals must be
mentally reversed. The wire color is a help in this
situation. If there is more than one wire of the same
color, you may need to locate a test point from its
terminal number. A useful trick is to imagine that you
are probing a terminal from behind the page you are
looking at. Then mentally locate that terminal with
respect to the keyway or other reference mark.
2-3
INTRODUCTION
WINDSHIELD
HEADER
REAR SHELF
DASH PANEL
END PANEL
LH "A"
PILLAR
LH REAR
QUARTER PANEL
Figure 4 - Body Part Names
OTHER INFORMATION
BODY PART NAMES
Refer to Figure 4 for the correct body part names.

VIN REFERENCES
If schematics for more than one variation of an

engine type - V6, for example - are shown, then the
schematics will be labeled with VIN designation to
distinguish the variations.
ABBREVIATIONS
A/C
Air Conditioning
CCM
Central Control Module
CKT
Circuit
Connector
CONN
Electronic Brake Control Module
EBCM
Electronic Brake and Traction Control
EBTCM
ECM
HARN
SERVICE PARTS IDENTIFICATION LABEL
1/P
To aid service and parts personnel in identifying

options and parts originally installed, a Service Parts
Identification Label has been placed in the vehicle.
See SECTION OA for the location of the label and the
definition of the option codes.
LH
PCM
RH
TERM
Module
Engine Control Module
Harness
Instrument Panel
Left Hand
Powertrain Control Module
Right Hand
Terminal
For a list of additional abbreviations, refer to

SECTIONOA.
POWER DISTRIBUTION
wirmg to the first component in each circuit is

extremely helpful in locating short circuits which
cause fusible links and fuses to open.
Figure 5 is a sample Power Distribution
schematic. It shows how voltage is applied from the
positive battery terminal to the various circuits on the
vehicle. For example, battery voltage is applied to the
Starter Solenoid, Fusible Link D, Fuses 1 and 2 in the
Fuse Block and the Light Switch in the LH Pod. These
fuses are said to be Hot At All Times, since battery
voltage is always applied to them.
Notice that battery voltage is also applied to
Fusible Link F and Coolant Fan Relay.
The Power Distribution schematic shows the

wiring from the Battery and Generator to the Starter
Solenoid, Fuse Block, Ignition Switch and Light
Switch. The first component after a Fusible Link is
also shown. In certain instances, the first component
after a Fuse Block fuse and Light Switch is also shown.
The Power Distribution schematic refers to Fuse
Block Details or the appropriate section schematics.
By using these schematics, power distribution wiring
can be followed from the Battery and Generator to the
first component after a Fusible Link, Fuse or Light
Switch. The ability to follow the power distribution
POWER DISTRIBUTION
3 RED
FUSIBLE LINK D
........................................
r:~~.:~.
V6 VIN L
-1
P100 ...-----,
V6 VINL
3RED
r" -
2 RED
V6 VIN L
L4 VIN U
1 RED I
1 BLK I
I
FUSIBLE LINK F
V6 VIN L
l4 VIN U
I
I
I
/,l'
r" -
... _
1FANTELAv
.
C
: D5-------=--=--=--~-
PAGE SA-31-0
.....I
- . COOLANT
... _
IFANRELAV
PAGE SA-311
.....I
:~---2--
I
I
3RE):
- . COOLANT
.SGRNI
1 BLK :
A-._....:;;;~=:.-.,
/ 2R:l
r-
V6 VIN L
L4 VIN U
32 BLK
19 BLK
-.STARTER
SOLENOID
PAGE SA-31-1
I
I
........._.....
3 RED
5206
3RED
LHPODr- -
I
,
I
I
I,
~~:~~H:
_. _ :=i- , ,
1
-C1!- --+ ____________ ...
---------
HEAD
OFF
HEAD
PARK
OFF
PARK
L--
L- -
C1
1YEL
-----
.8 ORN
240
HOT AT ALL TIMES
,.
I
~ g - - _J
_.J
FUSE 1
20AMP
10
._
HEADLIGHTr"' DIMMER SWITCH

PAGE SA-100-0
I
I
-.
I
.....I
... _
SEE EXTERIOR
LIGHTS
PAGE SA-1100
2-5
~
SEE FUSE
BLOCK DETAILS
PAGE 8A111
Figure 5 - Typical Power Distribution Schematic
""IFUSE
BLOCK
I
I
I
I
I
SA 2 6 ELECTRICAL DIAGNOSIS
INTRODUCTION
FUSE BLOCK DETAILS
FUSE 1 AND FUSE 2
,FUSE
BLOCK
I
I
I
I
I
FUSE 2
20AMP
FUSE 1
20AMP
L_
__ J
.SORN
340
g
H2
C205
.8 ORN
.SORN
240
.SORN
r- I
I
I
I
r- -
-,LHPOD
PAGE SA-120
-,LIGHT
340
I
I SWITCH I
I
I
I
._ _ ..1
I
L-----.J
340
.8 ORN
340
- - )
COURTESY LAMPS
PAGE 8A114-0
.8 ORN
340
,.. - -,
A
....
C1
_....
ANTENNA
RELAY
PAGE SA-151-0
Figure 6 - Typical Fuse Block Details Schematic
FUSE BLOCK DETAILS
The Fuse Block Details schematic, see Figure 6,

shows all of the wiring 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.
.8 ORN
C233
340
CONSOLE REAR
COURTESY LAMP
PAGE SA-1140
GROUND DISTRIBUTION
FRONT LIGHTS GROUNDS G101 AND G102
LH FRONT
PARKffURN
LAMP
LH
HIGH BEAM
HEADLIGHT
LH DUAL
BEAM
HEADLIGHT
RH FRONT
PARKffURN
LAMP
--...,.
.,
:;"
.8 BLK
'
150
"".;-'
.8 BLK
.8 BLK
150
150
RH
HIGH BEAM
HEADLIGHT
--.....
I
.8 BLK/WHT
:;"
"".;-'
.8 BLKIWHT
151
.8 BLKIWHT
151
..._______..
1,
5105
S100 - - - - - - - - - -
.8 BLK
RH DUAL
BEAM
HEADLIGHT
150
.8 BLKIWHT
Figure 7 -Typical Ground D1stribut1on Schematic
GROUND DISTRIBUTION
Figure 7 is a sample Ground Distribution

schematic for the Headlamps. It shows exactly which
components share each ground. This information can
often be a time-saver when troubleshooting ground
circuits.
For example, if both Headlamps and the
Park/Turn Lamp on one side are out, suspect an open
in their common ground wire or the ground connection
itself. On the other hand, if one of the lamps work, the
ground and the wire up to the splice are good. You
have learned this just by inspecting the schematic and
knowing the vehicle's symptoms. No actual work on
the lighting system was needed.
151
151
2-7
SA -
3-0
SYMBOLS
ELECTROSTATIC DISCHARGE (ESD) AND SUPPLEMENTAL INFLATABLE RESTRAINT (SIR)
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are Solid State and
the following information applies to them.
The ESD symbol (Figure 1) is used on schematics
(Figure 2) to indicate which components are ESD
sensitive. When handling any electronic part, the
service technician should follow the guidelines below
to reduce any possible electrostatic charge build-up on
the service technician's body and inadvertent
discharge to the electronic part. If it is not known
whether or not a component is ESD sensitive, assume
it is susceptible.
HANDLING PROCEDURES
1. Always touch a known good ground before
handling the part. This should be repeated while
handling the part and more frequently after
sliding across a seat, sitting down from a standing
position or walking a distance.
2. Avoid touching electrical terminals of the part,
unless so instructed by a written diagnostic
procedure.
3. When using a voltmeter, be sure to connect the
ground lead first.
4. Do not remove a part from its protective package
until it is time to install the part.
5. Before removing the part from its package, ground
the package to a known good ground on the
vehicle.
MEASURING PROCEDURES
The circuits shown within the boxes are greatly
simplified. Do not troubleshoot by measuring
resistance at any terminal of these devices unless so
Figure 1 - ESD Symbol
.,,.,}., .,,_J::M
A61--------~1~
l;;;IT-;;;'N-
I
I
POWER
A12y
-;::;A~U~I;;
INDICATOR
LAMP
~O~D- -
c2
ENGINE
CONTROL
I MODULE (ECM)
,---:.
...J
4v."-
1 BLKIWH;.tso
Figure 2 Typical Schematic
instructed by a written diagnostic procedure. Due to

the simplification of the schematics, resistance
measurements could be misleading, or could lead to
electrostatic discharge.
SUPPLEMENTAL INFLATABLE RESTRAINT

(SIR) SYSTEM: IF EQUIPPED
The SIR symbol (Figure 3) is used on schematics to
alert the technician of the following important
caution:
CAUTION: This vehicle is equipped with

Supplemental Inflatable Restraint (SIR).
Refer to CAUTIONS in SECTION 9J under
"ON-VEHICLE SERVICE" and the SIR
Component and Wiring Location view in
SECTION 9J before performing service on
or around SIR components or wiring.
Failure to follow CAUTIONS could result
in possible air bag deployment, personal
injury, or otherwise unneeded SIR system
repairs.
Figure 3 SIR Symbol
SYMBOLS
D
r- - .,
I
I
ENTIRE
COMPONENT
SHOWN
PART OF A
COMPONENT
SHOWN
I
I
-lR111E11D/YiiEiiiLIIIIIII ..,.____
79
JL
WIRE GAGE AND INSULATION

COLOR ARE LABELED .
,..
. 5 RED
L..-..1
12
, -----
-~
I
~
NAME OF
COMPONENT
.5 RED
COMPONENT CASE
IS DIRECTLY
ATTACHED TO
METAL PART
OF VEHICLE
(GROUNDED).
WIRE IS ATTACHED TO
METAL PART OF VEHICLE
(GROUNDED).
GROUND IS NUMBERED
FOR REFERENCE ON
COMPONENT LOCATION LIST.
I-I
SEE GROUND
DISTRIBUTION
PAGE 8A140
A WAVY LINE
__.,.,.... MEANS A WIRE IS
TO BE CONTINUED.
1 RED
FUSIBLE
LINK
WIRE IS INDIRECTLY
WIRE MAY HAVE ONE OR
MORE SPLICES OR CONNECTORS
BEFORE-IT IS GROUNDED .
TO GENERATOR
PAGE SA-30-0
C103
CONNECTOR.REFERENCE
NUMBER FOR COMPONENT
LOCATION LIST
LIST ALSO Sl!OWS TOTAL
NUMBER Of TERMINALS
POSSIBLE. C103 (6 CAVITIES)
PASSTHROUGH
GROMMET, NUMBERED
FOR REFERENCE.
....-Ji101
17"~""
CIRCUIT NUMBER IS
SHOWN TO HELP IN
TRACING CIRCUITS.
DETAILS ABOUT
COMPONENTOR
ITS OPERATION
PlOO ~
SPLICES ARE SHOWN

AND NUMBERED.
es200
PARK
BRAKE ~
SWITCH
CLOSED WITH .
PARKING ~
BRAKE ON
WIRE INSULATION
IS RED WITH A
YELLOW STRIPE.
1 DKGRN
19
FUSIBLE LINK SIZE AND

INSULATION COLOR
ARE LABELED.
CURRENT PATH
IS CONTINUED
AS LABELED.
THE ARROW SHOWS
THE DIRECTION OF
CURRENT FLOW
AND IS REPEATED
WHERE CURRENT
PATH CONTINUES.
A WIRE WHICH
CONNECTS TO
ANOTHER CIRCUIT.
THE WIRE IS
SHOWN AGAIN
ON THAT CIRCUIT.
~'"""
PAGE SA-81-3
CONNECTOR
ATTACHED TO
COMPONENT
CONNECTOR ON
COMPONENT
LEAD (PIGTAIL)
CIRCUIT
BREAKER
Il l: I
-___ ~ ~.,.i:-t----!
SWITCHCONTACTSTHAT
MOVE TOGETHER
DASHED LINE SHOWS
A MECHANICAL
CONNECTION BETWEEN
SWITCH CONTACTS.
3-1
SYMBOLS
.SLTBLUt4
.8 YEL
INDICATES THIS CIRCUIT

CONTINUES WITHIN DEVICE;
.
I.E., OTHER BULBS
TWO TERMINALS
INTHE SAME
CONNECTOR
237
r1~--,
DASHED LINE SHOWS

A PHYSICAL
CONNECTION
BETWEEN PARTS
(SAME CONNECl"OR).
I
I
I
"'
<D
~J____ J
"BRAKE"
iN'oicATOR I
AN INDICATOR
WHICH DISPLAYS
THE LIGHTED
WORD "BRAKE"
(RED)
ECM CONNECTOR IDENTIFICATION

C1 BLACK
C2 BLACK
32WAV
24WAV
A91g
rS:c;L;- -
I
I
I
L
-,- -
.
-
3BLK
--~--.J
D4JC2
=---...tllil
,ENGINE
CONTROL
MODULE (ECM)
I
I
~
I ~
/-:=====:---
150
-
SEE GROUND
~ DISTRIBUTION
PAGE SA-140
INDICATES THAT
THECIRCUITRVIS
NOT SHOWN IN
COMPLETE DETAIL
BUT IS COMPLETE ON
THE INDICATED PAGE
....AJ200
'"-.
ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE DEVICES
ARE IDENTIFIED. REFER TO
PAGE 8A30 FOR HANDLING
AND MEASURING PROCEDURES.
_ _ _ _1_o_RN140
NO GAGES
1 ORN
HEATING
ELEMENT
HEATACTUATED
CONTACT
I I
GAGES
WIRE CHOICES
FOR OPTIONS
OR DIFFERENT
MODELS ARE
SHOWN AND
LABELED.
C309
40--
LABEL OF
FUSE BLOCK
CONNECTOR
CAVITY
UNLESS NOTED,
THE RELAY WILL
BE SHOWN INA
I! 1L
-----
1-
_ _ _ _ _ __,__..
WHEN CURRENT FLOWS

THROUGH COIL, CONTACT
WILL TOGGLE.
DE-ENE.RGIZED STATE
WITH NO CURRENT
FLOWING THROUGH
THE COIL.
INDICATES THAT
POWER IS
SUPPLIED WITH
IGNITION SWITCH
IN "ACCV" AND
"RUN" POSITIONS
.... FUSE
RADIO
FUSE
Ill(
10AMP
I~
I
CLOSED
NORMALLY
CONTACT
.
NORMALL V
Of>EN
CONTACT
DIODE
ALLOWS CURRENT
TO FLOW IN ONE
DIRECTION ONLY
...L..
V.BT
V.MT
V.D
FUSIBLE LINK
CONNECTS TO
SCREW TERMINAL.
SHOWN SEPARATED
C210
3CONNECTORSARE
SHOWN CONNECTED
TOGETHER AT A
JUNCTION BLOCK.
:~~~;~E::~oMMON
CONNECTION ON
BLOCK.
NUMBER FOR TOTAL
CONNECTOR
lEITi:.RS FOR EACH

CONl\l~CTOR TERMINAL
VACUUM JUNCTION
BLUE
3-3
EASY FLOW DIRECTION
B ~ HOSECOLOR
---
VACUUM
CHECK
VA~VE
RED
NO FLOW DIRECTION
VACUUM SOURCE
AA.
VENT
MECHANICAL
VACUUM
VALVE
IN THE "AT REST"

POSITION SHOWN,
THE VALVE DOES
THE FOLLOWING:
PORT A IS SEALED.
PORT B IS VENTED
TO THE ATMOSPHERE.
DOUBLE DIAPHRAGM MOTOR

NO VACUUM
....
VACUUM SOURCE
AA.
VENT
SOLENOID
VACUUM
VALVE
WHEN THE VALVE IS

MOVED TO THE
"OPERATED" POSITION,
VACUUM FROM PORT A
IS CONNECTED TO
PORTB.
THE SOLENOID VACUUM
VALVE USES THE
SOLENOID TO MOVE
THE VALVE.
NO VACUUM
SERVOMOTOR
SINGLE DIAPHRAGM MOTOR
....
NO VACUUM
....
VACUUM
Vacuum Motors operate like electrical solenoids,

mechanically pushing or pulling a shaft between two
fixed positions. When vacuum is applied, the shaft is
pulled in. When no vacuum is applied, the shaft is
pushed all the way out by a spring.
Double Diaphragm Motors can be operated by

vacuum in two directions. When there is no vacuum,
the motor is in the center "at rest" position.
Some Vacuum Motors such as the Servo Motor in
the Cruise Control can position the actuating arm at
any position between fully extended and fully
retracted. The servo is operated by a control valve that
applies varying amounts of vacuum to the motor. The
higher the vacuum level, the greater the retraction of
the motor arm. Servo. Motors work like the two
position motors; the only difference is in the way the
vacuum is applied. Servo Motors are generally larger
and provide a calibrated control.
BASIC KNOWLEDGE REQUIRED
Without a basic knowledge of electricity, it will be
difficult to use the diagnostic procedures contained in
this section. You should understand the basic theory
of electricity and know the meaning of voltage, current
(amps) and resistance (ohms). You should understand
what happens in a circuit with an open or a shorted
wire. You should be able to read and understand a
wiring diagram.
The following four-step troubleshooting procedure
is recommended:
Step 2: Read the Electrical Schematic

Study the schematic. Read the Circuit Operation
text if you do not understand how the circuit should
work. Check circuits that share wiring with the
problem circuit. (Shared circuits are shown on Power
Distribution, Ground Distribution; Fuse Block Details
and Light Switch Details pages.) Try to operate the
shared circuits. If the shared circuits work, then the
shared wiring is OK. The cause must. be within the
wiring used only by the problem circuit. If several
circuits fail at the same time, chances are the power
(fuse) or ground circuit is faulty.
Step 1: Check the Problem

Perform a System Check to determine a symptom.
Don't waste time fixing part of the problem! Do not
begin disassembly or testing until you have narrowed
down the possible causes.
Step 3:
Find the fault and repair

Narrow down the possible causes.
Use the Troubleshooting Hints.
Make the necessary measurements or checks
as given in the System Diagnosis.
HEADLIGHTS
1
- CIRCUIT
- BREAKER
-
t.
HEAD
L-!.
OFF
.,;RK
5~ - ,HEADLIGHT
SWITCH
HEAD
OFF
. . . , . .,;RK
1I
SEE PAGE BA-30

FOR MEASURING
AND HANDLING
PROCEDURES
_____ 4j; __ .J
1v;}o
, - - - - ~ - - - - , HEADLIGHT
DIMMER
SWITCH
.8LTGRN
1 TAN
12
11
r- - - - - ,
1 LTGRN
INSTRUMENT
ICLU;ER
HIGH BEAM
INDICATOR
'. =
-o
II
L---=-..J
SEE GROUND
DISTRIBUTION
PAGE BA-14-4
.88~Kl50
IJli,,,- - -
5205
3 BLK 1150
....A.J200
Figure 1 -Typical Headlights Schematic
, .. _....
ELECTRICAL DIAGNOSIS 8A - 4 .J 1
Before replacing a component, check power,

signal and ground wires at the component
harness connector. If the checks and
connections are OK, the most probable cause is
component failure.
Step 4: Testthe Repair
Repeat the System Check to verify the fault has

been corrected and that no other faults were induced
during the repair.
Example:
A customer brings in a vehicle and says that the

HI beams do not work.
Step 1: Perform a System Check on the Headlight
Circuit. You may discover that both LO beams operate.
In "HI," you may notice that the HI Beam Indicator

comes on, but neither HI beam operates.
Step 2:' Read the Headlights Electrical Schematic, see
Figure 1. This is the step that will save time and
labor.; Remember, it is essential to understand how a

circuit should work, before trying to figure out why it
doesn't.
Step 3: Find the fault and repair it. Using the

Component Location List and the corresponding
figure, you can quickly find ClOO and the LT GRN
wire, locate the exact trouble point and make the
repair.
Step 4: Check the repair by performing a System
Check on the Headlights Circuit. This, of course,
means making sure that both HI beams, both LO

beams and the HI Beam Indicator are all working.
Now suppose that the symptoms were different.
You may have operated the Headlamps and found that
the LO beams were working, but neither the HI beams
nor the HI Beam Indicator were working. Looking at
the schematic, you might conclude that it is unlikely
that both HI beam filaments and the HI Beam
Indicator have all burned out at once. The cause is
probably the Headlight Dimmer Switch or its
connector.
TROUBLESHOOTING TOOLS
Electrical troubleshooting requires the use of
common electrical test equipment.
TEST LIGHT/DIGITAL VOLTMETER
After you understand how the circuit should

operate, read the schematic again, this time keeping in
mind what you have learned by operating the circuit.
Since both LO beams work, you know that the
Headlight Switch, the YEL wire, the LO contacts of
the Headlight Dimmer Switch, terminal "IE" of ClOO,
the TAN wires and grounds Gl05 and Gl09 are all
good.
Furthermore, since you saw that the HI Beam
Indicator came on when the Headlight Dimmer Switch
was moved to "HI," you know that the HI contacts of
the Headlight Dimmer Switch and the LT GRN wire
between the Headlight Dimmer Switch and C 100 are
,good.
At this point, you could test for voltage at the RH
Headlamp with the Headlight Dimmer Switch in "HI."
However, it is extremely unlikely that the HI beam
filaments have burned out in both headlamps, or that
both headlamps connections are bad. The cause must
be a bad connection at ClOO, or a break in the LT GRN
wire between ClOO and the RH Headlamp.
You have quickly narrowed the possible causes
down to one specific area, and have done absolutely no
work on the vehicle itself.
Use a test light to check for voltage. A Test Light

(J 34142-B) is made up of a 12 volt light bulb with a
pair ofleads attached. After grounding one lead, touch

the other lead to various points along the circuit where
voltage should be present. When the bulb goes on,
there is voltage at the point being tested.
A DVM can be used instead of a test light. While a
test light shows whether or not voltage is present, a
DVM indicates how much voltage is present.
An increasing number of circuits include solid
state control modules. One example is the Engine
Control Module (ECM). Voltages in these circuits
should be tested only with a 10-megohm or
higher impedance DVM or multimeter (J 39200).
Unless directed to within the diagnostics, never use a
test light on circuits that contain solid state
components, since damage to these components may
result.
8A -
4 -2
When testing for voltage or continuity at the
connection, it is not necessary to separate the two
halves of the connector. Unless testing a Weather
Pack connector, always probe the connector from the
back. Always check both sides of the connector. An
accumulation of dirt and corrosion between contact
surfaces is sometimes a cause of electrical problems. A
terminal contact checking procedure can be found on
page 8A-4-6.
CONNECTOR TEST ADAPTERS
Connector Test Adapter Kit (J 35616-A) is

available for making tests and measurements at
separated connectors. This kit contains an assortment
of probes which mate with many of the types of
terminals you will see. Avoid using paper clips and
other substitutes since they can damage terminals and
cause incorrect measurements.
SELF-POWERED TEST LIGHT
A self-powered test light (J 21008-A) can be used to

check for continuity. This tool is made up of a light
bulb, Battery and two leads. If the leads are touched
together, the bulb will go on.
" ' A self-powered test light is used only on an
unpowered circuit. First remove the fuse which feeds
the circuit you're working on. Select two specific
points along the circuit through which there should be
continuity. Connect one lead of the self-powered test
light to each point. If there is continuity, the test light
circuit will be completed and the bulb will go on.
Never use a self-powered test light on circuits that
contain solid state components, since damage to these
components may result.
OHMMETER
An ohmmeter can be used instead of a self-powered

test light. The ohmmeter shows how much resistance
there is between two points along a circuit. Low
resistance means good continuity.
Circuits which include any solid state control
modules, such as the Engine Control Module (ECM),
should be tested only with a 10-megohm or higher
impedance digital multimeter (J 39200).
When measuring resistance with a DVM, the
vehicle Battery should be disconnected. This will
prevent incorrect readings. DVMs apply 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 an ohmmeter to give a false reading. To find out
if a component is affecting a measurement, take a

reading once, reverse the leads and take a second
reading. If the readings differ, the solid state
component is affecting the measurement.
FUSED JUMPER WIRE
A fused jumper (J 36169) is available with small

clamp connectors providing adaptation to most
connectors without damage. This fusedjumper wire is
supplied with a 20 amp 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 being
tested.
NOTICE: A fused jumper may not protect solid

state components from being damaged.
SHORT FINDER
Short Finders (J 8681-A) are available to locate

hidden shorts to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows
you the location of the short through body trim or
sheet metal.
FUSE TESTER
A simple tester (J 34764) can detect a blown fuse.

To check a fuse, the tester is applied directly to the
fuse in the Fuse Block. Two probes contact the fuse,
either into the slots of a flat fuse or to the metal ends of
a glass fuse. With power on, a red LED in the tester
lights if the fuse is open. The handle of the testeris a
tool for removing either type of fuse.
TROUBLESHOOTING TESTS
Always check for aftermarket accessories (non
OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the
system to verify that these add-on accessories are not
the cause of the problems.
Some possible causes of vehicle problems related to
aftermarket accessories include:
1. Power feeds connected to points other than the
Battery.
2. Antenna location.
3. Transceiver wiring located too close to vehicle
electronic modules or wiring.
4. Poor shielding or poor connectors on antenna
feedline.
Refer to 1990/1991 model year bulletin entitled,
"Installation Guidelines for Aftermarket Accessories"
for specific information.
PROBING
After probing, when reconnecting connectors or
replacing terminals, al ways be sure to reinstall
Connector Position Assurance (CPA) and Terminal
Position Assurance (TPA).
Front probe
When frontprobing of connectors is required,
always use a mating terminal adapter from Connector
Test Adapter Kit (J 35616-A). The use of proper
adaptors will ensure that proper terminal ,contact
integrity is maintained. For a terminal contac.t
checking procedure, refer to page SA-4-6.
Back probe
Only backprobe connector terminals when
specifically called for in diagnostic procedures. Since
backprobing can be a source of damage to connector
terminals, extra care must be take.n to a void
deforming the terminal, either by forcing the test
probe too far into the cavity or by using too large ate.st.
probe.
4 -3
After backprobing any connector, always check for

terminal damage If terminal damage is suspected,
check for proper terminal contact, refer to "Checking
Terminal Contact," page SA-4-6.
TESTING FOR VO~ TAGE (Figure 2)
1. Connect one lead of a test light to a known good
ground
When using a DVM, 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. When using a DVM, note the voltage
reading.
TESTING FOR CONTINUITY (Figure 3)
1. Remove the fuse to the circuit involved.
2'. Connect one lead of a self-powered test light or
ohmmeter to one end of the part of the circuit you
wish to test.
3. Connect the other lead to the other end of the
circuit.
4. If the self-powered test light glows, there i:;;,
continuity. When using an ohmmeter, low or no
resistance means good continuity.
HOT AT ALL TIMES

FUSE
BLOCK
ON
SELFPOWERED
BLOWER
SWITCH
LIGHT
(OR
OHMMETER)
,,,..-- .....
LO
',OFF
''
TESTLJGHT
(ORDVM)
',
\
\
l
-..
BLU
'
IJif"""
Figure 2 Voltage Check
Figure 3 Continuity Check through a Switch
8A -
4 -4
HOT AT ALL TIMES

FUSE
BLOCK
RED
(+-)
'-1-../
(-)
[ZJ<WIT<S
[]<~rre
-
)'"
llU
LOAD,
Dill <~rno
DISCONNECTED
Dill''"'"""
Figure 5 - Testing for Short with Test Light

orDVM
Figure 4 - Voltage Drop Test
TESTING FOR VOLTAGE DROP (Figure 4)
This test checks for voltage being lost along a wire 1

or through a connection or switch.
1. Connect the positive lead of a DVM to the end of
the wire (or to one side of the connection or switch)
which is closer to the Battery.
2. Connect the negative lead to the other end of the
wire (or the other side of the connection or switch).
3. Operate the circuit.
4. The DVM will show the difference in voltage
between the two points.
TESTING FOR SHORT TO GROUND

With a Test Light or DVM (Figure 5)
1.
2.
3.
4.
Remove the blown fuse arid disconnect the load.

Connect a test. light or voltmeter across the fuse
terminals (be sure that the fuse is powered).
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 DVM.
When the test light glows, or the DVM registers,
there is a short to ground in the wiring near that
point.
4-5
With a Self-Powered Test Light or Ohmmeter

{Figure 6)
1.
2.
3.
4.
5.
Remove the blown fuse and disconnect the Battery

and load.
Connect one lead of a self-powered test light or
ohmmeter to the fuse terminal on the load side.
Connect the other lead to a known good ground.
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.
When the self-powered test light glows, or the
ohmmeter registers, there is a short to ground in
the wiring near that point.
BATTERY DISCONNECTED
FUSE
BLOCK
(FUSE
REMOVEDI
SELF
POWERED
~
LIGHT
(OR
OHMMETER)
Fuses Powering Several Loads
1.
Find the schematic in "Fuse Block Details," page

SA-11-0 for the fuse that has blown.
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 wiring
leading to the first connector or switch. Use a
test light or meter 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 lamp or meter at the connector to the
suspect circuit (disconnected) rather than at the
fuse terminals.
INTERMITTENTS AND POOR CONNECTIONS

Most intermittents are caused by faulty electrical
connections or wiring, 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 seated in the connector body (backed
out).
Dirt or corrosion on the terminals. The
terminals must be clean and free of any foreign
material which could impede proper terminal
contact.
LU
LOAD
/;
DISCONNECTED
Figure 6 - Testing for Short with Self-Powered

Test Light or Ohmmeter
JUMP STARTING PROCEDURE
Refer to SECTION 60-1 for jump starting

procedure.
gJ'-rn
Damaged connector body, exposing the

terminals to moisture and dirt, as well as not
maintaining proper terminal orientation with
the component or mating connector.
Improperly formed or damaged terminals. All
connector terminals in problem circuits should
be checked carefully to ensure good contact
tension. Use a corresponding mating terminal
to check for proper tension. Refer to "Checking
Terminal Contact" in this section for the
specific procedure.
The J 35616-A Connector Test Adapter Kit
must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the adapter will ensure that no damage
to the terminal will occur, as well as giving an
idea of whether contact tension is sufficient .. If
contact tension seems incorrect, refer to
"Checking Terminal Contact" in this section
for specifics.
SA.;
4 -6
Poor terminal-to-wire connection. Some

conditions which fall under this descriptio'n
are poor crimps, poor solder joints, crimping
over wire insulation rather than the wire
itself, corrosion in the wire-to-terminal contact
area, etc.
Wire insulation which is rubbed through,
causing an intermittent short as the bare are.a
touches other wiring or parts of the vehicle.
Wiring broken inside the insulation. This
condition could cause a continuity check to
show a good circuit, but if only 1 or 2 strands of
a multi-strand-type wire are intact, resistance
could be far too high.
To avoid any of the above problems when making
wiring or terminal repairs, always follow the
instructions for wiring and terminal repair outlined in
SECTION 8A-5.
CHECKING TERMINAL CONTACT

When diagnosing an electrical system that utilizes
Metri-Pack 150/280/480/630 series terminals (refer to
Terminal Repair Kit, J 38125-A, instruction manual,
J 38125-4 for terminal identification), it is important
to check terminal contact between a connector and
component, or between in-li.ne connectors, before
replacing a suspect component.>
Frequently, a diagnostic chart leads to a step that
reads: "Check for poor connection." Mating terminals
must be inspected to assure good terminal contact. A
poor connection between the male and female terminal
at a connector may be the result of contamination or
deformation.
Contamination is caused by the connector halves
being improperly connected, a missing or damaged
connector seal, or damage to the connector itself,
exposing the terminals to moisture. and dirt.
Contamination, usually in underhood or underbody
connectors, leads to terminal corrosion, causing an
open circuit or intermittently open circuit.
Deformation is caused by probing the mating side
of a connector terminal without the proper adapter,
improperly joining the connector halves or repeatedly
separating and joining the connector halves.
Deformation, usually to the female terminal contact
tang, can result in poor terminal contact, see figure 7,
causing an open or intermittently open circuit.
Follow the procedure below to check terminal

contact.
l. Separate the connector halves. Refer to
Terminal Repair Kit, J 38125-A, instruction
manual, J 38125-4.
2. Inspect the connector halves for
contamination. Contamination will result in a
white or green build-up within the connector
body or between terminals, causing high
terminal resistance, intermittent contact or an
open circuit. An underhood or underbody
connector that shows signs of contamination
should be. replaced in its entirety: terminals,
seals and connector body.
3. Using an equivalent male terminal from the
Terminal Repair Kit, J 38125-A, check the
retention force of the female terminal in
question by inserting and removing the male
terminal to, the female terminal in the
connector body. Good terminal contact will
require a certain amount of force to separate
the terminals.
4. Using an equivalent female terminal from the
Terminal Repair Kit, J 38125-A, compare the
retention force of this terminal to the female
terminal in .question by joining and separating
the male terminal to the good female terminal,
and then joining and separating the male
terminaLto the female terminal in question. If
the retention force is significantly different
between the two female terminals, replace the
female terminal in question, refer to Terminal
Repair Kit, J 38125-A.
If a visual (physical) check does not reveal the
cause of the problem, the vehicle may be able to be
driven with a DVM connected to the suspected circuit.
An abnormal voltage reading when the problem occurs
indicates the problem may be in that circuit.
d ABOUT EQUAL TO 0, GOOD TERMINAL CONTACT
-_.,;: :::~--:f-__
_
------"""""
,,,,, ,,,,. ___ ,

,,,,,, ,,,,.,,,,. ,,,,. ,,,,.
d MUCH GREATER THAN 0, POOR TERMINAL CONTACT
OJ TYPICAL METRI-PACK 150/280/480/630 SERIES FEMALE TERMINAL

(150 SERIES PUSH-TO-SEAT SHOWN)
CONTACT TANG
( ] ] AMOUNT OF DEFORMATION
Figure 7 Deformation of a Typical Metri-Pack 150/280/480/630 Series Female Terminal
SA -
4 -8
DETECTING ELECTRICAL INTERMITTENTS
Use the following procedure to detect intermittent
terminal contact or a broken wire with an intermittent
connection inside the insulation.
The J 39200 Digital Multimeter has the ability to
monitor current, resistance, or voltage while recording
the minimum (MIN) and maximum (MAX) values
measured. The meter can also be set to display the
average (AVG) value measured.
When diagnosing circuits that have voltage
applied, use the voltage setting to monitor a connector
(or length of a circuit) which is suspected of having an
intermittent connection but is currently operating
normally.
1. Connect the J 39200 Digital Multimeter to
both sides of a suspect connector (still
connected) or from one end of a suspect circuit
to the other. This will continuously monitor
the terminal contacts or length of wire being
checked. See "Meter Connections" for
examples of the various methods for
connecting the meter to the circuit.
2. Set the meter for voltage. Since the "MIN
MAX" mode does not use auto ranging,
manually select the voltage range necessary
before proceeding.
3. Press the "MIN MAX" button. The meter
should read "100 ms RECORD" (100
millisecond record) and emit a 1/4 second beep.
The meter is now ready to record and will
generate an audible tone for any change in
voltage. At this point, you may wish to press
the "PEAK MIN MAX" button, which will
record any voltage variations that occur for at
least 1 millisecond.
4. Try to simulate the condition that is
potentially causing an intermittent
connection, either by wiggling connections or
wiring, test driving or performing other
operations. If an open or resistance is created,
a voltage will be present and the meter will
emit a tone for as long as the open or resistance
exists. Any change in voltage will cause the
meter to emit a tone for no less than 1/4 second.
(Listening for a tone while manipulating
wiring is very helpful for narrowing in on an
intermittent connection.)
rn
Use the MIN and MAX values when the meter

is out of sight or sound range, in noisy areas or
for test driving when it may not be possible to
monitor the meter.
To check the MIN and MAX recorded voltages
press "MIN MAX" once for MAX and twice for
MIN. A variation between MIN and MAX
recorded voltages (unless nearly O volts)
suggests an intermittent open or resistance
exists and should be repaired as necessary.
Refer to SECTION SA-5 of any current GM
Service Manual for approved repair
procedures.
Important:
The "100 ms RECORD" (100 millisecond record)
mode is NOT the amount of time allowed to
perform a specific procedure. It is the amount of
time used to record each snapshot of information
used for calculating "A VG" when in the "MIN
MAX"mode.
METER CONNECTIONS
The previous diagnostic procedure was written to
detect intermittents using the meter set to voltage.
Whether using the current, voltage or resistance
setting to detect intermittents, it is necessary to
connect the meter to the circuit.
Following are examples of the various methods of
connecting the meter to the circuit to be checked:
Backprobe both ends of the connector and
either hold the leads in place while
manipulating the connector or tape the leads
to the harness for continuous monitoring while
performing other operations or test driving.
(Do not backprobe "Weather Pack" type
connectors.)
Disconnect the harness at both ends of the
suspect circuit where it connects either to a
component or to other harnesses.
Use Connector Test Adapter Kit J 35616-A to
connect the meter to the circuit.
If the system being diagnosed has a specified
pinout or breakout box, it may be used to
simplify connecting the meter to the circuit or
for checking multiple circuits quickly.
\ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _E_L_E_C_T_RI_C_A_L_D_IA_G_N_O_S_IS_S_A_-_4_-_9
\\
\
A~ITIONAL INFORMATION
\
NOTICE: Turn off power to the test circuit before

attempting in-circuit resistance measurements to
prevent false readings or damage to the meter. Do
not use the meter to measure resistance through a
solid state module.
Continuity tests that work well for detecting
intermittent shorts to ground can be performed by
setting the meter to ohms then pressing the "PEAK
MIN MAX" button. An audible tone will be heard
whenever the meter detects continuity for at least 1
millisecond.
The J 39200 Instruction Manual is a good source of
information and should be read thoroughly upon
receipt of the meter as well as kept on hand for
reference during new procedures.
SA -
REPAIR PROCEDURES
ELECTRICAL REPAIRS
This section provides instruction in the following
repairs:
Circuit Protection
Typical Electrical Repairs
Splicing Copper Wire
Splicing Twisted/Shielded Cable
Repairing Connectors (Except Weather Pack)
Repairing Weather Pack (Environmental)
Connectors
Terminal Repair
After any electrical repair is made, always test the
circuit afterwards by operating the devices in the
circuit. This confirms not only that the repair is
correct, but also, that it was the cause of the complaint.
CIRCUIT PROTECTION
The purpose of circuit protection is to protect the
wiring assembly during normal and overload
conditions. An overload is defined as a current
requirement that is higher than normal. This
overload could be caused by a short circuit or system
malfunction. The short circuit could be the result of a
pinched or cut wire or an internal device short circuit,
such as an electronic module failure.
The circuit protection device is only applied to
protect the wiring assembly, and not the electrical load
at the end of the assembly. For example, if an
electronic component short circuits, the circuit
protection device will assure a minimal amount of
damage to the wiring assembly. However, it will not
necessarily prevent damage to the component.
CIRCUIT PROTECTION DEVICES
There are three basic types of circuit protection
devices: Circuit Breaker, Fuse and Fusible Link.
CIRCUIT BREAKERS
A circuit breaker is a protective device designed to
open the circuit when a current load is in excess of
rated breaker capacity. If there is a short or other type
of overload condition in the circuit, the excessive
current will open the circuit between the circuit
breaker t_erminals. There are two basic types of circuit
breakers used m GM vehicles:
cycling and
non-cycling.
CYCLING CIRCUIT BREAKER
The cycling breaker will open due to heat

generated when excessive current passes through it for
a period of time. Once the circuit breaker cools, it will
close again after a few seconds. If the cause of the high
current is still present it will open again. [t will
continue to cycle open and closed until the condition
causing the high current is removed.
NON-CYCLING CIRCUIT BREAKER
There are two types of non-cycling circuit

breakers. One type is mechanical and is nearly the
same as a cycling breaker. The difference is a small
heater wire within the non-cycling circuit breaker.
This wire provides enough heat to keep the bimetallic
element open until the current source is removed.
The other type is solid state, called out in this
section as Electronic Circuit Breaker (ECB). This
device has a Positive Temperature Coefficient. It
increases its resistance greatly when excessive current
passes through it. The excessive current heats the
ECB. As it heats, its resistance increases, therefore
having a Positive Temperature Coefficient.
Eventually the resistance gets so high that the circuit
is effectively open. The ECB will not reset until the
circuit is opened, removing voltage from its terminals.
Once voltage is removed, the circuit breaker will
re-close within a second or two.
FUSES
The most common method of automotive wiring
circuit protection is the fuse (Figure 1). A fuse is a
device that, by the melting of its element, opens an
electrical circuit when the current exceeds a given
level for a sufficient time. The action is non-reversible
and the fuse must be replaced each time a circuit is
overloaded or after a malfunction is repaired.
Fuses are color coded. The standardized color
identification and ratings are shown in Figure 2. For
service replacement, non-color coded fuses of the same
respective current rating can be used.
Examine a suspect fuse for a break in the element.
If the element is broken or melted, replace the fuse
with one of equal current rating.
There are additional specific circuits with in-line
fuses. These fuses are located within the individual
wiring harness and will appear to be an open circuit if
blown.
AU~FUSE
1
~e Autofuse, normally referred to simply as

"Fuse/ is the most common circuit protection device in
today's vehicle. The Autofuse is most often used to
protect the wiring assembly between the Fuse Block
and the system components.
MAXI FUSE
The Maxifuse was designed to replace the fusible

link and Pacific Fuse Elements. The Maxifuse is
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 Maxifuse performs much ,more like an
Autofuse, although the average opening time is
slightly longer. This is because the Maxifuse was
designed to be a slower blowing fuse, with less chance
of nuisance blows.
AUTOFUSE
CURRENT RA Tl NG
COLOR
3
5
7.5
10
15
20
25
30
VIOLET
TAN
BROWN
RED
BLUE
YELLOW
NATURAL
GREEN
MAXIFUSE
CURRENT RA TING
COLOR
20
30
40
50
60
70
80
YELLOW
GREEN
AMBER
RED
BLUE
BROWN
NATURAL
MINIFUSE
CURRENT RATING
Fuse Element
Maxifuse
COLOR
5
7.5
10
15
20
25
30
TAN
BROWN
RED
BLUE
YELLOW
WHITE
GREEN
PACIFIC FUSE ELEMENT

CURRENT RATING
Autofuse
Minifuse
Figure 1 - Fuse Devices
30
40
50
60
COLOR
PINK
I
GREEN
RED
YELLOW
Figure 2 - Fuse Rating and Color
5-1
SA -
REPAIR PROCEDURES
MINI FUSE
The Minifuse is a smaller version of the Autofuse

and has a similar performance. As withthe Autofuse,
the Minifuse is usually used to protect the wiring
assembly between
Fuse Block and system
components. Since the Minifuse is a smaller device, it
allows for more system specific fusing to be
accomplished within the same amount of space as
Autofuses.
PACIFIC FUSE ELEMENT/MAXI FUSE
The Pacific Fuse Element and Maxifuse were

developed to be a replacement for the fusible link.
Like a fusible link, the fuses are designed to protect
wiring from a direct short to ground. These elements
are easier to service and inspect than a fusible link and
will eventually replace fusible links in all future
vehicle applications.
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 will melt and create an open circuit (see Figure 3).
I Not all fusible link open circuits can be detected by
observation. Always inspect that there is battery
voltage past the fusible link to verify continuity.
Fusible links are used instead of a fuse in wiring
circuits that are not normally fu'sed, such as the
ignition circuit. For AWG sizes, each fusibfe link is
four wire gage sizes smaller than the wire it is
designed to protect. For example: to protect a 10 gage
wire use a 14 gage link or for metric, to protect a 5 mm 2
wire use a 2 mm 2 link (see Figure 6). Links are
marked on the insulation with wire-gage size because
the heavy insulation makes the link appear to be a
heavier gage than it actually is. The same wire size
fusible link must be used when replacing a blown
fusible link.
Fusible links are available with three types of
insulation: Hypalon, Silicone/GXL (SIL/GXL) and
Expanded Duty. All future vehicles that use fusible
links will utilize the Expanded Duty type of fusible
link. When servicing fusible links, all fusible links
can be replaced with the Expanded Duty type.
SIL/GXI fusible links can be used to replace either
SIL/GXI or Hypalon fusible links. Hypalon fusible
links can only be used to replace Hypalon fusible
links.
Determining characteristics of the types of fusible

links:
Hypalon (limited use): only available in
.35 mm 2 or smaller and its insulation is one
color all the way through.
SIL/GXL (widely used): available in all sizes
and has a white inner core under the outer
color of insulation.
Expanded Duty: available in all sizes, has an
insulation that is one color all the way through
and has three dots following the writing on the
insulation.
Service fusible links are available in many
lengths. Choose the shortest length that is suitable. If
the fusible link is to be cut from a spool, it should be
cut 150-225 mm (approx 6-9 in.) long. NEVER make a
fusible link longer than 225 mm (approx 9 in.).
CAUTION: Fusible links cut longer than

225 mm (approx 9 in.) will not provide
sufficient overload protection.
CONNECTOR COVERING
FUSIBLE LINK BEFORE SHORT CIRCUIT
BROKEN CIRCUIT
INSIDE INSULATION
FUSIBLE LINK AFTER SHORT CIRCUIT
Figure 3 Good and Damaged Fusible Links
To replace a damaged fusible link (Figure 4), cut it

off beyond the splice. Replace with a repair link.
When connecting the repair link, strip wire and use
staking-type pliers to crimp the splice securely in two
places. For more details on splicing procedures, see
"Splicing Copper Wire." Use Crimp and Seal splices
whenever possible. When using Splice Clips, refer to
page 8A-5-3; when using Crimp and Seal splice
sleeves, refer to page 8A-5-6.
To replace a damaged fusible link which feeds two
harness wires, cut them both off beyond the splice.
Use two repair links, one spliced to each harness wire
(see Figure 5).
TYPICAL ELECTRICAL REPAIRS

An open circuit is an incomplete circuit. Power
cannot reach the load or reach ground. If a circuit is
open, active components do not energize. A short
circuit is an unwanted connection between one part of
the circuit and either ground or another part of the
circuit. A short circuit causes a fuse to blow or a
circuit breaker to open.
SHORT CIRCUITS CAUSED BY DAMAGED WIRE

INSULATION
Locate the damaged wire.

Find and correct the cause of the wire insulation
damage.
For minor damage, tape over the wire. If damage
is more extensive, replace the faulty segment of
the wire (Refer to the splicing instructions for
copper or shielded cable for the correct splicing
procedure).
SPLICING COPPER WIRE USING SPLICE CUPS

Splice Clips are included in the J 38125-A
Terminal Repair Kit. The Splice Clip is a general
purpose wire repair device. It may not be acceptable
for applications having special requirements such as
moisture sealing. Refer to the appropriate Service
Manual Section to determine if there are any special
requirements.
DAMAGED
FUSIBLE
LINK
DAMAGED
FUSIBLE
LINK
5-3
CUT HERE
CUT HERE
o~
TERMINAL
TERMINAL
SPLICE
SPLICE
ONE HARNESS
WIRE (RED)
REPAIR LINKS
REPAIR LINK
ONE HARNESS
WIRE (RED)
Figure 4 - Single Wire Feed Fusible Link
HARNESS
WIRES(RED)
HARNESS
WIRES (RED)
.. \
Figure 5 Double Wire Feed Fusible Link
8A -
REPAIR PROCEDURES
Step 1: Open the Harness
If the harness is taped, remove the tape. To avoid
wire insulation damage, use a sewing "seam ripper" to

cut open the harness (available from sewing supply
stores). If the harness has a black plastic conduit,
simply pull out the desired wire.
Step 2: Cut the Wire
Begin by cutting as little wire off the harness as

possible. You may need the extra length of the wire
later if you decide to cut more wire off to change the
location of a splice. You may have to adjust splice
locations to make certain that each splice is at least
40 mm (1 t") away from other splices, harness branches
or connectors.
Step 3: Strip the Insulation
When replacing a wire, use a wire of the same size

as the original wire or larger. The schematics list wire
size in metric units. The following table (Figure 6)
shows the commercial (A WG) wire sizes that can be
used to replace each metric wire size. Each A WG size
is either equal to or larger than the equivalent metric
size.
To find the correct wire size either find tlie wire on
the schematic page and convert the metric size to the
A WG size, or use an AWG wire gage.
.
If you aren't sure of the wire size, start with the
largest opening in the .wire stripper and work dowri
u.ntil a clean strip of the insulation is removed. Be
careful to avoid nicking or cutting any of the wires.
METRIC WIRE
SIZES (mm 2 )
AWG SIZES
.22
24
.35
22
.5
20
.8
18
1.0
16
2.. 0
14
3.0
12
5.0
10
8.0
13.0
19.0
32.0
8
6
4
2
Figure 6 - Wire Size Conversion Table
Figure 7 - Centering the Splice Clip
Step 4: Crimp the Wires
Select the proper clip to secure the splice. To

determine the proper clip size for the wire being
spliced, follow the directions included in the J 38125-A
Terminal Repair Kit. Select the correct anvil on the
crimper. On most crimpers your choice is limited to
either a small or large anvil. Overlap the stripped
wire ends and hold them between your thumb and
forefinger as shown. in Figure 7. Then, center the
splice clip under the stripped wires and hold it in place .
Open the crimping too.I to its full width and rest
one handle on a firm flat surface.
Center the back of the splice clip on the proper
anvil and close the crimping tool to the point
where the former touches the wings of the clip.
Make sure that the clip and wires are still in the
correct position. Then, apply steady pressure until
the crimping tool closes (see Figure 8).
Before crimping the ends of the clip, be sure that:
The wires extend beyond the clip in each
direction.
No strands of wire are cut loose, and
No insulation is caught under the clip.
Crimp the splice again, once on each end. Do not
let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires (Figure 9).
existing wires. Do not flag the tape. Flagged tape may

not provide enough insulation, and the flagged ends
will tangle with the other wires in the harness (see
Figure 11).
If the wire does not belong in a conduit or other
harness covering, tape the wire again. Use a winding
motion to cover the first piece of tape (Figure 12).
Step 5: Solder
Apply 60/40 rosin core solder to the opening in the

back of the clip (see Figure 10). Follow the
manufacturer's instruction for the solder equipment
you are using.
SPLICE CLIP
Step 6: Tape the Splice
Center and roll the splicing tape. The tape should

cover the entire splice. Roll on enough tape to
duplicate the thickness of the insulation on the
ALIGN TOOL WITH EDGE OF CLIP

TO CRIMP ENDS OF SPLICE
WINGS OF CLIP
TOUCHING
FORMER
Figure 9 - Completing the Crimp
Figure 8 Crimping the Splice Clip
5-5
Figure 10 Applying the Solder
SA -
5-6
REPAIR PROCEDURES
SPLICING COPPER WIRE USING CRIMP AND
SEAL SPLICE SLEEVES
Crimp and Seal splice sleeves may be used on all
types of insulation except tefzel and coaxial to form a
one to one splice. They are to be used where there are
special requirements such as moisture sealing. Refer
to the appropriate section of the Service Manual to
determine if the Crimp and Seal is necessary. Crimp
and Seal splice sleeves are included in the J 38125-A
Terminal Repair Kit.
GOOD (ROLLED)
If the harness is taped, remove the tape. To avoid

wire insulation damage, use a sewing "seam ripper" to
cut open 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.
Step 2: Cut the Wire
Begin by cutting as little wire off the harness as

possible. You may need the extra length of wire later
if you decide to cut more wire to change the location of
a splice. You may have to adjust splice locations to
make certain that each splice is at least 40 mm (1.5 in.)
away from other splices, harness branches or
connectors. This will help prevent moisture from
bridging adjacent splices and causing damage.
Step 3: Stripe the Insulation
BAD (FLAGGED)
If it is necessary to add a length of wire to the

Figure 11 - Proper First Taping
=
TAPE AGAIN IF NEEDED
Figure 12 - Proper Second Taping
existing harness, be certain to use the same size as the

original wire (refer to Figure 6, "Wire Size Conversion
Table").
To find the correct wire size either find the wire on
the schematic and convert the metric size to the
equivalent AWG size or use an AWG wire gage. If
unsure about the wire size, begin with the largest
opening in the wire stripper and work down until a
clean strip of the insulation is removed. Strip
approximately 7.5 mm (5/16 in.) of insulation from
each wire to be spliced. Be careful to avoid nicking or
cutting any of the wires. Check the stripped wire for
nicks or cut strands. If the wire is damaged, repeat
this procedure after removing the damaged section.
Step 4: Select and Position the Splice Sleeve
Select the proper splice sleeve according to wire

size. The splice sleeves and tool nests are color coded
(see following chart).
CRIMP AND SEAL SPLICE SLEEVE CHART

Color splice
sleeve
Crimp tool
nest color
Wire gage
AWG I (metric)
Salmon
(yellowish-pink)
Red
20, 18/
(0.5, 0.8)
Blue
Blue
16, 14/
(1.0, 2.0)
Yellow
Yellow
12, 10/
(3.0, 5.0)
w.,.
. . .,
7.Smm (5/16 in)
1 ~'-stop
'
a. Splice before crimping
b. Splice after crimping

r;.Sealant=l
_;!:a
c. Splice after heating
Figure 14 - Seal Splice Sequence

Step 5: Insert Wires into Splice Sleeve and Crimp
RED FILL
BLUE FILL
YELLOW FILL
Insert the wire into the splice sleeve until it hits

the barrel stop and close the handles of the J 38125-8
crimper tightly until the crimper handles open when
released. The crimper handles will not open until the
proper amount of pressure is applied to the spli
sleeve. Repeat steps 4 and 5 for opposite end of the
splice.
Step 6: Shrink the Insulation around the Splice
Figure 13 - Hand Crimp Tool
Using the J 38125-8 splice crimp tool (Figure 13),

position the splice sleeve in the proper color nest of the
hand crimp tool. Place the splice sleeve in the nest so
that the crimp falls midway between the end of the
barrel and the stop.
The sleeve has a stop in the middle of the barrel to
prevent the wire from going further (Figure 14). Close
the hand crimper handles slightly to hold the splice
sleeve firmly in the proper nest.
Using the Ultratorch J 38125-5 (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 will come out of
the end of the tubing when sufficient shrinking is
achieved (Figure 14).
SPLICING TWISTED/SHIELDED CABLE

Twisted/shielded cable is sometimes used to
protect wiring from electrical noise (stray signals).
For example, two-conductor cable of this construction
is used between the ECM and the distributor. See
Figure 15 for a breakdown of twisted/shielded cable
construction.
SA-
5-8
REPAIR PROCEDURES
OUTER
JACKET
DRAIN WIRE
(UNINSULATED)
~6--~,,_a__1,
,
Figure 16-The Untwisted Conductors

MYLAR TAPE
Figure 15 - Twisted/Shielded Cable

DRAIN WIRE
Step 1 : Remove Outer Jacket
Remove the outer jacket and discard it. Be careful

to avoid cutting into the drain wire or the mylar tape.
Step 2: Unwrap the Tape
Unwrap the aluminum/mylar tape, but do aot

11~move it. The tape will be used to rewrap the twisted
conductors after the splices have been made.
Figure 17 - The Re-assembled Cablt!
Step 3: Prepare the Splice
Untwist the conductors: Then, prepare the splice

by following the splicing instructions for copper wire
presented earlier. Remember to stagger splices to
avoid shorts (F'igure 16).
Step 4: Re-assemble the Cable
After you have spliced and taped each wire, rewrap

the conductors with the mylar tape. .Be careful to
avoid wrapping the drain wire in the tape.
Next, splice the drain wire following the splicing
instructions for copper wire. Then, wrap the drain
wire around the conductors and mylar tape
(J.<'igure 17).
Figure 18- Proper Taping

Step 5: Tape the Cable
Tape over the entire cable using a winding motion

(see Figure 18). This tape will replace the section of
the jacket you removed to make the repair.
REPAIRING CONNECTORS
The following general repair procedures can be
used to repair most types of connectors. The repair
procedures are divided into three general groups:
Push-to-Seat and Pull-to-Seat and Weather Pack.
See "Harness Connector Faces," page SA-202-0 to

determine which type of connector is to be
serviced.
Use the proper Pick(s) or Tool(s) that apply to the
terminal.
The Terminal Repair Kit (J 38T25~'A'.) confairis
further information.
TERMINAL
PICK RELEASING
LOCKING TANG
LOCKING
TANG
CONNECTOR
BODY
Figure 19 ~ Typical Push-to-Seat Connector and Terminal
PUSH-TO-SEAT AND PULL-TO-SEAT
Step 2:
Follow the steps below to repair Push-to-Seat

(Figure 19) or Pull-to-Seat (Figure 20) connectors. The
steps are illustrated with typical connectors. Your
connector m:ay differ, but the repair steps are similar.
Some connecto'rs do not require all the steps shown.
Skip those that don't apply.
'
Step 1:
Remove any CPA (Connector Position

Assurance) Locks. CPAs are designed to
retain connectors when mated.
PICK RELEASING
LOCKING TANG
Remove any TPA (Terminal Position

Assurance) Locks. TPAs are designed to
keep the terminal from backing out of the
connector.
NOTICE: The TPA must be removed prior

to terminal removal and must be replaced
when the terminal is repaired and reseated.
Step 3:
Open any secondary locks. A secondary lock

aids in terminal retention and is usually
molded to the connector.
LOCKING
TANG
Figure 20 - Typical Pull-to-Seat Connector and Terminal
REPAIR PROCEDURES
Step 4:
Separate the connector halves and back out

seals.
Step 5:
Grasp the lead and push the terminal to the

forward most position. Hold the lead at this
position.
Step 6:
Step 7:
Step 8:
Step 2:
Open secondary lock. A secondary lock aids

in terminal retention and is usually molded
to the connector.
Step 3:
Grasp the lead and push the terminal to the

forward most position. Hold the lead at this
position.
Locate the terminal lock tang in the

connector canal.
Step 4:
Insert the proper size pick (refer to Terminal

Repair Kit J 38125-A) straight into the
connector canal at the mating end of the
connector.
Insert the Weather Pack terminal removal

tool. into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder.
Step 5:
Gently pull on the lead to remove the

terminal through the back of the connector.
Depress the locking tang to unseat the

terminal.
Push-to-Seat - Gently pull on the lead to
remove the 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.
NOTICE: Never use force to remove a

terminal from a connector.
Step 6:
Inspect the terminal and connector for

damage. Repair as necessary (see
"Terminal Repair," on the following page).
Step 7:
Reform the lock tang and reseat terminal in

connector body.
Step 8:
Close secondary locks and join connector

halves.
NOTICE: Never use force to remove a

terminal from a connector.
Step 9:
Inspect terminal and connector for damage.

Repair as necessary (see "Terminal Repair,"
page SA-5-11).
Step 10:
Reform lock tang and reseat terminal in

connector body. Apply grease if connector
was originally equipped with grease.
Step 11:
Install any CPAs or TPAs, close any

secondary locks and join connector halves.
WEATHER PACK
CONNECTOR
BODY
WEATHER
PACK TERMINAL
REMOVAL TOOL
LOCKING
TANG
Follow the steps below to repair Weather Pack

connectors (Figure 21).
Step 1:
Separate the connector halves.
Figure 21 - Typical Weather Pack Connector

and Terminal
CORE WINGS
CABLE
5 - 11
Step 5:
Position strip (and seal for Weather Pack)

in terminal.
Step 6:
Hand crimp core wings.
Step 7:
Hand crimp insulation wings (non-Weather

Pack). Hand crimp insulation wings
around seal and cable (Weather Pack).
Step 8:
Solder all hand crimped terminals.
TYPICAL PUSH-TO-SEAT TERMINAL
CABLE
CORE
WINGS
MATING END
[s1
SEAL
INSULATION
WINGS
DIODE REPLACEMENT
Many vehicle electrical systems use a diode to
isolate circuits and protect the components from
voltage spikes. When installing a new diode, use the
following procedure:
If the diode is taped to the harness, remove all of

the tape.
Step 2: Remove Inoperative Diode
TYPICAL WEATHER PACK TERMINAL
Figure 22 - Terminal Repair
TERMINAL REPAIR
The following repair procedures can be used to
repair Push-to-Seat, Pull-to-Seat or Weather Pack
terminals (Figure 22). Some terminals do not require
all steps shown. Skip those that don't apply. The
Terminal Repair Kit (J 38125-A) contains further
information.
Step 1:
Cut off terminal between core and

insulation crimp (minimize wire loss) and
remove seal for Weather Pack terminals.
Step 2:
Apply correct seal per gauge size of wire and

slide back along wire to enable insulation
removal (Weather Pack terminals only).
Step 3:
Remove insulation.
Step 4:
Align seal with end of cable insulation

(Weather Pack terminals only).
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 terminal(s) from the
connector to prevent damage from the soldering tool.
Step 3: Strip the Insulation
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.
Step 4: Install New Diode
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. Reference Figure 23 for replacement diode
symbols and current flow explanations. Attach the
new diode to the wire(s) using 60/40 rosin core solder.
Use a heat sink (aluminum alligator clip) attached
across the diode wire ends to protect the diode from
excess heat. Follow the manufacturer's instructions
for the soldering equipment you are using.
SA -
5 - 12
REPAIR PROCEDURES
CURRENT FLOW
SILVER BAND
CORRESPONDS WITH
ARROW IN DIODE
ELECTRICAL SYMBOL
DIODE IDENTIFICATION MARKINGS

1. INDUSTRY STANDARD
RATING NUMBER
2.
TRADEMARK AND/OR
PART NUMBER
1 OR 2
,._
DIODE CURRENT FLOWS

ONLY IN DIRECTION
OF ARROW
Figure 23 - Diode Identification

Step 5: Install Terminal{s)
Install terminal(s) into the connector body if

previously removed in step 2.
Step 6: Tape Diode to Harness
Tape the diode to the harness or connector using

electrical tape. To prevent shorts to ground and water
intrusion, completely cover all exposed wire and diode
attachment points.
ACCEPTABLE DIODE REPLACEMENTS

Diode
Brand
Rating
Number
GMSPO
GMSPO
GMSPO
GMSPO
1N4004
1N5404
1N4001
1N4005
1 amp,
3 amp,
1 amp,
1 amp,
400 PIV
400 PIV
SOPIV
600 PIV
12112421
12112422
16020519
16011840
GMSPO
1N4004
1 amp, 400 PIV
16039386
RATING
PIN
In the event 1 amp, 50 PIV (Peak Inverse Rating)

diodes are unavailable, a universal diode withal amp,
400 PIV rating can be used for the fol!owing
applications:
NC Compressor Clutch
ABS/4WAL (the ABS Diode on the Delco
Moraine is hidden inside of an electrical
connector under the carpet at the right pane))
Wiper
Charging System (hidden in wire harness)
Parking Brake (vehicle with ABS)
Relays
Solenoids
Diesel Glow Plug Circuit
HEATED OXYGEN SENSOR (025) REPAIR

If the Heated Oxygen Sensor pigtail wiring,
connector or terminal is damaged, the entire Oxygen
Sensor Assembly must be replaced. Do not attempt to
repair the wiring, connector or terminals. In order for
the sensor to function properly, it must have provided
to it a clean air reference,. This clean air reference is
obtained by way of the Oxygen Sensor signal and
heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction
of the air reference and degraded 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 poor performance. 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 or vehicle lead wires should
be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through
the lead wire.
Do not remove or defeat the Oxygen Sensor
ground wire (where applicable). Vehicles that
utilize the ground wired sensor may rely on.
this ground as the 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
Packard's Crimp and Splice Seals Terminal Repair Kit
J 38125-A. Under no circumstances should repairs be
soldered since this could result in the air reference
being obstructed.
SA -
5 - 14
REPAIR PROCEDURES
SPECIAL TOOLS
J 36169
Jumper Wire
J 35689-A
Micro-Pack Connector
Terminal Remover
J 34636
Solenoid, Relay and
Circuit Tester
J 35616-A
Connector Test Adapter Kit
/ii&
J.-........-.,4."'u,.,oc--
:~~~
J 28742-A
Weather Pack II Terminal Remover
J 34142-B
Unpowered Test Light
J 8681-A
Universal Short Checker
J 22727
Electrical Terminal Remover
J 21008-A
Self-Powered Test Light
J 33095
Terminal Remover: Micro-Pack,
Com-Pack III and ECM Edgeboard
Connectors
J 39200
Digital Multimeter
J 34764
Autofuse Tester
J38125-A
Terminal Repair Kit
BLANK
5 - 15
8A -
9 -0
VEHICLE ZONING
100-199
300-399
CALLOUT NUMBERS
(For Splices, Connectors and Pass Thru Grommets)
ZONE DESCRIPTION
100-199
All forward of and including dash panel
200-299
Within Instrument Panel area
300-399
Passenger Compartment, forward of hatch
400-499
Hatch area, to rear of vehicle
500-599
To and within left door
600-699
To and within right door
For a Harness Routing View, refer to SECTION SA-203.
SA -
POWER DISTRIBUTION
.---,
..- ....--a-------------...-.-...........
L---1
13 RED
BATTERY
JUNCTION
BLOCK
19BLK
BRED
1 RUST
FUSIBLE
LINKA
5 RED
3 RED
202
3 RED
5 RED
402
FUSIBLE
LINKE
1 RUST
2 RUST
1 RUST
102
TO IGNITION SWITCH
302
PAGE 8A-102
r-
r-
-. STARTER
I SOLENOID
I PAGE SA-301
5 RED
302
..._ .....
........,._....
3 RED
-.GENERATOR
PAGE 8A301
202
A2
r- - .,
L. -
...
HIGH BLOWER
RELAY
PAGE 8A630
3 RED
r COOLANT FAN
I
I
I
5175 - - - - - - - -
S RED
402
COOLANT FAN
RELAY, SECONDARY
(PASSENGER SIDE)
OR COOLANT FAN
RELAY #2
RELAY, PRIMARY
(DRIVER SIDE)
OR COOLANT FAN
RELAY #1
-01
OPTIONAL
FORV8 VIN P
WITHC60
05
F4
WITH NW9
302
5 RED
ABS
RELAY
F2
CS
Cl
G4
302
---------.
G2
I
I
\
f[n1 f[n1
f[nl
\
Fm
I
:L___~
~
~
I
~
.::.,_ 1____ ~1 :1 __ -~ 1' ~1_ ----G~t:l _____/
:
02
SEE COOLANT FANS

PAGES BA-310, 1, 2
SEE ANTILOCK BRAKES

PAGE 8A44 1
SEE ANTILOCK BRAKES/

TRACTION CONTROL
PAGE BA-44-3
1-----------------------------
-----------------------------------------------0
FUSIBLE
LINK
1 RUST
FUSIBLE
LINK F
2 RUST
5 RED
10 - 1
502
5 RED
1002
3RED
1002
3 RED
702
3 RED
702
. - . - - - - - - - - S163
5 RED
502
5 RED
502
3 RED
1002
---,~
r----
FUSE
1
I
I
I
I BLOCK
I
I
I
DEFOG/SEATS
CIRCUIT
BREAKER 12
30AMP
___ J
LSEE FUSE BLOCK DETAILS

PAGE SA-11-7
,---
UNDERHOOD
ELECTRICAL
CENTER
.8 ORN
---------,
240
.SORN
r -
240
g_
DAYTIME
RUNNING
I LIGHTS (DRL)
I
I
I MODULE
PAGES SA-102-0, 1
L-..J
WITH T61
I
J
SEE SEQUENTIAL
FUEL INJECTION
PAGE SA-20-5 (V6 VIN S)
SA-21-3 (VS VIN P)
SEE FUSE
BLOCK DETAILS,,
PAGESA-11-10 .
SEE HEADLIGHT
DOORS
PAGE SA-104-0
PONTIAC
HEADLIGHTr SWIKHI
-\- -
CIRCUIT BREAKER
I
:
----------HEAD);RKOFF
L - -
~V
- - -
HEADj;A1;
_,l _ - -G V-/
EV
I
I
I
:
..J
WITH DAYTIME RUNNING LIGHTS (DRL) SEE PAGE SA-102-1

WITHOUT DAYTIME RUNNING LIGHTS (DRL) SEE PAGE SA-100-0
POWER DISTRIBUTION
.--,-1- __________________ - ___ -..----..

.
. .-----13RED--t-----<O __
19BLK
L--..J
8RED
BATTERY
JUNCTION
BLOCK
FUSIBLE
LINKE
1 RUST
+
STARTER,SOLENOID
PAGE SA-30-1
I
I
-.
-.GENERATOR
PAGE SA-30-1
f""
.. _....
~_,
5 RED
102
SRED
. .- - - - - - - - - - - - - - - - - - i i i i i i i - - - - - - - - - - - - - - - S 2 0 0
S RED
102
r - - ~.; - -
-,
IGNITION
SWITCH
I
I
I
I
TO ABS RELAY
ANDTCSRELAY
PAGE SA-10-0
102
- - - - - - - - -,,
e START
ACCY
'
LOCK,
OFF
.,. (I
BULB TEST
RUN
'\
\
L--------------J
Q
3 BRN
C1
3 BRN
3 RED
102
WITH AU3
3 RED
102
3REf02
E4r3RED
I
I
I
WITHOUT AU]
3BR~
- -
102
!~-lj;. g~~~
3BRN
C
RETAINED,- ACCESSORY
POWER(RAP)
MODULE
PAGE 8A-15-0
C200B
C200D
C6
C200D
C200C
D
-
RESET
B+
... ________
P::fo s~uJs
HOT IN ACCY, RUN OR
DURING RAP
3 RED
~~~~~
3 DK BL~S
102
3BRN
3 BRN
3 DK
E12 , - - - - - E ~ ,
3 PN~O
.....
E12
,-----!~,
3 PNXO
g~~~
3 DK BLXS
'~~~--~~~~~~~-.v~~~~~~~~~~~..-/
I/Pr
FUSE
BLOCK
I
I
I
I
I
-~-----CIGAR/
HORN
FUSE 11
25AMP
BATT
(NOT USED)
L----SEE FUSE BLOCK DETAILS

PAGESA-11-8
----i..------ .I.
PWRACCY
~
1SAMP
WINDOWS
CIRCUIT
BREAicER15
30AMP
WIPER/WASH
FUSE 14
2SAMP
A.CCV
(NOT USED)
----------SEE FUSE BLOCK DETAILS

PAGE SA-11-9
'\
\
-----J
10 . . 3
rr-~~-~--~------~--------------------,
f
,__________________t ________________
\
ACCY ,
START
LOCK ;FF _
"C
ACCY ,
RUN IIULB TES,T
LOCK ;FF _
:u:
/ START
ACCY ,
BULB TEST
LOCK ;FF _
;u:
A'(9-
BULB TEST :
S YEL
cs
S201
3 ORN
lSTART
Aig
3 ORN 1300
3 PNK
I
I
I
C200B
C2000
..-----..
-
300
5 VEL
5223
C200B
C200D
81
vEL
3 PNK
30RN
300
UNDERHOOD
ELECTRICAL
------,
-
~
~EE FUSE BLOCK DETAILS
PAGE SA-11-13
...
THEFT
DETERRENT
RELAY
PAGE 8A133-0
3 ORN
PCM IGN
FUSES
, lSAMP
GAGES
FUSE 9
10AMP
IGN
(NOT USEOI
300
S VEL
3 ORN
300
TURN B-U
20AMP
------------------~
SEE FUSE BLOCK QETAILS
PAGE BA-11-5
..I
MANUAL
~-~-------------~I
I.. -
SEE FUSE B~OCK DETAILS

PAGE SA-11.-14
3PNK
I
I
S VEL
'\
I
I
ill!ill
r---
s Is
....c1A -,
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
Bl
--,..---,
AUTOMATIC
II
I
I
I
CRAfi! I L. ...
FUSE 16 I CLUTCH
3 AMP I ~TART
SWITCH
I PAGE BA-133-0
__ J
SEE FUSE
BLOCK DETAILS
PAGE 8A11-9
,---,
I.. -
...
TRANSMISSION
POSITION
SWITCH
PAGE 8A 133-0
FUSE BLOCK DETAILS (CHEVY)

1/P FUSE BLOCK
12052685
BASE FUSE BLOCK PACK-CON III
BLK
PCM BAT
AUTOFUSE
HVAC
TURN B-U
COLOR/RATINGS
COLOR
AMPS
FRONT VIEW
PPL
TAN
RED
10
BLUE
15
YEL
20
WHT
25
REAR VIEW
AIRBAG
FUSE BLOCK DETAILS (PONTIAC)

1/P FUSE BLOCK
:1
11: 15 :121: 20 :1 31: 25 :1 41: 10

AIRBAG
TURN B-U
HVAC
PCM BAT
:1
12052685
BASE FUSE BLOCK PACK-CON
BLK
Ill
5(: 15 :161: 20
11: 15 :1 sl: 15 :1
PCM IGN STOP/HAZARD PWR ACCY
COURTESY
{9ul: 5 :1141:25 :1
1sl]]ABR~I
IGN IP DIMMER WIPER/WASH BATT WINDOWS
16C: 3 :1
(NOT USED)
CRANK
ACCY (NOT
USED)
AUTO FUSE
111:RADIO
15 :1
COLOR/RATINGS
COLOR
AMPS
PPL
TAN
RED
10
BLUE
15
YEL
20
WHT
25
FRONT VIEW
r;:---"
r,:---;,
rr
--"
~=~~=q~~=~
EJ11E] 811 ~
c __ :!) ~ - - - : ! ! l!; _ _
I~
(240 CKT has 2 Wires with DRL)
~-q : ra~~ 8 ~
00
G1 ~ d [] 8
~---!.J
~---:!l
REAR VIEW
~~
11 - 1
SA -
FUSE BLOCK DETAILS

1/P FUSE BLOCK
FUSE
.NUMBER
FUSE
NAME
RATING
(AMPS)
AIRBAG
1S
Diagnostic Energy Reserve Module, Dual Pole Arming Sensor
8A115
TURN BU
20
Backup Light Switch, Daytime Runnini Lights Module, Turn Flasher,

Performance/Traction Control Switch, ransmission Position Switch
SA-116
HVAC
25
HVAC Selector Switch, Rear Defogger
BA-116
PCM BAT
10
Powertrain Control Module, lnst.rument Cluster, Theft Deterrent

Module
BA-117
PCMIGN
15
Powertrain Control Module, Theft Deterrent Module, Fuel Pump

Relay, Mass Air Flow (MAF) Sensor
BA-115
STOP/HAZARD
20
Brake Light/Cruise Release Switch, Hazard Flasher
BA-117
PWRACCY
15
Power Door Locks, Power Mirrors, Hatch Release
8A118
COURTESY
15
Amplifier, Audio Alarm Module, Bose Relay, Hatch Release Relay,

Lamps: Console Co111partment, 1/P Compartment, Dome, Courtesy,
Rear Compartment Lamp, Keyless Entry Receiver, Rearview Mirror
and Radio
BA-11-8
GAGES AND
IGN TERMINAL
10
Audio Alarm Module, Daytime Running Lights Module, Diagnostic

Energy Reserve Module. Instrument Cluster, Keyless Entry Receiver,
Brake Switch Assembly
BA-11-5
10
TAIL LTS
20
Exterior Lighting
11
CIGAR/HORN
AND BATT
TERMINAL
25
Cigar Lighter, Horn Relay
SA-11-8
12
(Circuit
Breaker)
DEFOG/SEA TS
30
Power Seats. Rear Defogger
BA-11-7
13
1/PDIMMER
Interior Lights Dimming
BA-1170
14
WIPER/WASHER
ANDACCY
TERMINAL
25
Windshield Wiper/Washer
BA-91-0
or
BA1H
15
(Circuit
Breaker)
WINDOWS
30
Power Windows, Coolant Level Latching Module, Convertible Top

Switch
SA-1200
or
SA-11-9
16
CRANK
'Diagnostic Energy Re.serve Module
BA-11-9
17
RADIO
15
Radio, Steering Wheel Controls (Radio)
BA-11-9
RELATED CIRCUITRY
PAGE
With DRL (Z49)

SA-1021, 3
Without DRL (Z49)
SA-100-0,2
11 - 3
FUSE BLOCK DETAILS

12129351.
12110396
ASSEMBLY CONVENIENCE C~NTER
COVER CONVENIENCE CENTER
BLK (BLOCK)
BLK (COVER)
COOLANT FAN
RELAY #1
OR
COOLANT FAN
RELAY, PRIMARY
(DRIVER SIDE)
AIR PUMP
RELAY
ABS
RELAY
A/C COMPRESSOR
RELAY
~
~
INJECTOR
INJECTOR
0.0
IGNITION
F
u
FOG LIGHTS
RELAY
ASR/TCS
RELAY
COOLANT FAN
RELAY, SECONDARY
(PASSENGER SIDE)
OR
COOLANT FAN
RELAY #2
00
A/C-CRUISE
COOLANT FAN
RELAY #3
TOP VIEW
#48
~#8~
(PONT ONLYl
84
~4
[j}
04
B cfu E] sB C8J [~J sG C8J E] s0 I s! j ~
5 473
#?El
502
#3E3
#2
#5~
641
#1
[J]
El
B,
(PONTONLYl
~1
4
sE]
E
#128
1~1~1
C8J
3
~1
B sE)
2
01
B,
B
C8J
3
8s00 C8J ~sB

c El
~
2
(402 CKT has 2 Wires with 2 Coolant Fans)

(641 CKT has 2 Wires with NW9 option)
... (139 CKT has 2 Wires without K34 option)
BACK VIEW
0
C8J
E]
3
] 1
#113
#108
#98
FUSE BLOCK DETAILS
UNDERHOOD ELECTRICAL CENTER - FUSES

FUSE
NUMBER
FUSE
NAME
RATING
(AMPS)
RELATED CIRCUITRY
PAGE
ABS BAT
Electronic Brake Control Module or Electronic Brake/Traction Control

Module
SA-11-10
FOG LTS
20
Fog Lights
SA-11-10
HEADLAMP
DOOR.RH
(PONT ONLY)
15
Headlight Doors Module
SA-11-10
HEADLAMP
DOOR,LH
(PONT ONLY)
15
Headlight Doors Module
SA-11-10
ABS IGN
Antilock Brake System, Traction Control System
SA-11-11
FANS/ACTR
10
Coolant Fan Relays, EVAP Canister Purie Solenoid, Exhaust Gas

Recirculation, Reverse Lockout Solenoid, kip Shift Solenoid, Heated
Oxygen Sensors
SA-11-12
AIR PUMP
20
Air Pump Relay
SA-11-11
NOT USED
INJECTOR
7.5
Fuel Injectors
10
(V6 VIN S)
SA-11-14,
INJECTOR
7.5
Fuel Injectors
(VS VIN P)
SA-11-13
11
IGNITION
10
V6 VIN S: Camshaft Position Sensor, Crankshaft Position Sensor,

Ignition Control Module. Automatic Transmission
VS VIN P: Ignition Coil, Ignition Coil Module, Automatic Transmission
SA-11-15
12
A/C-CRUISE
20
A/C Compressor Relay. Cruise Control Switches and Module
SA-11-15
UNDERHOOD ELECTRICAL CENTER- RELAYS

RELAY
LOCATION
RELAY NAME
PAGE
A/C COMPRESSOR
SA-11-15
ABS
SA-11-11
COOLANT FAN, PRIMARY
AUTOFUSE
FUSE COLOR/RATINGS
COLOR
AMPS
SA-11-12
TAN
AIR PUMP
SA-11-11
BROWN
7.5
COOLANT FAN, SECONDARY
SA-11-12
RED
10
ASR/TCS
SA-11-11
BLUE
15
FOG LIGHTS
SA-11-10
COOLANT FAN #3
SA-11-12
YELLOW
20
11 - 5
FUSE BLOCK DETAILS

1/P FUSES 1, 5 AND 9
...
....-~~~~~~~~~~~~~~
----------------~~
1rusE
~~~~~~~~
BLOCK
.. ____ _
.8 YEL
GAGES
FUSE9
10AMP
AIR BAG
FUSE 1
15AMP
11
I
IGN
(NOT USED)
-----J
1139
5204
...........................
.8 YEL
1139
::l
1139
.5 PNK
439
.8 PNK
39
r------,
I"" -
.8 YEL
-,
.... _....
A10
L------J
ARMING
SENSOR,
DUAL POLE
PAGE 8A-47-1
DIAGNOSTIC ENERGY
RESERVE MODULE (DERM)
PAGE SA-47-0
.5 PNK
S20S
.-----------------~-----------~
--439
VB VIN p
V6 VIN S
.._..:.:.~.,ll.
439 .8 PNK
.8 PNK
r- - -,
....
_....
MASS AIR
FLOW(MAF)
SENSOR
PAGE 8A-21-S
.8 PNK
5 PNI439 '
.Q
I!
30
.._ _ _ _ _ .J
.... ....
POWERTRAIN
CONTROL
MODULE (PCM)
PAGE SA-21-0
POWERTRAIN
CONTROL
MODULE (PCM)
PAGE BA-20-0
439
....
....
_....
.... ....
I I
I I
1 PNK
- ...
A2
!'.;
.--~
439
....
439
~-----,
3
C1
- ...
THEFT
IJETERRENT
MODULE
PAGE 8A-133-1
FUEL PUMP
RELAY
PAGE BA-21-2 (VS VIN P)
OR
PAGE 8A-20-2 (V6 VIN S)
.35 PNK
39
.35 PNK
39
.35 PNK
.--
-- .
.... - ...
H
.... ....
AUDIO
ALARM
MODULE
PAGE iA-76-0
~---- ...
CONVENIENCE
CENTER
.35 PNK
39
C200D
C200C
E10
g_
.----,
I
B
TCC/SHIFT
INTERRUPT
SWITCH
I
I,_
__ ...,
BRAKE SWITCH
ASSEMBLY
PAGE BA-21-6 (V8 VIN P)
OR
PAGE BA-20-6 (V6 VIN S),
PAGE SA-138-0
.35 PNK
D
Q.
-,
_....
WITHAUO
39
.35 PNK
.35 PNK
D13
AS
39
r------,
I
I
._
..._....I
39
(CHEVY) D7
(PONT) A 1
.--~
82
KEYLESS
ENTRY
RECEIVER
PAGESSA-112-1,3
.8 PNK
39
I"" -
....
39
....
--.
C1
_____ _. .... _....
DIAGNOSTIC
INSTRUMENT
ENERGY
CLUSTER
RESERVE
PAGE SA-81-0
MODULE (DERM)
PAGE BA-47-0
DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
PAGITTA-1020, 2
WITHT61
SA - 11 .. 6 ELECTRICAL DIAG:NOSIS
FUSE BLOCK DETAILS

1/P FUSES 2 AND 3
TURN BU
FUSE 2
20AMP
... -
- - ....
3 BRN
241
.35 BRN
lj
241- - - - - - - - -
5248 - - - -
I I
PONT
CHEVY
,--~~~~~~A~~~~~~--.,
3 BRN
-------
r-I
I
I
I
141
PNK
... ~.,
c
I
I
I
1
I
.8 BRN
J~
241
I
I
'--..I
L...-....1
REAR
DEFOGGER
TIMER/RELAY .
PAGE 8A611
liVAC
SELECTOR
SWITtH
iiAGEsSA-63-0,
8A640, 1
-------,I
....... .,cs I
l ' -_ _ _
PN_K___,
241
.1
L.-....1
REAR
QEFOGGER
SWITCH
AAGESA-61-1
I
I
I
I
I
I
'------------------~
HEATERNENT/
AIR CONDITIONING (HVAC)
CONTROL ASSEMBL V
"" - ..,
A
L.-....1
REAR DEFOGGER
SWITCHmMER
PAGE 8A-610
PONT WITH M30
,-A_U_T_O_M_A_TI_C_-,
TRANSMISSION
.35 BRN
"" - ..,
TRANSMISSION
'--..I
WITHNW9
141
"" ..,
I
I
,.(..
141
.8 BRN
I
I
5207. - - - - - - - - - - - - - -. . .
MANUAL
'--..I
PERFORMANCE/
TRACTION
~SWITCH
WITHOUT NW9
PERFORMANCE
SWITCH.
PAGTSA-39-1
TRANSMISSION
POSITION
SWITCH
PAGE SA-1120
.88RN
,. 8BRN
141
r---,
I
I
L. -
141.
I
I
.....
BACKUP
LIG~
SWITCH
PAGE SA-1120
.88RN
141
"" - .,
,.. - .,!.
'-- .....
L.-....1
I
I
TURN
FLASHER
PAGE SA-1100
DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
PAGESSA-1020, 2
WITH T61
ELECTRICAL DIAGNOSIS 8A - 11 - 7
FUSE BLOCK DETAILS

1/P FUSES 4, 6 AND DEFOG/SEATS CIRCUIT BREAKER
---.1/P
,I FUSE
BLOCK
DEFOG/SEATS
CIRCUIT
BREAicER 12
30AMP
..
1
I
----SORN
------
--.J
1240
SEE PAGESSA-102-1, 3 (WITH DRL)

SEE PAGES SA-100-0, 2 (WITHOUT
SEE FUSE
BLOCK DETAILS
PAGE SA-11-8
5252 - - - - - - -
SORN
1240
.SORN
140
.8 ORN
/------1-.,
.SORN
340
3 ORN
1240
-----.
,- - ..,
r-
C4
I ORN,J,..1240
I ,---,
I
I L.-..1
I REAR
DEFOGGER
I ~y
I PAGE SA-61-1
- ..,
L . - ...
r-~-----.,
,-
140
LIGHT/ I
I BRAKE
CRUISE
I RELEASE
I
I
I
I
I
I
I
I
I
I
Q_
r----~
SWITCH
L. -
L---...1
...
HAZARD
FLASHER
PAGE 8A-1100
BRAKE SWITCH
ASSEMBLY
PAGE SA-110-1
L..-----~
CONVENIENCE
CENTER
L.-----..J
REAR DEFOGGER
SWITCHITIMER
PAGE SA-61-0
HEATERNENT/
AIR CONDITIONING (HVAC)
CONTROL ASSEMBLY
AIC310
I-----.1
PONT
WITHAQ9
WITH AC3
-----------111
3 0 R f 240
5320
.8 ORN
.SORN
340
.8 ORN
340
2 ORN/
BLK
1240
340
I mo
I
I
I
5106-----
.8 ORN
15
340
.8 ORN
31
;! - .;;.-.;;.-2 -
.Jf _____ ,::};,

1
340
B (VS VIN Pl
~.!~I~)
L.-------..1
POWERTRAIN
CONTROL
MODULE (PCM)
PAGE SA-21-0 (VS VIN P)
OR
PAGE SA-200 (V6 VIN S)
C14
A13
,-
- ..,
(CHEVY)
(PONn
At
,-
- ..,
3 ORN
1240
I
I
II
II
L.-,.1
1.-..1
INSTRUMENT
CLUSTER
PAGES
SA-81-1,2
THEFT .
DETERRENT
MODULE
PAGE SA-133-1
POWER
SEATSWITCH
PAGESA-1400
1240
.-- --,1
,!--,
II ,!--,
L . - ...
3 ORN
I
I
I
1
I
II
11
11
I
I
1r-
,!--,
I
I
1.-..1
1. .... ..1
POWERSEAT
SWITCH, DRIVER
POWERSEAT
CONTROL
PAGESA-141-0
~...~~~i:-141-0
--,
II,!--,
II I
I
II I
I
II 1.-..1
11 POWERSEAT
SWITCH. -
11
~~~:1.1
L----~L---------~L---SEATASSEMBLY,
DRIVER
SEAT ASSEMBLY,
Qfilill
SEAT ASSEMBLY,
PASSENGER
.JI
8A - 11 - 8 ELECTRICAL DIAGNOSIS
FUSE BLOCK DETAILS

1/P FUSES 7, 8 AND 11
HOT IN ACCY, RUN OR
RETAINED ACCESSORY
POWER(RAP)
---,,;p
I FUSE
BLOCK
11
I
PWRACCY
BAIT
(NOT USED)
15AMP
-------------
.8 ORN
--J
! IMPORTANT:
640
FUSE 7 SHOWN
WITH ALL OPTIONS.
1 ORN
540
.8 ORN
5211 - - - - - -
540
.8 ORN
.5 ORN
640
640
--,
rI L
I r---,
I
I '- --1
I HORN RELAY
PAGE SA-40-0
I
r- - .,
r- - .,
- ...
....
....
.SORN
CIGAR
LIGHTER
PAGES 8A-114-0, 1
640
~F
r---,
40
40 (CHEVY WITH U82)
PAGESA-ns-o
CONVERTIBLE ONL y
.f~
1 ORN
3 ORN
HATCH
RELEASE
SWITCH
L----.1
CONVENIENCE
CENTER
_...
I
.8 ORN
.5 ORN
640
HATCH
RELEASE
RELAY
PAGE SA-135-0
640
5317
.SORN
r---,
I
I
I
I
....
'---1
.... _..,
&,. -
COURTESY
LAMP,
LEFT REAR
PAGE SA-114-1
REAR
COMPARTMENT
LAMP
PAGE SA-114-1
COURTESY
LAMP,
RIGHTREAR
PAGE SA-114-1
.SORN
...
r---,
I
I
I
I
(CHEVY)
(PONT)
... -.,
r---,
I
I
I
I
r---,
A
H
40
- ...
....
_...
POWER
DOORLOCK
SWITCH, RH
PAGE SA-130-0
POWER
DOORLOCK
SWITCH, LH
PAGE 8A-130-0
__,
....
'(1- -
POWER
MIRROR
SWITCH
PAGES SA-147-0, 1
.5 ORN
.SORN
. . . ._ _ _ _ _
40
40
40
(2000
El TC200C
.SORN
...
40
5265
1 ORN
40
.5 ORN
40
.50~N~4~
C2
,... - -i
....
_...
r~-t ;_ ~
I IC
JC
~RTESY/ -
I~
LAMPS
KEYLESS
I, ENTRY
REARVIEW
MIRROR
RECEIVER
PAGES SA-132-1, 3 PAGES 8A-114-0, 1
10
1,r---,
, ,
I
J
I.. _
,1
-I
.8 ORN
B!
40
r-,
I -
I.., _
...J
1C_J1
RADIO
DOME
PAGES SA-150-0, 2, 4 LAMP
PAGESA-114-0
.5 ORN
re
.8 ORN
40
--,
r---,
Ir---,
.... - ...
I I....
I
I AUDIO
I ALARM
MODULE
I PAGE 8A-76-0
II
1/P
COMPARTMENT
LAMP
PAGES SA-114-0, 1
_...
L----J
CONVENIENCE
CENTER
40
3 ORIN40
1 ORIN O
- ..,
r---,
.... -.,
...._ ...
...._ ...
... - ...
,...B
CONSOLE
COMPARTMENT
LAMP
PAGES SA-114-0, 1
(1
BOSE RELAY
PAGE
SA-150-2
CHEVY
WITH US2
AMPLIFIER
8A-150-5
PONT
WITH UW2
FUSE BLOCK DETAILS

1/P FUSES 13, 14, 16, 17 AND WINDOWS CIRCUIT BREAKER
HOT IN ACCY, RUN OR

DURING RETAINED
ACCESSORY POWER (RAP)
HOTIN START
SEE INTERIOR LIGHTS DIMMING
PAGE SA-117-0
SEE STARTER & CHARGING

PAGE SA-30-0 FOR POWER FEED
r--i-------'
I
I
1/P DIMMER
FUSE 13
5AMP
- - .... 1,p
.----------CRANK
FUSE 16
3AMP
ACCY
FUSE 14 (NOT USED)
2SAMP
~---" - v------------"
1YEL
I FUSE
WINDOWS
CIRCUIT
BREAKER 15
30AMP
RADIO
BLOCK
,--
!1.1
FUSE
15AMP
__.
143
3 BRN
341
C2000
C200B
SEE INTERIOR
LIGHTS DIMMING
PAGE SA-117-0
43
.8 PPL
810
....
....
806
- ..,
_...
L..-..1
WIPER
MOTOR
ASSEMBLY
PAGE SA-91-0
WIPER/WASHER
SWITCH
ASSEMBLY
PAGE SA-91-0
L..-..1 3BRN
DIAGNOSTIC
ENERGY
RESERVE
MODULE (OERM)
PAGE BA-47-0
341
3 BRN
5253
....
341
_...
_...
STEERING
WHEEL
a>NTROLS,
RADIO
PAGEBA-150-1
c
..---,
....
....
....
_...
CONVERTIBLE ONLY
C1
...,-
RADIO
PAGES SA-150-0. 2, 4
PONT
WITH UK3
E11
CONVERTIBLE
TOP SWITCH
PAGE SA-121-0
C2000
C200C
WITHV8 VIN P
WITHOUTAU3
.---------------------~----~----~
5208
3 BRN
3 BRN
341
341
3 BRN
....
_...
POWER
WINDOW
SWITCH, LH
PAGE BA-120-0
3 BRN
341
P600
P500
.... -.,
341
- .,
.... _...
.... - .,
EXPRESS
DOWN
MODULE
PAGE SA-120-0
POWER
WINDOW
SWITCH,RH
PAGE BA-120-0
....c
....
_...
....
A
- ..,
...._ ...
COOLANT LEVEL
LATCHING
MODULE
PAGE 8A-81-3
8A -
FUSE BLOCK DETAILS

UNDERHOOD FUSES 1, 2, 3, 4AND FOG LIGHTS RELAY
HOT AT ALL TIMES
r - - - - - - - - - - ,- - - - - - - - - - - - -- - - - - - - - - - -- ., I
I
I
FOG
LTS
FUSE 2
20AMP
ABS BAT
FUSE 1
SAMP
.8 ORN
HEADLAMP
DOOR.RH
FUSE3
15AMP
HEADLAMP
DOOR, LH
FUSE 4
1SAMP
~
~
r;;;i
~
1340
4
FO
30G [ m
: :] H
.
LIGHTS
~
WITH T96
OPTION
L---
--
87
___________ :t.::i:_
-."...,- ;- --85
--,--...1
SEE HEADLIGHTS AND FOG LIGHTS:

WITHOUTT61
PAGES SA-100-1, 3
OR
.5 ORN
810
HEADLIGHTS AND FOG LIGHTS:

DAYTIME RUNNING LIGHTS (T61)
PAGES SA-102-4, S
440
-i
._ _
..J
ELECTRONIC
BRAKE CONTROL
MODULE (EBCM)
PAGE SA-441
OR
WITH NW9
740
1 ORN
840
,-------~
C2
I'" -
1 ORN
ELECTRONIC
BRAKE/TRACTION
CONTROL
MODULE (EBTCM)
PAGE 8A-44-3
______
~------~
HEADLIGHT
DOORS
MODULE
PAGE 8A-104-0
UNOERHOOD
ELECTRICAL
CENTER
ELECTRICAL DIAGNOSIS BA - 11 - 11
FUSE BLOCK DETAILS

UNDERHOOD FUSES 5 AND 7, ABS RELAY, ASR/TCS RELAY AND AIR PUMP
I
I
r----------------------------------HOTINRUN
AIR
PUMP
FUSE 7
ZOAMP
FANS/ACTR
FUSE 6
10AMP
.35
BRN
.5 BRN
.5 BRN 541
641
cs
C1
E1
ABS
RELAY
CZ
ES
5
G2
441
:.~:~
A5RITCS
RELAY
5
C4
,UNDERHOOD
ELECTRICAL
CENTER
GS
E4~
E21
______________ Ll_
'----v---"
SEE ANTILOCK
BRAKES
PAGE SA-44-1
.35 BRN
B11
641
C2
r- - -i
... _...
ELECTRONIC
BRAKE CONTROL
MODULE (EBCM)
iiAGE"iA-44-1
OR
WITHNW9
ELECTRONIC
BRAKE/TRACTION
CONTROL
MODULE (EBTCM)
iiAGE"iA-44-3
SEE ANTILOCK
BRAKES/TRACTION (NW9l
PAGE SA-44-3
~-------,-----SEE FUSE
BLOCK DETAILS
PAGESA-11-12
SEE
PAGE SA-205 (V6 VIN Sl
PAGE SA-21-3 (VS VIN Pl
SA -
11 - 12
FUSE BLOCK DETAILS

UNDERHOOD FUSE 6, COOLANT FAN RELA VS
.
"
HOT IN RUN
UNDERHOOO
ELECTRICAL
CENTER
r-----------------------------------~------~
FANS/ACTR
FUSE610AMP
.5 BRN
.35
BRN
2CAMP
541
641
J4
.35
BRN
AIR PUMP
01
JS
F4
OS
COOLANT
FAN
RELAY #3
641
J]y J1r
_L -
Jl1---
.S BRN
COOLANT
FANRELAY,
FANRELAY,
PRIMARY OR
COOLANT
FAN RELAY
SECONDARY
OR COOLANT
FAN RELAY #2
OPTIONAL
-D~'-D~l- -
_I_
______ ...
-----~
..
SEE COOLANT FANS

PAGE8A-3U
SEE COOLANT FANS

PAGE58A-31-0, 1, 2
FSY
VB VINP,
WITH (C60)
SEE COOLANT FANS

PAGES BA-31-1, 2
.35 BRN
.35 BRN
SEE
PAGE SA-21-3 (VB VIN P)
541
541
.35 BRN
541
.35 BRN
F
.--~-,I
541
C100
.35 BRNf 4-1-
VS VIN P .
,--~-,I
V6 VIN S
""l
5127. - - - - -. .
,8
541
.8 BRN
541
.35 BRN
541
BRN
,...
L.. -
r - -,
.....
,.. _.....
HEATED
OXYGEN
SENSOR
BANK#1
PAGE BA-21-5
.5 BRN
541
HEATED
OXYGEN
SENSOR
BANK #2
PAGE BA-21-5
.35 BRN
541
-,r--,
A
..,
i
I rB - - ,
11
I
II
I
I ,... .....
I REVERSE
I
LOCKOUT
SOLENOID
r--,
L..
.....
SKIP SHIFT
SOLENOID
PAGE SA-21-7
I
11,.._ ...I
I EVAPORATIVE
I EMISSION (EVAP)
CANISTER PURGE
I SOLENOID VALVE
PAGE SA-21-5
I
.35 BRN
541
r - ..,
II
L"'::_E ~-22,:? - - - - ~
MANUAL
TRANSMISSION
(MN6)
441
5
F11
&.---"-v--"~
SEE FUSE
BLOCK DETAILS
PAGESA-11-11
F2
COOLANT
,...
- ....
EXHAUST GAS
RECIRCULATION
(EGR) VACUUM
CONTROL SIGNAL
SOLENOID VALVE
PAGE BA-21-5
"~t
r--,
,...
- .....
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
PAGE SA-20-5
.5 BRN
541
r--,
,... -
.....
EXHAUST GAS
RECIRCULATION
(EGR) VACUUM
CONTIIOLSIGNAL
SOLENOID VALVE
PAGE SA-20-5
FUSE BLOCK DETAILS

UNDERHOOD FUSES 9 AND 10 (VS VIN P)
I
I
I
A/CCRUISE
FUSE 12
20AMP
I
I
_ _ _ .J
"--v-"
SEE FUSE
BLOCK DETAILS
PAGE 8A1115
.8 PNK
639
.8PNK
839
---------------------------------------
.5 PNK
639
.SPNK
639
.5 PNK
.SPNK
r- - .,
'---I
FUEL
INJECTOR2
639
.5PNK
639
,--.,
r- - .,
I
I
I
I
I
I
I
I
I
I
839
.5PNK
839
.5 PNK
.5 PNK
639
,--.,
B
.5 PNK
,--.,
B
.5PNK
839
r- - .,
r- - .,
I
I
'- - - 1
'- - - I
L.-J
'- - - 1
FUEL
INJECTOR3
FUEL
INJECTOR 5
FUEL
INJECTORS
FUEL
INJECTOR 1
SEE SEQUENTIAL MULTIPORT

FUEL INJECTION (V8 VIN Pl
PAGE SA-21-3
839
'- - - I
FUEL
INJECTOR4
I.. -
I
I
...
FUEL
INJECTOR 6
839
,---,
I
I
I
I
I.. -
...I
FUEL
INJECTOR 7
11 - 13
8A-11 -14 ELECTRICAL DIAGNOSIS
FUSE BLOCK DETAILS

UNDERHOOD FUSES 9 AND 10 (V6 VIN S)
I
I
I
L
INJECTOR
FUSE9
7.SAMP
A/C-CRUISE
FUSE 12
20AMP
___ ...
---------------------
.SPNK
639
.5 PNK/BLK
839
_ - - - - - - - _ - - - - - - - - - - - - - - - - - - - - - - - - ______K
.8 PNK
.8 PNK
639
SEE FUSE
BLOCK DETAILS
PAGE SA-11-15
C100
.8 PNK
839
-------------------------------------- H
639
.5 PNK/BLK
839
51041-------------
.5 PNK/BLK
639
.S PNKIBLK
.S PNK/BLK
r- - - ,
I
I
FUEL
INJECTOR 1
r- - .,
I
I
...
FUEL
INJECTOR3
.S PNK/BLK
839
.S PNK/BLK
r- - .,
I.. -
.5 PNK/BLK
639
I
I
... _...
639
I.. -
r- - ..,
I
I
...
FUEL
INJECTORS
'--
...
FUEL
INJECTOR 2
SEE'SEQUENTIAL MULTIPORT
FUEL INJECTION (V6 VIN Sl
PAGE SA-203
839
839
r- - ..,
r- - ..,
I.. -
I.. -
...
FUEL
INJECTOR4
....
FUEL
INJECTOR6
FUSE BLOCK DETAILS

UNDERHOOD FUSES 11, 12 AND A/C COMPRESSOR RELAY
UNDERHOOD
ELECTRICAL
CENTER
HOT IN RUN, BULB TEST OR START
-----'iiiiliiii_,............ ~- ... - _ --....-_,it........ -" .....
r - - - - - - ,_ - - - - - -
----- -
.. ------------~
SEE MULTIPORTFUEL
INJECTION
OR
PAGE SA-21-3 (VS VIN P)
.8 PNK
.8 PNK
VS VIN p
BS
~MPR.ESSOR
RELAY
139
.8 PNK
I yI
139
.8 PNK
.8 PNK
139
5165 IS ONLY PRESENT WITH

CRUISE CONTROL (K34).
WITHOUT K34 CKT 139 IS

WIRED DIRECTLY FROM
FUSE 12 TO TERM "81" OF
THE A!C COMPRESSOR
RELAY WHERE THE WIRE IS
DOUBLED TO FEED
TERM "82" OF THE AIC
COMPRESSOR RELAY .
5107
239
.35 PNK
IMPORTANT:
r- - .,
.8 PNK
- - - -.... ------...--...
239
1,
239- - - - - - - -
. .- - - - -
SEE HVAC
COMPRESSOR
CONTROL
PAGE SA-64-0, 1
~8PN~39
K
.S PNK
81
A/C-CRUISE
FUSE 12
20AMP
INJECTOR
FUSE 10
7.SAMP
INJECTOR
FUSE9
7.SAMP
''...i . . . -
.8 PNK
139
L..-...1
239
CRUISE
CONT:ROL
MODULE
PAGE'.SA-34-0
5107
~.~------------
.8 PNK/BLK
1846
.,
r- - .,
IGN
I
I
I
I
I
I
I
I
I
I
I
I
L.. -
r- - .,
L..-..1
AUTOMATIC
TRANSMISSION
(M30)
PAGE SA-39-0
.5
PNK
....
IGNITION
COIL MODULE
PAGE SA-21-1
AVQ
IGNITION
.35
PNK
239
.8PNK
.35 PNK
.J
r"' _
r---,
L..-...1
L..-.J
CAMSHAfT
POSITION
SENSOR
-,PAGE SA-20-1
r"
... --,
B
.35 P:K
CRANKSHAFT
P-OSITION
SENSOR
(HI RES)
PAGE SA-2.0-1
L.. -
IGNITION
CONTROL
MODULE (ICM)
PAGE SA-20-1
L.. -
AUTOMATIC
.8PN~39
.
CLUTCH
ANTICIPATE/
CRUISE RELEASE
SWITCH
(ALL V6 MANUALS
HAVE A 4 CAVITY
CONN, 2 UNUSED
WITHOUT K34)
PAGE SA-34-0
C21S
'
B+C250
.3SP:~139
r--.,
139
L.. -
....
Ivs
...
CRUISE
RELEASE/
BRAKE
SWITCH
PAGE BA-34-0
/,:%==:=:---===~
116 VIN
AUTOMATIC
TRANSMISSION
(M30)
PAGE SA-39-0
r---,
1
I
I
I
....
....
MANUAL
:~1~
239
239
r---,
I
I
PAGE SA-21-1
L.. -
WITHOUT
NW9
239
C2
AVQ
.8 PNK
VIN p
CR!,JlSE RELEASE/
CLUTCH SWITCH
(VS MANUALS
WITH K34 HAVE A
2 CAVITY CONN)
PAGE SA-34-0
~.f .,-,
I I
I I
11..-.J
CRUISE
I
I CONTROL
_.I
I._SWITCHES
PAGE SA-34-0
___
MULTI-FUNCTION
LEVER
FUSE BLOCK DETAILS

COMPONENT
Amplifier (part of UW2
Speaker Option) ....... .
Arming Sensor, Dual Pole .
Backup Light Switch (M49)
(V6 VIN S) ........... ..
Backup Light Switch (MM6)
(VS VIN P) ........... .
Bose Relay ............. .
Brake Switch Assembly .. .
201-PG
FIG.
CONN
Mounted behind Right Rear Armrest, on Rail ....... . 44

Mounted to Floor Tunnel Bracket, under console ..... . 43
83
81
202-9
202-19
Middle of Transmission, left side ................... . 16
30
LOCATION
Middle of Transmission, right side ................. . 26

51
41
Below center A/C Duct, mounted to SIR Bracket ..... . 22
Mounted in lower hole of brake pedal bracket (2 conn
with Automatic), (1 conn with Manual)
same switch for both ............................. . 0 .... 1

(V6 VIN S) . . . . . . . . . . . . . In front top of Engine Block, between Intake and
Water Pump .................................... .
Cigar Lighter ........... . Mounted on front of console ........................ .
Clutch Anticipate/
Cruise Release Switch
(all V6 Manual) ........ . Mounted in clutch pedal bracket (4 cavity conn) ..... .
Console Compartment Lamp Under Console Compartment Door ................. .
Convenience Center ..... . Left of Steering Column, mounted to bottom of
1/P Carrier ..................................... .
Convertible Top Switch ... Left side of upper console (Chevy) or lower console (Pont)
Coolant Level Latching
Module ............... . In molded pocket of dash mat, center above floor tunnel
Courtesy Lamp, Left Rear . Mounted in left sail panel
Courtesy Lamp, Right Rear Mounted in right sail panel
Crankshaft Position Sensor,
HI Resolution (V6 VIN S) Lower front of Engine Block, pigtail comes out
LH side of crank ................................ .
Cruise Control Module .... Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse ................................... .
Cruise Release/Brake Switch
(all with K34) . . . . . . . . . . Mounted in upper hole of brake pedal bracket
(2 cavity conn) .................................. .
Cruise Release/Clutch Switch
(VS Manual with K34)
Mounted in clutch pedal bracket (2 cavity conn) ..... .
(DRL) Module . . . . . . . . . . Mounted behind Radio and HVAC Controls, left of
1/P Compartment ............................... .
Diagnostic Energy Reserve
Module (DERM) ....... . Snapped in bracket, behind RH side ofl/P Compartment
Dome Lamp ............ . On roof, near hatch ............................... .
Electronic Brake Control
Module (EBCM) ....... . Under 1/P, next to LH hinge pillar,just above
Pass Thru Grommet ............................. .
Electronic Brake/Traction
Control Module (EBTCM) Under I/P, next to LH hinge pillar,just above
Ev~porative Emission
(EVAP) Canister Purge
Solenoid Valve (V6 VIN S) Left side of Engine, mounted to Intake Plenum . . . . . . .
13
43
202-21
24
81
0 .... 1 . ..
43 . .. 81
202-20
8 . ... 15
42
78,80
202-20
202-20
45 ... '~4
202-20
11
20
19
36
12
202-20
8
4
15
6
202-12
202-11
8 .... 14 ..
202-13
8 .... 14 ..
202-13
13 . . . 24
COMPONENT
Solenoid Valve
(VS VIN P) ........... .
Exhaust Gas Recirculation
(EGR) Vacuum Control
Signal Solenoid
Valve (V6 VIN S) ...... .
Signal Solenoid
Valve (VS VIN P) ...... .
Express Down Module ... .
Fuel Injectors (V6 VIN S)
Fuel Injectors (V8 VIN P)
Fuel Pump Relay ........ .
LOCATION
201-PG
FIG.
11 - 17
CONN
Right center of Engine, mounted to Manifold . . . . . . . . . 26 . . . 50
Right side of Engine, mounted to Manifold . . . . . . . . . . . 12 . . . 23 ..
Left rear of Engine, mounted to Intake Plenum ...... . 24 ... 44

Mounted to center of dash mat, above floor tunnel .... . 9 .... 17
Mounted on Intake Manifold, part of Fuel Rail
Mounted on Intake Manifold, part of Fuel Rail ....... . 24 ... 44
Forward of LH kick panel, mounted to foot rest bracket
under carpet .................................... . 7 ... . 13
Hatch Release Relay .... . Mounted to right side of SIR Bracket, behind 1/P ..... . 22 .. . 41
Hatch Release Switch ... . Left of Steering Column, in knee bolster pad ........ . 31,38 60,67
Headlight Doors Module .. Forward of LH front wheelhouse, mounted to Air Intake 19
36
44
Bank #1 . . . . . . . . . . . . . . . Mounted in left Exhaust Manifold . . . . . . . . . . . . . . . . . . . 24
72 ..
Bank #2 . . . . . . . . . . . . . . . Mounted in right Exhaust Manifold . . . . . . . . . . . . . . . . . 40
Heater/Vent/Air Conditioning
(HVAC) Control Assembly Center ofl/P ..................................... . 21
40
1/P Compartment Lamp . . . Inside top center of compartment ................... . 22
41
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. . 8 .... 15
Ignition Coil (VS VIN P) . Front LH side of Engine ........................... . 16
29
(V8 VIN P) . . . . . . . . . . . . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29
Ignition Control Module (ICM)
(V6 VIN S) . . . . . . . . . . . . . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
52 ..
Instrument Cluster . . . . . . . LH side ofI/P ................................................... .
71
Key less Entry Receiver . . . Behind RH side kick panel, in molded pocket . . . . . . . . . 40
Mass Air Flow (MAF) Sensor Mounted on air duct, in front of Intake Manifold . . . . . . 24 . . . 45
Multi-Function Lever . . . . Left Arm on Steering Column . . . . . . . . . . . . . . . . . . . . . . . 27 . . . 53
Performance Switch . . . . . . Mounted in center console behind shifter ........................... .
Performance/Traction
Control Switch ........ . Mounted in center console behind shifter . . . . . . . . . . . . . 42
79
Power Door Lock Switch, LH Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
33
Power Door Lock Switch, RH Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . . 18
33
Power Mirror Switch ..... Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
33
(AQ9) . . . . . . . . . . . . . . . . . . Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
86 ..
Power Seat Switch (AC3) . On left side of Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . 41
76
Power Seat Switch,
Driver (AQ9) . . . . . . . . . . . On left side of Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . 47
86
Power Seat Switch,
Passenger (AQ9) . . . . . . . . On right side of Passenger Seat . . . . . . . . . . . . . . . . . . . . . 47
86 ..
19
(PCM) (V6 VIN S) . . . . . . In Engine Compartment, rearward of RH Shock Tower
35
(PCM) (V8 VIN P) ...... In Engine Compartment, rearward of RH Shock Tower
19
35
Power Window Switch, LH
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
33
Power Window Switch, RH
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . . 18
33
202-20
202-21
202-21
202-21
202-21
202-22
202-22
202-22
202-23
202-22
202-22
202-23
202-23
202-24
202-24
202-24
202-24
202-24
202-24
202-24
202-24
202-24
202-25
202-26
202-27
202-27
SA -
FUSE BLOCK DETAILS

COMPONENT
LOCATION
201-PG
FIG.
Radio . . . . . . . . . . . . . . . . . . . Center of 1/P Carrier . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 36

65
Rear Compartment Lamp . Center of rear compartment below Hatch Release
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
58
Rear Defogger Switch . . . . Part of HV AC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
39
Rear Defogger Switch/Timer Mounted on 1/P knee bolster, right of Steering Column
37
66
Rear Defogger Timer/Relay Part of HVAC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
39
Rearview Mirror . . . . . . . . . Top center of windshield ......................................... ,
Reverse Lockout Solenoid
(VS VIN P Manual) . . . . . Rear LH side of Transmission ...................... . 26 ... 51
SIR Coil Assembly . . . . . . . Top of Steering Column ............................ . 3,34 . 5,51
Skip Shift Solenoid . . . . . . . Center LH side of Transmission .................... . 26 ... 51
Steering Wheel Controls,
3 ...
Radio (UK3) . . . . . . . . . . . On Steering Wheel ............................... . 2
15
Theft Deterrent Module . . . In 1/P,just right of Radio, attached to Air Bag Bracket . 8
Transmission Position
Switch . . . . . . . . . . . . . . . . . Under console, on base of shift control lever . . . . . . . . . . 22 . . . 42
Turn Flasher . . . . . . . . . . . . Mounted to bracket, right of Steering Column,
above Data Link Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Underhood Electrical Center LH side of Engine Compartment, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
Wiper Motor Assembly
Rear of LH Shock Tower, mounted to dash panel below
LH Wiper Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
18
Wiper/Washer Switch
Assembly ............. . In left side of Steering Column, actuated by
Multi-Function Lever ........................... . 3 .... 5
ClOO (10 cavities) ....... . Engine to Forward Lamp Harn, behind LH wheelhouse,
28
attached to PCM bracket ......................... . 15
CHO (10 cavities) (L32) .. Engine to Injector Harn, top center oflntake Manifold
12
22
C200B (18 cavities)
Part of Forward Lamp Harn, between LH kick panel
49
and Steering Column ............................ . 25
Part of Cross Car Harn, between LH kick panel and
C200C (13 cavities)
Steering Column ................................ . 25
49
Part of 1/P Harn, between LH kick panel and
C200D (48 cavities)
49
Steering Column ................................ . 25
37
C210 (4 cavities) ........ . Under RH side ofl/P, behind RH kick panel ......... . 20
64
C215 (11 cavities) ....... . Near base of Steering Column ..................... . 35
C217 (4cavities) ........ . Near base of Steering Column ..................... . 34
63
37
C230 (10 cavities) ....... . Under RH side ofl/P, behind kick panel ............. . 20
C250 (2 cavities) ........ . Forward Lamp Harn to Clutch Jumper Harn or Switch,
near brake/clutch pedal bracket .................. . 0, 1 .. 1,2
C300 (6 cavities) (AQ9) .. . Under Driver Seat Assembly ...................... . 47 ... 86
C305 (6 cavities) (AQ9) .. . Under Passenger Seat Assembly ................... . 46 ... 85
C310 (2 cavities) ........ . Between rear mounting bolt of Driver Seat near #3 Rail 6 .... 11
PlOO ................... . Left side in dash panel, Engine to Passenger
Compartment ................................... . 19
36
Right side in dash panel, Engine to Passenger
PHO
35
Compartment ................................... . 19
31
P500 ................... . Between LH door and" A" pillar .................... . 17
84
P600 ................... . Between RH door and "A" pillar .................... . 45
50
8101 (LTl) ............. . Engine Harn, between Injectors 4 and 6 breakouts ... . 26
CONN
202-16
202-27
202-27
202-27
202-18
202-28
202-28
202-28
202-0
202-1
202-2
202-2
202-2
202-19
202-4
202-19
202-7
202-19
202-19
COMPONENT
S102 (LTl)
S103 (L32)
S104 (L32)
Sl06 (L32)
S106 (LTl)
S107 (LTl)
S107 (L32)
S127 (L32)
S127 (LTl)
S132 (LTl)
Sl65
Sl90
S204
S205
S206
S207
S208
S209
S210
S211
S248
S252
S253
S265
S317
S320
S330
S500
LOCATION
201-PG
FIG.
Engine Harn, approx 5 cm from Injector 3 breakout ... 24 ... 44

Injector Jumper Harn, approx 7 cm from LH
Branch breakout
Injector Jumper Harn, approx 9 cm from Injector 6
Engine Harn, approx 25 cm from PCM Connectors
Engine Harn, approx 4 cm from main branch and
PCM breakout
Engine Harn, approx 7 cm from main breakout,
at right rear of Engine
Engine Harn, approx 30 cm from Cl 10 breakout
12 . . . 22
Engine Harn, approx 13 cm from RH branch
Engine Harn, approx 8 cm from left clip, on Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . .'. 44
Engine Harn, approx 2 cm from clip near PCM and
main branch
Forward Lamp Harn, approx 7 cm from Electrical
Center breakout
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . 68
1/P Harn, approx 10 cm from Steering Column breakout
1/P Harn, approx 31 cm from Convenience Center
breakout
breakout
1/P Harn, approx 4 cm before DLC breakout
Cross Car Harn, approx 5 cm from Express Down
Module breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . 84
. 1/P Harn, approx 24 cm from Convenience Center
breakout
I/P Harn, approx 44 cm from Convenience Center (Pont)
or 12 cm from RR Defog Switch (Chevy) breakouts
1/P Harn, approx 4 cm from antenna cable (Chevy) or
Convenience Center (Pont) breakouts
1/P Harn, approx 4 cm before RR Defog Switch (Chevy)
or from Instrument Cluster (Pont) breakouts
1/P Harn, approx 17 cm back from HVAC Controls
(Pont) or RR Defogger Switch/Timer (Chevy)
I/P Harn, approx 35 cm from Convenience Center
breakout
Cross Car Harn, approx 20 cm from Rearview
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . 84
I/P Harn, approx at rear edge of door below left sail panel
Seat Jumper Harn, near rosebud tinder Driver Seat
Driver Seat Harn, approx 22 cm from Power Seat
Switch Conn
17 . . . 31
Cross Car Harn, approx 6 cm from Speaker breakout
For a Service Part Cross Reference List and Information, r~fer to SECTION 8A-200.
CONN
8A -
14 - 0
GROUND DISTRIBUTION
VS VIN P
CRUISE
CONTROL
MODULE
r- - .,
I
I
L. _
A/C
COMPRESSOR
CLUTCH
,--.,
A/C
CLUTCH
DIODE
...
IGNITION
~
MODULE
r- - .,
I
I
I
I
r- - .,
L. -
L. -
HEATED
OXYGEN
SENSOR
BANK #1
....
.35 BLK
450
,--.,
I
I
I
I
c
.8 BLK
.8BLK
HEATED
OXYGEN
SENSOR
BANK #2
....
POWERTRAIN
CONTROL
MODULE (PCM)
,-------,
,._
L..--1
18
_____ ...
~
450
.88LK
450
450
WITH (60
ONLY
. . . . . . . . . . . . . . . y . . . . . . . . . . . ..
5108
.8 BLK
.8 TAN/WHT
1650
1 BLK
450
551
.8 TAN/WHT
BRAIDED GROUND STRAP

350
LEFT FRONT
FRAME RAIL
__.__ __---.J 109
_.__ _ __._ ___________________ __._G102
551
AUTOMATIC
TRANSMISSION
POWERTRAIN
CONTROL
MODULE (PCM)
,----,
OIL
LEVEL
SENSOR
MASS AIR
FLOW(MAF)
SENSOR
r- - .,
TRANSMISSION
POSITION
SWITCH
THEFT
DETERRENT
MODULE
,---,
,---,
r- -
.,
PONT WITH M30

W!OUTNW9
FUEL
PUMP
RELAY
r- - .,
I
I
L. BS
DATA LINK
CONNECTOR
A1
,...
I
I
L.-..1
..I
PERFORMANCE
SWITCH
- .,
INSTRUMENT
CLUSTER
PONT WITH M30

ANDNW9
PERFORMANCE/
TRACTION
CONTROL
SWITCH
L.-..1
(PONT) 815
(CHEVY) D8
MANUAL
TRANSMISSION
(NOT USED)
(DLC)
C270
,...
I
I
I.. -
.35
BLK/
WHT
.8 BLKI
451
.35 BLK/
WHT
WHT
451
.8 BLK/WHT
451
.35
BLK/
WHT
....
451
451
.35 BLK/WHT
.35 BLK/
WHT
451
451
451
.35 BLK/WHT
451
.8 BLK/
WHT
451
.35
BLK/WHT
451
........."..'.......................
.5 BLK/WHT
5109
.8 BLK/WHT
451
451
TRACTION
CONTROL
SWITCH
.-=--,
.35
BLK/
WHT
CHEVY
WITH NW9
- -,
I.. B
I
I
_,
SA -
GROUND DISTRIBUTION
V6 VIN S
CRUISE
CONTROL
MODULE
r- - ..,
L.-..1
E
A!C
COMPRESSOR
CLUTCH
,---,
AIC
CLUTCH
DIODE
, ~.f~
IGNITION
CONTROL
MODULE (ICM)
OIL
LEVEL
SENSOR
r- - ..,
r- - ..,
L. _
...
.8 BLK
450
L . - ....
A
5115-----'
WITH AIR
CONDITIONING
.35 BLK
450
.8 BLK
.8 BLK
450
1650
.5 BLKIWHT
.8 BLK
1 BLK
451
450 (WITHOUT (60)

450 (WITH C60)
.5 BLK,WHT
.5 BLK:WHT
451
451
.5 BLK,WHT
451
.8 BLKIWHT
451
BRAIDED GROUND STRAP

350
LEFT FRONT
FRAME RAIL
ENGINE
BLOCK
--!----------------!:-------------------~
ELECTRICAL DIAGNOSIS SA - 14 -3
MANUAL
TRANSMISSION
DATA LINK
CONNECTOR
(DLC)
.35 BLK/
WHT
451
PERFOIIMANCE
SWITCH
r- - ..,
r- - ..,
I
I....
PONT WITH M30

Wt0UTNW9
FUEL
PUMP
RELAY
TRANSMISSION
POSITION
SWITCH
I"
BS
.35
BLK/
WHT
AUTOMATIC
TRANSMISSION
... -..,
I
..__ ...I .... _...
r- - ..,
i.-.----~
CLUTCH
ANTICIPATE/
CRUISE
RELEASE
,SWITCH
THEFT
DETERRENT
MODULE
POWERTRAIN
CONTROL
MODULE (PCMl
:,1
I
I
_...
..;a
L. _
,. - ..,
I
I....
F
A1
r---------------..,
&..' _ _ ...., _ _ ... _ _ _ _ _ _ _ _
16
32
20
23
I!
(BLKl
-17
~ (BLUl
I
I
_...
451
.8 BLK/
.35 BLK/
WHT
451
WHT
451
.35 BLK/
WHT
451
A f C270
.35 BLK/ 451
WHT
____
,._
.35 BLiq!WHT
451
.5 BLK!WHT
.35 BLK/
WHT
451
451
.35
BLK/
WHT
351
.8 TAN/
WHT
551
(PONT) 815
(CHEVVl 08
I"" -
P110
.5 BLK/WHT
....
451
-,
.35
BLK.'
WHT
_...
351
.5
TANI
WHT
551
INSTRUMENT
CLUSTER
.5 BhK/WHT
451
~
.8 BLK/WHT
1-------------------------------------------------------
351
---------!-------~~TU~:::
2 TERMINALS ON EACH
(INTERCHANGEABLE)
8A-14- 4 ELECTRICAL DIAGNOSIS
GROUND DISTRIBUTION
ANTILOCK BRAKE SYSTEM (ABS) OR TRACTION CONTROL SYSTEM (NW9) AND
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR)
r~----------------,
I ... - .,
ABS
I
I
I
L.
B
L_
... -
I
I BRAKE
PRESSURE
I VALVE
I
I
I
HYDRAULIC
MODULATOR
ASSEMBLY
.....
g_
SOLENOID,
LEFT
FRONT
L. B
-----
. , ABS
BRAKE
PRESSURE
VALVE
SOLENOID
I
I
... -
I
I
-I ~ L. -
FRONT
-----
. , BRAKE
COMBO
VALVE
I
I
-I
~
___ J
WITHOUTNW9 DISCRIMINATING
'-- - - ~ - SENSOR,
ELECTRONIC
FORWARD
BRAKE
I"' - -,
CONTROL
MOOiJiT(EBCM)
. WITH NW9
I ..._
I
.....I
DISCRIMINATING
SENSOR,
PASSENGER
COMPARTMENT
.... -.,
L.~-1
c'
ELECTRONIC
B 1 -,
BRAKE/TRACTION
CONTROL
MODULE (EBTCM)
DIAGNOSTIC
ENERGY
RESERVE
MODULE (OERM)
r-------,
L..-----...1
I
A12 1 f
A1 1
... -.,
L.-..1
E
g
.8 BLKIWHT
.8 BLKIWHT
.8 BLK.WHT
651
65 I
.8 BLKIWHT
651
.8 BLKIWHT
S BLKIWHT
.8 BLK,WHT
1751
.8BLK,WHT
1751
1751
1751
651
______
._
01""' lot C2000

~ -, (2008
~
.8 BLKIWHT
5 BLKIWHT
19 BLK
50
13 BLK
651
8 BLK/WHT
651
SO
_ . _ _______ _ . _ _______________________
.~01
1751
GROUND DISTRIBUTION
ENGINE COOLANT LEVEL SENSOR AND FORWARD LAMP
CHEVY
I I
HIGH BEAM
HEADLAMP,
RIGHT
I I
WITHT96
CHEVY
FOG
LAMP,
RIGHT
FRONT
LOW BEAM
HEADLAMP,
RIGHT
-,--_...,
, _...,
(
-,
B
_...,
8-, ,
WITH vs VIN p
ENGlljlE
COObANT
LEV~L
SENSOR
81 ,
(
L.
...
c''
PONT
PARK/TURN
LAMP,
RIGHT
FRONT
,. - .,
I
I I
----- I
_...,
G' "j
MARKER
LAMP,
RIGHT
FRONT
B ~
HEADLAMP
DOOR
ASSEMBLY, RH
r---,
I HEADLAMP,
RIGHT
1--1
I(
II
I _...,
c-, I
L-
1 BLK
.. - J
2 50
c1 ~
3 BLK
1 BLK
250
3BLK
250
250
.8BLK
.5BLK
250
\.......L
3 BLK
250
1 BLK
250
.SBLK
250
2 50
SA -14 - 6 ELECTRICAL DIAGNOSIS
GROUND DISTRIBUTION
AIR PUMP, COOLANT FAN, HEADLIGHT DOOR MODUL-E, FORWARD LAMP,
WINDSHIELD WIPER AND WASHER
I I
PONT
WIPER
MOTOR
WASHER
PUMP
HEADLAMP DOOR
ASSEMBLY,LH
~BLY
MOTOR
r- - ., r- - ., I
I I
11
,_'.-, ... ,_
B ,-:;
H-;;.~;.:- .,
LEFT
f
...
--_. -c:
1 BLK
.SBLK
150
~::t
I
MARKER
LAMP,.
LEFT
FRONT
COOLANT
FAN,
PRIMARY
(LEFn
r- - ., ,---,
I I
I
I
I I
&..
,.; ,-:; ...
s :"-1
COOLANT
FAN,
SECONDARY
(RIGHn
&..
_.;,-, ...
I I
PONT
HEADLIGHT
DOORS
MODULI:
SECONDARY
AIR
INJECTION
ASSEMBLY
,---, ,---,
o-, g ,.-, .
...
...
&..
...
I I
CHEVY
CHEVY
LOW BEAM
HEADLAMP,
LEFT
'
1 BLK
150
~:~~~URN
I WTFRONT FRONT
11--;...- I - 11(
)11
I()
B~
I c7 I G' "
I, -
1
BL K
WITHT96
FOG
WITH VS VINP
ANDC60
--
HIGH BEAM
HEADLAMP,
LEFT
------
-- -B' ~
"
150
~ C160
150
1 BLK
.SBLK
3 BLK
150
.5 BLK
150
150
.J
,....
r
...
"::;;jjl . ~
7
3 BLK
3 BLK
3 BLK
~
.
150
150
.SBLK
150
..
....
5113
3BLK
150
150
150
3 BLK
150
14 - 7
GROUND DISTRIBUTION
POWER DOORS, LOCKS, MIRRORS AND WINDOWS
WITHAU3
RETAINED
ACCIBORY
POWIR(RAP)
MODULE
WITHOUTAU3
ITHV8 VIN PI
co OlANT
... - ..,
r- - ..,
... - ...
... .., ...
I
I
9;.,
~
EL
POWER
WINDOW
SWITCH,LH
POWER
MIRROR
'SWITCH
DOOR
ILLUMINATION
LAMP, LH
I
I
(POl'.ln A'
(CHEVY)H
A'
LATCHING
MO OULE
r-
--.
1
I
I
I
REARVIEW
MIRROR
r-------,
.-
r"' -
... - ..,
-, COURTESY/
I~
LAMPS
...n, ...g
._J_.____ JI
I
L-
DOOR
ILLUMINATION
LAMP, RH
KEYLESS
ENTRY
RECEIVER
B' I
POWER DOOR
LOCK SWITCH, RH
r-----,
L-----.1
,
B'
'
E1
e''
... . , ...
E
.35 BLK
.35 BLK
750
,35 BLK
750
.S BLK
,8 BLK
.35 BLK
3BLK
750
----
r- ......
--
750
.SBLK
750
750 (WITHOUT POWER
ACCESSORIES)
.35 BLK
750
'
....
.SBLK
,_
J411P'
...
""'- 5220
rn
IMPORTANT:
5220 SHOWN WITH ALL
OPTIONS COMBINED.
FROM 5216
PAGE SA-14-8
650
750
------
P500
3 BLK
750
3BLK
.SBLK
_.__--------------------
750
750 (WITHOUT POWER
ACCESSORIES)
eG200
--
750
GROUND DISTRIBUTION
AUDIO ALARM MODULE, HATCH RELEASE, LIGHT SWITCHES, POWER SEATS
AND REAR DEFOGGER
I I
PONT
CONVENIENCE
CENTER
r------,
I I"" - -, AUDIO
I
I ALARM I
I I
I MODULE
I I
I
I L;,..., ...
I
L-.
____ J
HEADLIGHT
SWITCH
r--,
INSTRUMENT
CLUS~
1/P
DIMMER
SWITCH
FOG
LIGHT
SWITCH
I"" -
I"" -
I"" -
.,
r-;AR--;;A;--,
.,
DEFOGGER
~AV
,-"!""-,
I
I
';,? ...
.,
HEATERNENT/AIR
CONDITIONING (HVAC)
CONTROL ASSEMBLY
...._ ...
'e,? ...
(PONT) 83 ' ")

(CHEVY) C4
.... -
(POND G
(CHEVY) B
...
';1ii' Lj'.;'
~- =---~J
I
I
.5 BLK
.5 BLK
650
.35 BLK
650
1 BLK
.35 BLK
650
.35 BLK
650
DEFOGGER I
SWITCH
,---, I
I
I
I
650
650
......................,..~.,....................
~~
.....................................
3 BLK
""l
"'s~S2.16. . . . . . . . . . . . . . . .3.B.LK. . . . . . . . . . . . . . . . . .
650
650
TO G200
PAGE SA-147
14 - 9
GROUND DISTRIBUTION
DIAGNOSTIC ENERGY RESERVE MODULE (DERM), DAYTIME RUNNING LIGHTS (DRL)
MODULE, RADIO, INSTRUMENT PANEL AND CONSOLE AREA
CHEVY
REAR
DEFOGGER
SWITCH/
TIMER
WITHZ49
WITHOUT
BOSE
RADIO
MANUAL
TRANSMISSION
SEAT BELT
SWITCH
r- - ., r- - ., r- - .,
I I
I I
I
I
L..
....
B ,..,
L..
...
s 1~ci
...
L..
CIGAR
LIGHTER
,..-.,
ASHTRAY LAMP
I
I
I
CONSOLE
COMPARTMENT
LAMP
650
--
I
I
A
PRNDL
ILLUMINATION
LAMP
I/P
COMPARTMENT
LAMP
en
A,,
,..-.,
AMPLIFIER
i- - .,
I
I
L..
41~
1 BLK
----;-..
...
,"";g_
STEERING
WHEEL
CONTROLS,
RADIO
PONT
WITHUW2
I
I
L..
AUTOMATIC
TRANSMISSION
.35
BLK
r- - .,
...s'- ...
BI .,
B};
DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
PONT
WITH UK3
... ... ...
Dl
...... @~
650
SIR COIL
ASSEMBLY
.5BLK
A' .,
I
I
,~
650
(217
HEATERNENTIAIR
CONDITIONING (!WAC)
CONTROL ASSEMBLY
.35 BLK
1 BLK
650
650
.8BLK
.5 BLK
.8 BLK
650
.5 BLK
650
.35 BLK
650
650
.8BLK
650
650
r--;v~ - --,
- -
ILLUMINATION
I
I
LAMPS
I
I
I(
) .( )I
I
I ~
I
I
~
L. ----...I
B~
~g
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
,..-.,
.S 8LK
"
, ...
650
I
I
I
I
I..,?
..I
2
A
r--
""
.5 BLK
.8BLK
650
3 BLK
650
650
rn
IMPORTANT:
5217 SHOWN WITH ALL
OPTIONS COMBINED.
.,
I
I
I
I
ti,? ...
.35 8LK
5217
'
'
HIGH
BLOW
_ _E_R
RELAY
650
SA -
GROUND DISTRIBUTION
BLOWER MOTOR, BOSE RADIO AND CONVERTIBLE TOP SWITCH
I
CONVERTIBLE
TOP SWITCH
r- - .,
._
_...
BLOWER
MOTOR
r- - .,
._
_...
BOSE
RELAY
r---,
._
_...
A1
1 BLK
RADIO
(DELCO-Bose)
r---,
I
I
I._
I
_...
1051
OPTIONAL
SPEAKER/AMP,
REAR (BOSE)
r--.,
I
I
I
I
SPEAKER/AMP,
LEFT FRONT
(BOSE)
r---,
I
I
1350
3 BLK
850
1051
.......... ----------S221
1 BLK
1051
3BLK
CONVERTIBLE
ONLY
r---,
I
I
1051
1 BLK
3 BLK
SPEAKER/AMP,
RIGHT FRONT
(BOSE)
~.r ~r ~.r
1 BLK
1 BLK
1051
CHEVY COUPE
WITH BOSE
-----------~---------------------..2201
1051
1 BLK
1051
GROUND DISTRIBUTION
FUEL PUMP/SENDER, POWER SEATS, REAR DEFOGGER, CHMSL
I
I
r-----,
PONT
WITHAQ9
WITHAC3
FUEL
TANK
UNIT
r- - .,
SEAT ASSEMBLY,
DRIVER
I ... I I
11
.,POWER
PEAT
SWITCH
1-
r--------,
I I
I I
I I
___ .JI
I
I
I
I
I
2 BLK
I"" -
- , POWER
SEAT
I CONTROL
I MODULE
CENTER HIGH MOUNTED

STOP LIGHT (CHMSL)
,--.,
... _...
A
11
L--..1
L c
REAR
DEFOGGER
SEAT ASSEMBLY,
DRIVER
'er:18~:1:o
3 BLK 11450
BLK
5335
3 BLK
L-
1450
.....
1150 BLK
t:,,,
1450
------J
3BLK
"'l"' """'
3 BLJ:450 (WITH AQ9)
>
1 BLK
1050
AOI
1150
5450
1150
.5 BLK
C420
1150
..-----
5420
C310
REAR
DEFOGGER
GRID
,--.,
3 BLK
1450
3 BLK
.5 BLK
1150 (WITH C49)

1150 (WITHOUT C49)
....
..I
3 BLK
1750
CONVERTIBLE
ONLY'
_.._ _____________ __.__G305
8A -
GROUND DISTRIBUTION (PONTIAC)

REAR LIGHTS
MARKER
LAMP,
LEFT REAR
(
B
TAIL/STOP/
TURN LAMP,
LH
OUTBOARD
TAIL/STOP/
TAIL/STOP/
TURN LAMP,
LH
INBOARD
BACKUP
LAMP,
TAIL/STOP/
TURN LAMP,
RH
OUTBOARD
BACKUP
LAMF,
MARKER
LAMP,
RIGHT
REAR
- - --- --- - - - -- -- - - - - - - )
TAILLAMP,
lli
_,,,
.8BLK
.5 BLK
lli
_,,,
.8 BLK
.8 BLK
LAMP.RH
INBOARD
I!!!
TAILLAMP,
I!!!
-;-'
G1
G 1 ,
1250
1250
LICENSE
LAMP
G1
_,,,
B',
1250
.8 BLK
1250
.5 BLK
.8 BLK
1250
1250
' .8 BLK
1250
1250
.5 BLK
,,
. ._ _ _ _ _ _ _ _.5415
.5 BLK
,5 BLK
1250
.5 BLK
1250
HATCH
RELEASE
ACTUATOR
CENTER HIGH MOUNTED

STOP LIGHT (CHM SL)
))
C430
II
I
!...
CD CD ,,
.5 BLK
1250
1250
REAR DOME
LIGHT
SWITCH
,---,
r- - .,
L. -
~I
II
IL.-..1
..I
P400
MtS~i:
mo ~"" "~ "~'
.5 BLK
.5 BLK
5470
,5 BLK
1550
.5 BLK
1250
.....c. ~,..................
1550
.8BLKI 1550
CONVERTIBLE
..I
,s~
5450
..I
1250
.5 BLK
5430
HATCH
RELEASE
ACTUATOR
REAR DOME
LIGHT
SWITCH
r--------,r---.,-- ,---,
I
COUPE AND
COUPE
CONVERTIBLE ::::...._ __________________ _._G400

_.__
__________
1550
1250
14 - 13
GROUND DISTRIBUTION (CHEVROLET)

REAR LIGHTS
MARKER
LAMP,
LEFT REAR
TAILLAMP,
TAIL/STOP/
TAIL/STOP/
TAILLAMP,
-RH
___
LAMP, RH
OUTBOARD
- - -- -- - - -- -_
__,
- - -__, -__, - - -__,
OUTBOARD
LAMP, LH
1250
.8 BLK
1250
BACKUP
LAMP, RH
.5 BLK
.5 BLK
BACKUP
LAMP, LH
TAILLAMP,
LH INBOARD
.5 BLK
TAILLAMP,
RH INBOARD
LICENSE
LAMP
MARKER
LAMP,
RIGHT
REAR
(
B
1250
.8 BLK
1250
.5 BLK
1250
.5 BLK
1250
1250
.5 BLK
.5 BLK
.5BLK
1250
1250
.5 BLK
.5 BLK
5430
,.................:)1111---------------------~
1250
C430
1250
.5 BLK
1250
HATCH
RELEASE
ACTUATOR
CENTER HIGH MOUNTED

STOP LIGHT (CHM SL)
r----------,r--~
I
I
I
I
I
....
II
II
CD CD
~t:J.,.
11...B -
I
..I
I
I
HATCH
RELEASE
ACTUATOR
REAR DOME
LIGHT
SWITCH
r- - -,
I
I
....
P400
....
..I
..I
...I
.5 BLK
1550
.5 BLK
1550
.5 BLK
.5 BLK
5470
..-c:................
.5 BLK
1550
.5 BLK
1250
1550
.8 BLK 11550
CONVERTIBLE
.... -
r- - -,
5450
REAR DOME
LIGHT
SWITCH
..---,
I
I
..I
COUPE AND
CONVERTIBLE
COUPE
_L_ __ -- _ - - _ -- :::::....JL_ __ ______ - - - _______ ___.__ G400
1550
1250
SA-14-14 ELECTRICALDIAGNOSIS
GROUND DISTRIBUTION
COMPONENT
LOCATION
201-PG
FIG.
AIC Clutch Diode

(V6 VIN S) . . . . . . . . . . . . . Sealed in Harn, 10 cm from A/C Compressor
Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
54
AIC Clutch Diode
26
(V8 VIN P) ........... . Sealed in Harn, 12 cm from Generator breakout . . . . . . 14
AIC Compressor Clutch .. . RH side of Engine, below Generator . . . . . . . . . . . . . . . . . 14, 28 26,54
ABS Brake Pressure Valve
Solenoid, LF ........... . Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 39
68
Solenoid, RF .......... . Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 39
68
Amplifier (part of UW2
Speaker Option) ....... . Mounted behind Right Rear Armrest, on Rail . . . . . . . . 44
83
Ashtray Lamp (Auto Trans) Lighting Tube from PRNDLLamp
Ashtray Lamp
(Manual Trans) ........ . Rearward of shifter, in ashtray ..................... . 43 ... 82
Backup Lamp, LH ....... . Mounted in Taillamp Assembly ............. , ...... . 32,33 61,62
Backup Lamp, RH ....... . Mounted in Taillamp Assembly .................... . 32,33 61, 62
Battery ................ . RH front of Engine Compartment .................. . 19
35
20
37
Blower Motor ........... . Under lower RH side ofl/P; n;ioun,ted in HVAC Module
41
Bose Relay ............. . Below center A/C Duct, mounted to SIR Bracket ..... . 22
Brake Combo Valve (ABS)
39
68
Part of Hydraulic Modulator Assembly, in ward side
Center High Mounted Stop
Light (CHMSL) ........ . Rear center of Spoiler
Cigar Lighter ........... . Mounted on front of console .. . .. .. .. . . . . . . .. . .. . . . . . 43 . . . 81
Clutch Anticipate/
(all V6 Manual) ........ . Mounted in clutch pedal bracket (4 cavity conn) ..... . 0 . . . . 1 ...
Console Compartment Lamp Under Console Compartment Door ................. . 43 . .. 81
I/P Carrier ...................... ,................ . 8 . ... 15
Convertible Top Switch .. . Left side of upper console (Chevy) or lower console (Pont) 42 ... 78,80
Coolant Fans ........... . Behind radiator
Module ............... . In molded pocket of dash mat, center above floor tunnel 45
84
Cruise Control Module
Front LH side of vehicle, mounted to frame rail, forward
36
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Data Link Conn (DLC)
Mounted to I/P Tie Bar, below and right of
Steering.Column ..................................... , .......... .
(DRL) Module . . . . . . . . . . Mounted behind Radio and HVAC Controls, left of
12
1/P Compartment ............... , . . . . . . . . . . . . . . . . 7
15
Module (DERM) . . . . . . . . Snapped in bracket, behind RH side ofl/P Compartment 8
Discriminating Sensor,
Forward . . . . . . . . . . . . . . . Mounted to center of front end Tie Bar, near hood latch 19 . . . 36
Passenger Compartment
Mounted to upper dash,just right of Steering Column
Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
38
Door Illumination Lamp, LH Behind door trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31
31
Door Illumination Lamp, RH Behind door trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Module (EBCM) ....... . Under I/P, next to LH hinge pillar,just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14
CONN
202-9
202-21
202-20
202-20
202-20
202-20
202-11
202-11
202-20
202-12
202-13
ELECTRI.CAL DIAGNOSIS SA -
COMPONENT
Control Module (EBTCM)
Engine Coolant Level Sensor
(VS VIN P) . . . . . . . . . . . .
Fog Lamp, Left Front . ... . .
Fog Lamp, Right Front . . .
Fog Light Switch . . . . . . . . .
Fuel Pump Relay . . . . . . . . .
LOCATION
201-PG
FIG.
Under I/P, next to LH hinge pillar,just above

Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14...
Mounted on upper right side ofradiator . . . . . . . . . . . . . .
Lower LH side offront Fascia
Lower RH side of front Fascia
Lower LH side ofl/P .............................. .
Forward ofLH kick panel, mounted to foot rest bracket
under carpet .................................... .
Under rear of vehicle
Center of end panel, in Cargo Compartment ......... .
LH front of vehicle ................................ .
RH front of vehicle
Forward of LH front wheelhouse, mounted to Air Intake
LH side ofl/P .................................... .
14 - 15
CONN
202-13
19 . . . 35
37,38
66,67
202-21
7 .... 13
Fuel Tank Unit . . . . . . . . . .
Hatch Release Actuator . . .
57
30
Headlamp, Left (PONT) . .
23
43
Headlamp, Right (PONT) .
Headlight Doors Module . .
19
36
Headlight Switch . . . . . . . .
37,38 66,67
Bank #1 . . . . . . . . . . . . . . . Mounted in left Exhaust Manifold .................. 24
44
Bank #2 . . . . . . . . . . . . . . . Mounted in right Exhaust Manifold ................ . 40
72
(HVAC) Control Assembly Center ofl/P ..................................... . 21
40
High Beam Headlamp, Left
(CHEVY) . . . . . . . . . . . . . . Exterior, left front
High Beam Headlamp, Right
(CHEVY) . . . . . . . . . . . . . . Exterior, right front
High Blower Relay . . . . . . . Under 1/P, above left side of floor tunnel . . . . . . . . . . . . . 42
77
Hydraulic Modulator
Assembly ............. . Front left of Engine Compartment ............... ,. . . 39
68
1/P Compartment Lamp .. . Inside top center of compartment . . . . . . . . . . . . . . . . . . . . 22
41
1/P Dimmer Switch ...... . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66, 67
(VS VIN P) . . . . . . . . . . . . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29
(V6 VIN S) . . . . . . . . . . . . . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
52
Instrument Cluster . . . . . . . LH side ofl/P ................................................... .
Keyless Entry Receiver . . . Behind RH side kick panel, in molded pocket . . . . . . . . . 40
71
License Lamp . . . . . . . . . . . . Center ofrear Fascia, above license plate . . . . . . . . . . . . 31 . . . 59
Low Beam Headlamp, Left
(CHEVY) . . . . . . . . . . . . . . Exterior, left front
Low Beam Headlamp, Right
(CHEVY) . . . . . . . . . . . . . . Exterior, right front
Marker Lamp, Left Front . Exterior, left front ................................ . 17
32
Marker Lamp, Left Rear. . . Exterior, left r1::a, ................................. . 31
59
Marker Lamp, Right Front Exterior, right front .............................. . 17
32
Marker Lamp, Right Rear . Exterior, right rear ............................... . 31
59
45
Mass Air Flow (MAF) Sensor Mounted on air duct, in front oflntake Manifold ..... . 24
Oil Level Sensor . . . . . . . . . Lower left side of Engine, in oil pan ................. . 11,24 20,44
ParkJTurn Lamp, Left Front Exterior, left front ................................ . 17
32
ParkJTurn Lamp,
Right Front . . . . . . . . . . . . Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
202-21
202-21
202-15
202-22
202-22
202-22
202-23
202-22
202-22
202-23
202-23
SA-14-16 ELECTRICAL DIAGNOSIS
GROUND DISTRIBUTION
COMPONENT
Performance Switch ..... .
Control Switch . . . . . . . . .
Power Door Lock Switch, RH
Power Mirror Switch . . . . .
(AQ9) . . . . . . . . . . . . . . . . . .
Power Seat Switch (AC3) .
(PCM) (V6 VIN S) . . . . . .
(PCM) (VS VIN P) ..... .
PRNDL Illumination Lamp
(Auto Trans) .......... .
Radio .................. .
Rear Defogger Grid ...... .
Rear Defogger Switch
(PONT) .............. .
Rear Defogger Switch/Timer
(CHEVY) ............. .
Rear Defogger Timer/Relay
(PONT) ............... .
Rear Dome Light Switch ..
Rearview Mirror ........ .
Retained Accessory Power
(RAP) Module ......... .
Seat Belt Switch ........ .
Pump Assembly ....... .
SIR Coil Assembly ...... .
Speaker/Amp, Left
Front (BOSE) ......... .
Speaker/Amp, Rear (BOSE)
Speaker/Amp, Right
Front (BOSE) ......... .
Radio (UK3) .......... .
Taillamp, LH Inboard
(CHEVY) ............. .
Taillamp, RH Inboard
(CHEVY) ............. .
Taillamp, LH Outboard
(CHEVY) ............. .
Taillamp, RH Outboard
(CHEVY) ............. .
Taillamp, LH (PONT)
Taillamp, RH (PONT) ....
Tail/Stop/Turn Lamp,
LH (CHEVY) .......... .
RH (CHEVY) .......... .
201-PG
LOCATION
FIG.
CONN
202-24
Mounted in center console behind shifter

Mounted in center console behind shifter ............ . 42
Mounted in right door armrest ..................... . 18
Mounted in left door arrmrest ...................... . 18
79
33
33
202-24
202-24
202-24
Under Driver's Seat .............................. . 47

On left side of Driver's Seat ........................ . 41
86
76
202-24
202-24
19
35
202-25
35
33 ..
202-26
202-27
In Engine Compartment, rearward of RH Shock Tower
19
Mounted in left door armrest ...................... . 18
Under console, left of Shifter . . . . . . . . . . . . . . . . . . . . . . . . 43

81
Center of I/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
65
Mounted on rear wind'shield . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 7
Part of HV AC Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounted on I/P knee bolster, right of Steering Column
37
202-16
39
66
Part of HVAC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

39
Center of end panel, in Cargo Compartment . . . . . . . . . . 30
57
Top center of windshield ......................................... .
In molded pocket of dash mat, center above floor tunnel 9 . . . . 17
Part of Driver's Seat Buckle Assembly . . . . . . . . . . . . . . . 43
81
202-27
202-27
202-27
21
Front LH Frame Rail, in Engine Compartment ...... . 11
Top of Steering Column ........................... . 3, 34 . 5,51
Mounted in left door .............................. . 17 ... 31 ..
Mounted in left rear Cargo Compartment trim ...... . 5 .... 8 ...
202-27
202-27
Mounted in right door ............................. . 17 ... 31 ..
202-27
On Steering Wheel ............................... . 2 .... 3 . ..
202-27
Exterior, left rear ................................. . 32
61
Exterior, right rear ............................... . 32
61
61

62
62
62
61
61
\\
14 - 17
COMPONENT
LH Inboard (PONT)
LH Outboard (PONT) ...
RH Inboard (PONT) .....
RH Outboard (PONT) .. .
Theft Deterrent Module .. .
Traction Control Switch ..
Switch ................ .
Washer Pump Motor .... .
Wiper Motor Assembly .. .
C160 (3 cavities)
C165 (3 cavities)
C200B (18 cavities)
C200D (48 cavities)
C210
C217
C240
C270
(4 cavities) ........ .
(4 cavities) ........ .
................... .
(2 cavities) ........ .
C300 (6 cavities) (AQ9) .. .

C310 (2 cavities) ........ .
C405A (4 cavities) ...... .
C405B (10 cavities) ..... .
C420 ................... .
C430 (2 cavities) ........ .
GlOO (L32) ............. .
GlOO (LTl) ............. .
GlOl ................... .
G102 (LTl) ............. .
G103 (LTl)
G104 (L32)
G105 ................... .
G106 ................... .
G108 (L32) ............ ..
G109
G200
LOCATION
201-PG FIG.
CONN
Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
62
62
Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
62
Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

62
In 1/P,just right of Radio, attached to Air Bag Bracket
8 . . . . 15
78
Left side of upper console . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Under console, on base of shift control lever . . . . . . . . . .
Front of vehicle, below Engine Hood Latch . . . . . . . . . . .
LH Wiper Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Headlight to Forward Lamp Harn Jumper, behind
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Headlight to Forward Lamp Harn Jumper, behind
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .
and Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part of I/P Harn, between LH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Under RH side of 1/P, behind RH kick panel . . . . . . . . . .
Near base of Steering Col urnn . . . . . . . . . . . . . . . . . . . . . .
Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . .
1/P Harn to Clutch Jumper Harn, near brake/clutch
pedal bracket ................................... .
Under Driver Seat Assembly ...................... .
Between rear mounting bolt of Driver Seat near #3 Rail
Part of Pass Thru Conn, forward of rear axle, to
Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part of Pass Thru Conn, forward ofrear axle, to
Pass Thru Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH side of Hatch, between Hatch Frame and plastic
panel .......................................... .
Between Rear Fascia and rear end panel, on LH side ..
Bolted to Belt Tension Bracket Bolt, lower RH front
of Engine ( 1 ring, 1 wire) . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolted to RH side of Engine Block, same bolt used for
NC Compressor if equipped (1 ring, 1 wire) . . . . . . . . .
Top of RH Shock Tower (3 rings, 5 wires) . . . . . . . . . . . . .
LH front of Engine Block, just below head
(4 rings, 3 wires and braided strap) . . . . . . . . . . . . . . . . .
RH side ofEngine Block,just above Starter
(1 ring, 1 wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, 1 stud in Intake Manifold . .
Near top RH side of radiator, in top of T-Bar . . . . . . . . . .
Near top LH side of radiator, in top of'T-Bar . . . . . . . . . .
Braided ground strap, bolted to forward left side
of Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolted to left front frame rail (2 rings,1 wire and
braided strap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Near base of LH "A" pillar, bolted to l/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . .
202-18
22
25
42
46
202-28
10
18
202-28
23
43
23
43
25
49 ..
202-2
25
20
34
20
49
37
63
37
202-2
202-19
202-19
202-19
1 .... 2
47 ... 86
6
11
202-19
202-8
202-8
4
32,33
7
61,62
13
25
39
10
69
19
23
40
40
72
29
19
19
56
36
35
11
20
11
21
9 . . . . 16
SA -
GROUND DISTRIBUTION
COMPONENT
LOCATION
201-PG
G201 ................... . Near base of RH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (1 ring, 1 wire) . . . . . . . . . . . . . . . . . .
G305
Bolted to Floor Pan Bar #2, under Driver's Seat
(2 rings, 2 wires, with AC3/AQ9), (1 ring, 1 wire
without AC3/AQ9) .............................
G310
Bolted to roof, left of Dome Lamp (1 ring, 1 wire) . . . . . .
G320
Bolted to body frame above RH rear wheelhouse
G400
Bolted to Hatch Release Bracket in Rear Compartment
(2 rings, 3 wires Coupe) or (2 rings, 2 wires
Convertible) .................................... .
PlOO
Left side in dash panel, Engine to Passenger
Compartment ................................... .
PllO
Compartment ................................... .
P300 ................... . In rear center of roof, near Dome La/mp ............. .
P400 ................... . Left rear in end gate panel ......................... .
P410 ................... . In left side spoiler
P500 ................... . Between LH door and "A" pillar .................... .
P600 ................... . Between RH door and "A" pillar .................... .
8108 (L32) ............. . Engine Harn, approx 4 cm from braided ground strap .
8108 (LTl) ............. . Engine Harn, approx 17 cm from Injector 3 breakout
8109 (LTl) ............. . Engine Harn, approx 4 cm from main branch and
PCM breakout
8110 (L32)
Engine Harn, approx 7 cm from RH Oxygen Sensor
breakout
8111
Forward Lamp Harn, approx 3 cm from Wiper Motor
Assembly breakout
8112
Forward Lamp Harn, approx 10 cm from G105 breakout
8113
Center breakout
8115 (L32)
Engine Harn, approx 10 cm from A/C Compressor
Clutch Conn .....................................
8115 (LTl) ............. . Engine Harn, approx 12 cm from Generator breakout .
8131 (L32) .............. . Engine Harn, approx 17 cm from RH branch
8215 ................... . 1/P Harn, approx 30 cm before DLC breakout
8216 ................... . 1/P Harn, approx 5 cm from Convenience Center (Pont)
or from Instrument Cluster (Chevy) breakouts
8217
8220
Cross Car Harn, approx 9 cm from C200 breakout . . . . .
8221
1/P Harn, approx 7 cm from DERM breakout
8335
Control Module Conn
8410
Rear Body Harn, approx 7 cm from Left Backup
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8415
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8420
Hatch Harn, approx 7 cm from P300 . . . . . . . . . . . . . . . . .
8430
Rear Fascia Harn, approx 5 cm from License
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8450
CHMSL Jumper Harn, approx 15 cm from bulbs
8470
1/P Harn, approx 24 cm from Hatch Release Actuator
For a Service Part Cross Reference List and Information, refer to SECTION 8A-200.
FIG.
9 . . . . 16
6
4
11
6
30
57
19
36
19
4 ....
30
35
7
57
32
32
11
24
49
49
20
44
28
14
54
26
45 . . . 84
33
62
33
62
4 .... 7
31 . . . 59
CONN
ELECTRICAL DIAGNOSIS BA -
BLANK
14 - 19
1 RUST
5 RED
FUSIBLE
LINKE
102
" " " - - - -. . . TO ABS RELAY AND TCS RELAY

- - - - - - ~ PAGES BA-44-1, 3
5 RED
BAQ
2
102
r----r-------,IGNITION
SWITCH
SEE POWER DISTRIBUTION
,-PAGE BA-10-2
: :1102
Cl
I
I
C200B
C200D
ACCY
I
I
3 RED
102
LOCK-.....
OFF
3 RED
RUN
3 BRN
102
I
I
_... euLB TEST
EI
L- - - -
START
C6
g -
I
-s:-1N:R:E:
CLUSTER
PAGE BA-81-3
4
C200B
C200D
~---;---.=:::::.----------,
3BRN
.35 YEL/
BLK
RETAINED
68
ACCESSORY
POWER(RAP)
MODULE
rn
IMPORTANT:
BOTH RELA VS WILL
REMAIN ENERGIZED FOR
10 MINUTES IF DOORS ARE
NOT OPENED.
_ _ _"""_ _ _ _ _ RAP 2 RELAY

BATTERY
INPUT
DE-ENERGIZES
IMMEDIATELY
WHEN A DOOR
IS OPENED.
SOLID
STATE
RAP2
CONTROL GROUND
El
SEEGROUND
DISTRIBUTION
PAGE BA-14-7.
L
3 BLK
3 DK BLU
75
650
.35 BLK
750
es220
3 BLKl750
- - - - - -......._
~200
IGNITION
INPUT, RESET
DOOR
OPEN
INPUT
RAP1
CONTROL
.SGRY/B~Ki45
RAP 1 RELAY
ALWAYS ENERGIZED
WITH A DOOR OPEN.
REMAINS ENERGIZED
FOR 35 SECONDS
AFTER BOTH
DOORS ARE
CLOSED.
LOW
COOLANT
INDICATOR
CONTROL
(LATCHING)
.SGRYIBLK
.,
-------------
ISOLATION 15266
745
TO IGNITION
DIODE(RAP)
~ K E Y WARNING
(3 AMP)
SWITCH
.5 TAN 159
.S GRY/BLK 745
PAGE BA-76-0
SEE INTERIOR
LIGHTS
.._PA_G_E_a_A_-_11_4_.o.....
B
A
~~-ft~
CLOSED
WITH
DOOR OPEN
_
70
~r -----------------~ - - - - - - - - - - - - - - - - - - - - - - - - - - - -
FUSE
BLOCK
I
I
I
RADIO
FUSE 17
15AMP
WINDOWS
CIRCUIT
IIREAKER 15
30AMP
---,
PWRACCY
~
lSAMP
I
I
I
------------------------------~
'---v-"
SEE FUSE
BLOCK DETAILS
PAGEBA-11-9
SEE FUSE
BLOCK DETAILS
PAGEBA-11-8
\\
1/P HARNESS TO FORWARD

LAMP/CROSS CAR HARNESS
C200D
E13
DDDDDDDD DODD D
:::__:_:_::
_1_11
86
11
:~
~:
c:==J 1
El
==:::
::
:=:
11
11
.....___.I
01
ADDDDDDDDDDDDDDDDDA
11
12077822
M CONNECTOR
F TERMINAL
48-WA Y M METRI-PACK MIXED SERIES
BLK
FORWARD LAMP HARNESS TO

1/P HARNESS
C200A
c1A DDDDDDDDDDDDDDDDDA
17
\.
12047842
17-WAY F METRI-PACK 150 SERIES
BLK

1/PHARNESS
C200B
81
,1
01
I
I
1
11
11
11
~~
II
II
11
11
11
11
11
II
II
1
I
1
86
(6
06
12084183
18-WAY F METRI-PACK MIXED SERIES
BLK
CROSS CAR HARNESS TO

1/P HARNESS
C200C
IAlDDDDDD DODD DDDA13l

\.
12047840
13-WA Y F METRI-PACK 280 SERIES
GRY
SA
12010966
12052854
5-WAY F 56 SERIES
BLU
BLK
IGNITION SWITCH (C2)
RETAINED ACCESSORY POWER (RAP) MODULE
COMPONENT
Door Jamb Switch, LH
Door Jamb Switch, RH
1/P Fuse Block .......... .
Ignition Switch ......... .
Isolation Diode (RAP) ... .
201-PG
LOCATION
Near base of LH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . .
Near base of RH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . .
LH side of 1/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . .
Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Sealed in Harn, approx 9 cm right of Rearview
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

(RAP) Module ......... . .In molded pocket of dash mat, center above floor tunnel
C200B (18 cavities)
C200C (13 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G200
Near base of LH "A" pillar, bolted to 1/P Mounting Stud
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8200
Forward Lamp Harn, approx 5 <:m from EBCM
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8220
8266
Cross Car Harn, approx 9 cm from Rear\riew
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIG.
CONN
84
49
15
63
202-23
202-23
84
9 . . . . 17
202-27
25
49
202-2
25
49
202-2
25
49
202-2
9 . . . . 16
, "r" '
19 . . . 36
8 . . . . 14
45
84
45
84
(~erfor!'1 before
D1agnos1s)
1.
2.
3.
4.
beginning
System
Check Fusible Link E for open.

Check Window Circuit Breaker 15, Radio Fuse 17
and PWR ACCY Fuse 7 for an open. (f open,
replace fuse or circuit breaker. (f fuse blows again
or circuit breaker reopens, use schematics and
DVM to check suspect power circuits for a short to
ground po.tential, either through a faulty
component or wiring.
Check for poor connections at C200 terminals
"Cl", "E2", "E4", "E6" and "El2".
Check that G200 is clean and tight.
Check for a broken (or partially broken) wire
inside of the insulation which could cause system
malfunction but prove "GOOD" in a

continuity/voltage check with a system
disconnected. These circuits may be intermittent
or resistive when loaded, and if possible, should be
checked by monitoring for a voltage drop with the
system operational (under load).
Check for proper installation of aftermarket
electronic equipment which may affect the
integrity of other systems (see ''Troubleshooting
Procedures," page 8A-4-0).
Refer to System Diagnosis.
SYSTEM DIAGNOSIS
Perform the System Check and refer to the
Symptom Table for the appropriate diagnostic
procedures.
\\
15 - 3
SYSTEM CHECK
ACTION
NORMAL RESULTS
(1)
Ignition "OFF."
Open either LH or RH door.
(2)
Close doors.
(3)
Ignition Switch to "ACCY" or "RUN."
[4]
Power Door Locks, Hatch Release and Power

Mirrors all operate for approximately 10 minutes.
Radio and Power Windows operate for
approximately 10 minutes.
Ignition Switch to "RUN."

Ignition Switch to "OFF."
Open either LH or RH door.

Mirrors all operate as long as a door is open.
Radio and Power Windows are disabled
immediately when a door is opened.
Close doors.

Mirrors all continue to operate for approximately
35 seconds.
Radio and Power Windows do not operate .
rn

Mirrors all operate as long as the Ignition Switch is
in "ACCY" or "RUN."
Radio and Power Windows operate as long as the
Ignition Switch is in "ACCY" or "RUN."
(6)

Mirrors all continue to operate for approximately
35 seconds.
[5]

Mirrors all operate as long as a door is open.
Important:
If aftermarket equipment is installed on any circuit(s) for the Retained Accessory Power (RAP) System and
a problem exists with the Retained Accessory Power System operation, disconnect the aftermarket
equipment and retest.
These diagnostic procedures assume related fuse(s) or circuit breaker(s) and the circuitry to their related
components are all good.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Components on PWR ACCY Fuse 7, Radio Fuse 17 and

Windows Circuit Breaker 15 totally inoperative.
Chart #1
8A-15-5
Retained Accessory Power (RAP) Feature inoperative,

components on PWR ACCY Fuse 7, Radio Fuse 17 and
Windows Circuit Breaker 15 operate with Ignition
Switch in "RUN" or "ACCY" only.
Chart #2
8A-15-5
SA -
15 - 4

SYMPTOM
SYMPTOM TABLE
'
Components on Windows Circuit Breaker 15 and

Radio Fuse 17 totally inoperative, components on
PWR ACCY Fuse 7 operate normally.
PROCEDURE
PAGE NUMBER
Chart #3
8A-15-6
Components on Windows Circuit Breaker 15 and Replace Retained Accessory Power (RAP) Module.
Radio Fuse 17 do not operate during Retained
Accessory Power (RAP). operation is normal with
Ignition Switch in "ACCY" or "RUN" (components on
PWR ACCY Fuse 7 operate normally during RAP).
Chart #4
Components on PWR ACCY Fuse 7 totally inoperative,

components on Windows Circuit Breaker 15 and Radio
Fuse 17 operate normally.
8A-15-6
Components on PWR ACCY Fuse 7 do not operate Replace Retained Accessory Power (RAP) Module.
during Retained Accessory Power (RAP), operation is
normal with Ignition Switch in "ACCY" or "RUN"
(components on Circuit Breaker 15 and Radio Fuse 17
operate normally during RAP).
Retained Accessory Power (RAP) deactivates when
another vehicle system is used (otherwise RAP times
out normally).
If use of Interior Lights causes deactivation of

Retained Accessory Power (RAP). check Isolation
Diode (RAP).
Narrow in on system causing deactivation and
shield or filter power and grounds to component,
then retest system.
If unable to correct complaint, contact technical
assistance.
Retained Accessory Power (RAP) deactivates before

specified time has elapsed (deactivation not caused by
the use of other vehicle systems).
Refer to System Check to make sure the RAP

System is not operating properly.
Check for technical service bulletins.
If above checks do not correct symptom, replace
Retained Accessory Power (RAP) Module.
PWR ACCY Fuse 7 receives voltage continuously (past

the approximately 10 minute period) with doors
closed and Ignition Switch in "OFF."
Check for short to B + in CKT 70.

Check for short to ground through CKT 745,
including a bad Door Jamb Switch.
Check for poor connections at RAP Module
Connector.
If OK, replace Retained Accessory Power (RAP)
Module.
Radio Fuse 17 and Windows Circuit Breaker 15 receive

voltage continuously (past the approximately 10
minute period) with doors open and Ignition Switch in
"OFF."
Check for short to B + in CKT 75 .

Module.
Check for bad Door Jamb Switch on side of entry.

Check for open in CKT 745.
Check for poor connection at RAP Module.
Module.
Power Door Locks do not operate when one or

both doors are opened.
Power Door Locks only operate with Ignition
"ON," or for 10 minutes after Ignition is turned
"OFF." (Opening the door does not disable the 10
minute timer or enable "PWR ACCY" Fuse 7.)
15 - 5
CHART #1
rn
COMPONENTS ON PWR ACCY FUSE 7, RADIO FUSE 17

AND WINDOWS CIRCUIT BREAKER 15 TOTALLY INOPERATIVE
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE CIRCUITRY TO THEIR RELATED
COMPONENTS ARE All GOOD, AND INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.
IGNITION SWITCH TO "RUN."

WITH A TEST LIGHT TO GROUND, BACKPROBE RETAINED ACCESSORY POWER (RAP) MODULE CONN TERM "D" .
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE IGNITION SWITCH CONN (2 TERM "B".
IS TEST LIGHT "ON"?
GJ
WITH A TEST LIGHT TO GROUND, BACKPROBE

IGNITION SWITCH CONN C2 TERM "E".
IS TEST LIGHT "ON"?
GJ
Cl-iECK FOR POOR CONNECTION AT (200

TERM "(6" AND TERM "E2".
IF OK, REPAIR OPEN IN CKT 4 BETWEEN
IGNITION SWITCH AND RETAINED
ACCESSORY POWER (RAP) MODULE.
s
s
CHECK FOR:
POOR CONNECTIONS AT
RETAINED ACCESSORY POWER
(RAP) MODULE CONNECTOR.
POOR CONNECTIONS AT (200
TERM "E6" AND TERM "E12".
WIRING DAMAGE THAT MAY
CAUSE AN OPEN IN CKT 70
ANDCKT7S.
IF ABOVE CHECKS ARE OK,
REPLACE RETAINED
MODULE.
CHECK FOR OPEN IN FUSIBLE LINK "E".

IGNITION SWITCH AND FUSIBLE LINK.
CHECK FOR POOR CONNECTION

AT IGNITION SWITCH.
IF OK. REPLACE IGNITION SWITCH.
CHART #2
rn
RETAINED ACCESSORY POWER (RAP) FEATURE INOPERATIVE, COMPONENTS ON

PWR ACCY FUSE 7, RADIO FUSE 17 AND WINDOWS CIRCUIT BREAKER 15
OPERATE WITH IGNITION SWITCH IN "RUN" OR "ACCY" ONLY
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE CIRCUITRY TO THEIR RELATED
COMPONENTS ARE All GOOD, AND INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.
WITH A TEST LIGHT TO GROUND, BACKPROBE RETAINED ACCESSORY POWER (RAP) MODULE CONN TERM "C".
IS TEST LIGHT "ON"?
DISCONNECT RETAINED ACCESSORY POWER (RAP) MODULE CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERMINALS"(" AND "E" OF THE RAP
MODULE CONNECTOR.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT (200

TERM "(1" AND TERM "E4".
RETAINED ACCESSORY POWER (RAP)
MODULE CONNECTOR AND S200.
CHECK FOR POOR CONNECTIONS AT RETAINED ACCESSORY POWER

(RAP) MODULE CONNECTOR.
IF OK, REPLACE RETAINED ACCESSORY POWER MODULE. (IF POWER
ACCY FUSE RECEIVES VOLTAGE CONTINUOUSLY WITH DOORS CLOSED
AND IGNITION SWITCH "OFF," CHECK FOR A SHORT TO GROUND
THROUGH CKT 745, INCLUDING A BAD RAP ISOLATION DIODE OR
DOOR JAMB SWITCH.)
CHECK FOR POOR CONNECTIONS AT RAP MODULE

CONNECTOR.
IF OK, CHECK FOR OPEN IN CKT 750 BETWEEN RAP
MODULE AND G200.
15 - 6
SA -

CHART #3
rn
COMPONENTS ON WINDOWS CIRCUIT BREAKER 15 AND RADIO FUSE 17

TOTALLY I NO PERA TIVE, COMPONENTS ON PWR ACCY FUSE 7 OPERATE NORMALLY
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND.THE
CIRCUITRY TO THEIR RELATED COMPONENTS ARE ALL GOOD, AND
INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.

WITH A TEST LIGHT TO GROUND, FRONTPROBE RADIO FUSE 17.
IS TEST LIGHT "ON"?
, - - , ~ - - - - - - - - - - - - - - - - - - - - - - - - , r-
WITH A TEST LIGHT TO GROUND, BACKPROBE RAP MODULE CONN TERM "B".
:
IS TEST LIGHT "ON"?
1
'---,.---------------------------' :
--------------- .----------,
CHECK 1/P FUSE BLOCK FOR POOR WIRE

:
CONNECTIONS OR POSSIBLE DAMAGE.
1
IF OK, REFER TO "RADIO," PAGE SA-150-0.:
L----------------------------~
CHECK FOR POOR CONNECTION AT RAP MODULE CONN TERM "B".

IF OK, REPLACE RAP MODULE.
CHECK FOR POOR CONNECTION AT C200

TERM "E6".
IF OK, REPAIR OPEN IN CKT 75 BETWEEN RAP
MODULE CONNECTOR AND 1/P FUSE BLOCK.
CHART #4
rn
COMPONENTS ON PWR ACCY FUSE 7 TOTALLY INOPERATIVE, COMPONENTS ON

WINDOWS CIRCUIT BREAKER 15 AND RADIO FUSE 17 OPERATE NORMALLY
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE
CIRCUITRY TO THEIR RELATED COMPONENTS ARE ALL GOOD, AND
INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.

WITH A TEST LIGHT TO GROUND, FRONTPROBE PWR ACCY FUSE 7.
IS TEST LIGHT "ON"?

RAP MODULE CONN TERM" A".
IS TEST LIGHT "ON"?
,-
CHECK FOR POOR CONNECTION AT RAP MODULE CONN TERM "A".

IF OK, REPLACE RAP MODULE.
:
I
------------------------------------,
CHECK 1/P FUSE BLOCK FOR POOR WIRE CONNECTIONS

:
OR POSSIBLE DAMAGE.
1
IF OK, REFER TO "POWER DOOR LOCKS," PAGE SA-130-0. :
L--------------------------------------J
CHECK FOR POOR CONNECTION ATC200TERM "E12".

IF OK, REPAIR OPEN IN CKT 70 BETWEEN RAP MODULE
CONNECTOR AND 1/P FUSE BLOCK.
CIRCUIT OPERATION
The Retained Accessory Power (RAP) System is
designed to increase convenience and provide
increased security. Some Vehicle Systems will remain
operational for approximately 10 minutes after the
Ignition Switch is turned to "OFF" or until a door is
opened. Other systems will also be operational with
Ignition Switch "OFF" whenever a door is open or for
approximately 35 seconds after both doors are closed.
PWRACCY FUSE 7 OPERATION
The Retained Accessory Power (RAP) Module will

enable the Power Door Locks, Hatch Release and
Power Mirrors to operate with the Ignition Switch in
"OFF" whenever either door is open or for 35 seconds
after both doors are closed. All components on this
circuit will be enabled as long as the Ignition Switch is
in "ACCY" or "RUN." After the Ignition Switch is
turned to "OFF" and both doors remain closed, the
components on this circuit will be enabled for
approximately 10 minutes. If either door opens, the 10
minute timer cancels, and the components remain
enabled as long as a door is opened.
RADIO FUSE 17 AND WINDOWS CIRCUIT BREAKER
OPERATION
The Retained Accessory Power (RAP) Module will

enable the Radio, Power Windows and Convertible Top
to operate whenever the Ignition Switch is in "ACCY"
or "RUN." After the Ignition Switch is turned to
"OFF" and both doors remain closed, the Radio, Power
Windows and Convertible Top will be enabled for
approximately 10 minutes. If either door opens, these
components will be disabled immediately.
15 - 7
SA -
20 - 0
SEQUENTIAL MULTIPORT FUEL INJECTION: V6 VIN S

DATA LINK, GROUND AND POWER
rS;;P:E:- -
--- ---------- -,!le.I
SEE POWER
DISTRIBUTION
PAGE BA-10-3
I DISTRIBUTION
I PAGE 8A-101
FUSE
BLOCK
GAGES
FUSE9
10AMP
I
I
I
I
I
IGN
(NOT USED)
L ___ _
_____ J
.8 ORN
340
.5 PNK
S209-
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-7
.8 ORN
.8 PNK
439
----S206
SEEFUSE
BLOCK DETAILS
PAGE 8A-115
+I
340
C210
5205. -
39
.3SPNK
DATALINK
CONNECTOR (DLC)
39
,4~
(CHEVY) 013
(PONT) AS
-----,:;l
INSTRUMENT
CLUSTER
.35 TAN
r:E;- -:.:f"- - - - ~
INSTRUMEN.;'
):_
(MIL)
I
I CLUSTER
"SERVICE
I PAGE 8A-813
ENGINE
I
SOON"
I
y INDICATOR I
800
mse-
.35 TAN
800
.3 5TAN
800
-T
SEE DATA LINK
CONNECTOR
PAGE 8A-500
!.__ - - -~ - -- _ __:
(PONT) A4
(CHEVY) C8
.8 ORN
340
.5 PNK
.35 BRN/WHT
439
419
.35 WHT/BLK
448
C
C230
-----------Q(NOT USED)
"i'"
.::~i,..
14
r- - - -
15
~-...;;.~ -
3
INPUT
I
I
I
-z
1
---;N;;'o~ - - - - - -
19
t,w- -- -- - --
"SERVICE
ENGINE SOON"
INDICATOR
-1coNTROL
BATIERY
INPUTS
POWERTRAIN
CONTROL
MODULE
~
(PCM)
l .. &
------;-v--,
SERIAL
DATA
LINE
I
I
I
POWER
L _- - - - - -
-G~U,!!>S_
16
32
.5 BLK:W HT
LH OXYGEN
SENSOR GND
451 - -
. 5 BLK1WHT
lOr
.35 BLK:
WHT
RH OXYGEN
SENSOR GND
.35 BLK/W:T
.......__
,...- -
------17
3:1
.5 TANIWHT
----------~--..J
L32 PCM CONNECTOR IDENTIFICATION
S51
ALL CONNECTOR BODIES ARE GRAY

WITH COLORED TPAs
A - CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
351
.8 TAN/WHT
SEE GROUND
DISTRIBUTION
PAGES 8A-14-2, 3
REDUNDANT
GROUNDS
551
32 WAY
32 WAY
32 WAY
m1e
es110 - ,
.8 BLK.WHT 1451
.8 BLK,WHT
351
_._ ___ _.__ ___ -------------=- G104
2 STUDS WITH
2 TERMINALS ON EACH
(INTERCHANGEABLE)
1~
~SEEPAGE 8A-3-0
~.
FOR MEASURING
AND HANDLING
PROCEDURES
20 - 1

IGNITION
see PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
___ _..
GJC100
.35 PNK
.3SPNK
2 3 ~ ~ - - - - - - - - - - - - - - - - - ..- _____...
:,...._ _ __
TO AUTOMATIC ~
.5 PNK
,
239
A"'
TRANSMISSION .... - - - - - - .,_
.35 PNK
PAGE 8A-39-0
239
5107
~
I
IGN
239
A ,-..
-0-P-TI_CA_L_S_E-NS_O_R_ _ _ _ _ _......,.._CAMSHAFT
POSITION
SENSOR
PICKUP)
24X
REF
HI
LO REF
I'"' -
-, INSTRUMENT
TACH
INPUT
B';;
05
.8WHT
.35WHT
I CLUSTER
I
CAM H~I
...,;.
5125
35
. 35 PNKtBL:
:J
1800
BLU/
63~---6~~-~~!~A~-6~2-------~~T
~
r - CAMSHAFT
- - - - - - -LOW- - - - - - - 24X
- - - - - - ,
.35BRN~:T
;;-ONT)
(CHEVY)
.8 PNK
121
c '(:5::KiBLK
CRANKSHAFT
POSITION
SENSOR,
HIRESOLUTION
(INDUCTIVE
239
POWERTRAIN
CONTROL
MODULE
I
I
~ I
::i~~
POSITION
;CM)
IGNITION
' :
C230
REFERENCE
~~:;:~L
121
REFERENCE
sv
SIGNAL
-1
~~~~~o~
-__._
'
H h1v
--=-3X REF
L - - - - -2 ] :-- - -- ~7 - - .,:;::-_
- - - -30
-H~P~
- - - - - 31
.-L-3_2_P_C_M_C_O_N_N_EC_T_O_R_ID-E_N_TI_FI-CA-T-IO-N--,
WITH COLORED TPAs.
A CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
32 WAY
32 WAY
32 WAY
TACH SIGNAL
SOLID STATE
TA~~
424
BLK
.35 LT BLU/
.35 WHT
423
I
I
I
:
I
3X
REF LO
,.!IP~
...I
647
BLK
.35 REDIBLK
453
IGNITION COIL CONTROLS
IGNITION
COILS
~~======ii==E=:E====:;;::;;;;;;;;;===:;--------::A'T:7rc:;3----:-~~=-=~;-;;-----..1
.8 BLK
450
.35 BLK
_ _ _.. , - - - - - - - 5108
450
(WITH (60)
Jl ll ll
CYLINDER #5
#2
lt3
#6
TO SPARK
PLUG WIRES
FIRING ORDER
1-2-3-4-5-6
#4
#1
.8 BLK
1 BLK
see HVAC
COMPRESSOR
CONTROLS
PAGE 8A-64-0
SEE GROUND
DISTRIBUTION
PAGE 8A-14-2
......~ ~ ~ - - - '
450 (WITHOUT (60)

450 (WITH C60)
_ ___.A....,_ _.._..,.._.. CRANKSHAFT
HI
llii>-
....:....2104
POSITION
SENSOR,
LOW RESOLUTION
_ _ _ _ _ _ _ _ _.. (INDUCTIVE
PICKUP)
8A -
20 - 2

FUEL PUMP, HVAC AND PASS-KeyII INPUT
I" -
I
I
I
THEFT
DETERRENT
I MODULE
I
I
L--.J
SEE HVAC COMPRESSOR CONTROLS

PAGE SA-64-0
A3
.35 DK BLU
59
L32
.35 DK GRNi
WHT
23
762 .35 DK GRNI

WHT
.. 1/P
FUSE
BLOCK
,I
............
........-- -
439
5205
PCM CONNECTOR IDENTIFICATION

WITH COLORED TPAs .
459
A - CLEAR (CLR)
B - BLACK (BLK)
C - BLUE (BLU)
~
1
I
.S PNK
SEE FUSE
BLOCK DETAILS
PAGE SA-11-5
229
---- ___ ..
229
.5 DK GRN
.35 DK BLU
I SEE POWER
DISTRIBUTION
I PAGE SA-10-3
I
I
32 WAY
32 WAY
32 WAY
r - - - FUEL
- - - - ..... - AIC.._ .; . . - - -AiC- - - - A/C
- CLUTCH
- - -, POWERTRAIN
CONTROL
I
I
I
ENABLE
INPUT
REQUEST
INPUT
COMPRESSOR
CLUTCH
RELAY
STATUS
oo~
I
I
I
L _________
FUEL PUMP
s~~
FUEL PUMP
_ _ _ _ R!.;A:!.;O!!R.!! __
I MODULE
(PCM)
I
I~
I~
I
I
1 PNK
439
.J
.35 GR:r20 - - - - - - - - - - 8
.35 DK GRN/WHT
8GRY
P110
5280 - - 120
- - - - -. .
1
1
.8 GRY
SEE INSTRUMENT
CLUSTER
PAGE 8A-81-2
A2
\I;
2
C lO
_ GRY
8
.35 PP:+ 0
120
465
465
.--,"""------,_,,r--, FUEL
PUMP
RELAY
FUEL PUMP
PRIME CONNECTOR
120
.SS~:: t20---------:2:RY--------.8BLK,WA-~TJ:51
A1
----------
C40SB
~405~
. - - - - -....--------------.....111o-----~FUEL
F
TANK
90 Q
UNIT
s21se- .5 BLK;WHT
--,
I
I
451
FUEL
PUMP
oQ
_..ollllll
~. WITH A_C3 OR AQ9
SEE GROUND
DISTRIBUTION
PAGESA-14-11
3 BLK
1450
.8 BLKWHT
-.....
451
,.'1;104
-----
l
SEE GROUND
DISTRIBUTION
""f''~
I
__.
4WrA.
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
ELECTRICAL DrAGNOSIS SA - 20 - 3

INJECTORS
-.
r- - - - - - - - - - - - - - - - - - - - - - - - - - - -.
SEE POWER
ELE~~~~~I ~ - - - - - - - - - - - - - - - - - - - - - - - - - DISTRIBUTION
UNOERHOOO
INJECTOR PAGE 8A-10-3
INJECTOR
FUSE9
7.5AMP
I
I
FUSE 10
7.5AMP
______ ....
...
8 PNK
.8 PNK
639
.8P:Kx;39 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
839
.8 p:K~~;oo
.~
................
.5 PNK/B:KT:39 - - - - - - - - - - - - - - - - - - - - - - - - - - - - .5 PNK/BL18::lO
~103
.5 PNKI
BLK
5104
. 5 PNKI
BLK
639
639
.5 PNK/
BLK
639
FUEL
INJECTORS
.5 PNKI
BLK
839
.5 PNKI
BLK
.5 BLKIPNK
.5 BLK
A
.5 BLK/WHT.
1744
------c
------E
.5 PNKIBLK
.5 BLK
rI I
I
I
I
I
.5 BLK;WHT
1744
.S LTGRNIBLK
845
844
.5 BLK/VEL
------
.S LT BLUIBLK
1746
1745
-------D
----------- -- B
839
846
C110
844
.5 YELIBLK
1745
846
-1---r.---1--------1----1---7--14
CONTROL
POWERTRAIN
MODULE (PCM)
.5 BLK/LT GRN
845
.5 PNK/
BLK
.5 BLK/LT BLU
1746
839
16
------12
- - - - - - - - - - - - - - 13
______31
------15
-:_l
INJECTOR #1
CONTROL
-:_l
INJECTOR #3
CONTROL
ALL SOLID STATE
-:_l ~~1~~~~~s
INJECTOR #5
CONTROL
OR
-:_l
INJECTOR #2
CONTROL
-:_l
INJECTOR #4
CONTROL
-:_l
INJECTOR #6
CONTROL
I
I
I
I
I
I
L----------------------------------~
L32

WITH COLORED TPAs.
A CLEAR (CLRI
B BLACK (BLK)
C BLUE (BLU)
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
32 WAY
32 WAY
32 WAV
SA -
20 - 4

ENGINE DATA SENSORS
.35 GRY
.35 GRY
416
BI '
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
TEMP
v
1
I
s~~
416
r --B-,Ai:--,
.]SGRY
A/C
REFRIGERANT
PRESSURE
SENSOR
416
REF
V LO
A, I
r.,~
."
B
.35 BLK
A/C EVAPORATOR
TEMPERATURE
SENSOR - . - . . . ,..........___.
452
.35 BLK
452
---------5119
.35 TAN
PO~~~;:~~ r
I
.... I
~
I
~I
MODULE
(PCM)
:
I
472
432
-I
r-;-,;--
29,
c:;
SENSOR
INPUT
29,
.35 BLK
452
.35 RED/BLK
SENSOR
INPUT
GROUND
REF
[I f
732
REFRIGERANT
PRESSURE
SENSOR
INPUT
-=-
sv
.35 OK BLU
380
1"
SENSOR
GROUND
..,;;-- - - - - - - - -=E~ - - -
THROTTLE
POSITION
.5 BLK
.JS BLK
S.lf
TO AUTOMATIC
TRANSMISSION
(M30)
PAGE SA-39-0
REF
A
.35 GRY
416
REF
..o
"0"G"
,,,,,...
SENSOR
SENSOR
SENSOR
.!.p~ - - -
.3SOKBL:
_!P~ - - _!i>U,!_ - 21
.8::L
4:6
.8PPL/WHT
16:6
1665
.3SY:':.(4:ENGINE
COOLANT
~TURE
(ECT) SEN SOR
470
KNOCK
.S BLK'PNK
SENSOR
470
I
\
,cr
- - - - - - -
470
SENSOR
~ ,-;- .__ ~
SV
KTC110
es122
416
INPUT
1
4 1 ~ - - - - - - - - - - - - - - - ~ : B : : f 7 ~ - - - ~ ~ 214:0
:750BLK
- - -
EVAPORATOR
TEMPERATURE
SENSOR
INPUT
-=-
J:i~R
.35 GRY
~--;~-.:.-.:.~-;;.,;;.:.-.:.-.:.-.:.--t~-_;;,-.:.-.:.-.:.1! MC- .
l,;
.3SDKB::
.35 LT GRN
--a--..
OXYGEN
sENSOR, LH
OXYGEN
SENSOR, RH
I~
J
20 - 5

CONTROLLED DEVICES
HOT AT ALL TIMES
2 RUST
5 RED
SEE POWER
DISTRIBUTION
PAGE 8A-10-1
UNDERHOODr- ELECTRICAL
SEE POWER
CENTER
DISTRIBUTION
-PAGE8A-10-3
FUSIBLE
LINK K
I
------------------,
HOTINRUN
-
I
I
I
I
I
I
I
I
I
I
I
502
. . 5 RED
----5RED---f-------502 5~3
502
AIR""'"""'----...,.~-,
PUMP
RELAY
'
.5 BRN
541
__ .J
L-------SEECOOLANTFANS
PAGES8A-31-0, 1, 2
......... _
.........
-5190
.35 BRN I 541
F ~(100
I 541
.35 BRN
.35
DKGRN
335
.35 BR N
8
I 541
EVAPORATIVE~ EXHAU5TGAS
EMISSION
RECIRCULATION
11
(EVAPI
CANISTER
~URGE
SOLENOID
VALVE
21.8
AI
.35DKGRN/W:T
il
1.
r---,,"""--~-,
II
I______
VALVECI
.....__3_5_B_R:_I
...6_9_8_ _
-1-
428 - - - - - - - .35::D
SECONDARY
AIR
INJECTION
~
ASSEMBLY
SOLENOID-
(EGR)VACUUM
CONTROL
SIGNAL
SOLENOID
-r:-0:A:F: -z-E:P:N:E:RELAY CONTROL

PURGE SOLENOID
VALVE CONTROL
1.
5127
I~
.5 BDRN
699 _l
.3SLT~~U
.35
BRN
~~:T~~~~~gN
111...._::T:~~3
PAGE 8A-14-6
6 9 7 - - - - - - - - - - - - - - - - - - - 3 8 ~ ~ __ l
-lS:E:ID_l:_ SOLENOIDSOLENOIDCONTROL
CONTROL
CONTROL
1. 1.
1.
436
I!.
-z:"i:-1
RELAY
CONTROL
ALL SOLID STATE
1.
NO RELAYS OR SWITCHES
\
\
I
I
I
I
I
I
I
I
~~~~~;;~;~------------~~~1~.:~:~r'"::::1. .:~:~1~:J
COIL .. A.
A - CLEAR (CLR)
~ : :~~~~B(~~f)
WHT
32 WAY
!~ ::~
COIL .. A.
CONTR~t~1:~~
COIL "B"
WHT
---VALVE
COIL B
STEPPER
MOTOR
SEE PAGE8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
COIL "B"
SA -
20 - 6

AUTOMATIC TRANSMISSION CONTROLS (M30) AND VSS
-------;11p
FUSE
I BLOCK
I
I
I
IGN
(NOTUSED)
L-----....;--
...;._J
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-5
39
.---5206
.35 PNK 139
BAQ
,--------""----------~"""-------,BRAKE
BRAKE
SWITCH
TCC/SHIFT
BRAKE LIGHT
DEPRESSED
ASSEMBLY
INTERRUPT
CRUISE RELEASE
SWITCHSWITCH
(NORMALLV
(NORMALLY
CLOSED)
OPEN)
......_
--------------
SEE ELECTRONIC TRANSMISSION CONTROLS

PAGE 8A390
.35LTBL:y.,::
BLK
,---------------------''-------------------"
.35 LTBLU/BLK
1
[QJ
5238. - - - - - - - -. .
.35LT
BLU
.35 DK
BLU
553
1493
.5 DK
BLU
.5 PNK
.5 RED/
1225
1228
.5 LT
GRN
BLK
1224
.5 RED
1226
.5VEU
BLK
1229
.SLT
BLU/
WHT
.SWHT
1222
.5 VEL/
BLK
687
.STAN/
BLK
1223
.35LTBLU1/83
BLK
1227
H
Siil
C230
422
BRAKE
TRANSMISSION
SHIFT INTERRUPT.
(BTSI) SOLENOID
P110
!!
18
... -
I
I
I
I
10
-
21
22
,- -
PERFOR- PERFOR- RANGE

MANCE
MANCE SIGNAL
INDICAMODE
"A"
TOR
INPUT
CONTROL
23
-
5
-
___6
-
11
-
_ _!2
-
_ _!5
16
-
_}_2
-
RANGE '--._H_I__
.. __I.() / 1-2
2-3
3-2 SHIFT ' TCC
SIGNAL . ~ SHIFT
SHIFT SOLENOID SOLENOID
"C"
PRESSURE
SOLENOID SOLENOID CONTROL CONTROL
CONTROL
CONTROL CONTROL
- SOLID STA TE SOLENOID
RANGE
SIGNAL
"B"
A
-
TFT
SIGNAL
I ,,.
I ~
4000 PULSE
L -
~s~o -
29
A - CLEAR (CLR)
B
BLACK (BLK)
C BLUE (BLU)
SEE PAGE 8A-30

FOR MEASURING
AND HANDLING
PROCEDURES
32WAV
32WAV
32WAV
.35 PPL
28
30

All CONNECTOR BODIES ARE GRAV
WITH COLORED TPAs.
,!S~I ,_"E!_M!!! <>.!!,TP.!!J -
401
.35 VEL
.35 DK GRN/
WHT
400
!!
817
~ . , POWERTRAIN
BRAKE CONTROL
SIGNAL tMODULE
(PCM)
...
.J
~-------.
-
SEE HATCH RELEASE

PAGE 8A-135-0
.35 TAN/
WHT
816
ISOLATION
DIODE
(BTSI)
(1 AMP)
.35 ORN/
BLK
434
20 - 7

MANUAL TRANSMISSION CONTROLS (MMS) AND VSS
f - - - - - - - - - - - - - - - 1
I
I
I
4000 PULSE
CLUTCH
~.
POWERTRAIN
CONTROL
MODULE
(PCMI
J.
29
.35 PPL
~~T _ _ _!NP~ _ _
30
!!
28
.35 DK GRN/
WHT
401
.35 YEL
ANTICIPATE
PER MILE
L ~s11-o__ '!!.s ~ _
817
22
.35 GRV
48
.35 GRV
48
.35 GRV
48
400
SEE VEHICLE SPEED SENSOR

PAGE 8A-33-0
L32
ALL CONNECTOR BODIES ARE GRAV

WITH COLORED TPAs.
A CLEAR (CLR)
B - BLACK (BLK)
C - BLUE (BLU)
rn
- 32 WAY
- 32 WA V
- 32 WAY
IMPORTANT:
CKTS FROM C270 TO
SWITCH ARE CONTAINED
IN A CLUTCH JUMPER
HARNESS.
8"
CLUTCH - - - - - - - - - - - - - - - - BRAKE
ANTICIPATE;
DEPRESSED
CRUISE RELEASE
SWITCH
CLUTCH
ANT~SWITCH
'" ~~f: ,.
CRUISE
RELEASE
SWITCH
SEE CRUISE
CONTROL
PAGE SA-34-0
35 BLK1WHT 1451
.- -
-5215
.5 BLK.WHT
.l
.5 BLK,WHT
SEE GROUND
.......__
DISTRIBUTION
,...-- -
C210
---,
.8 BLK,WHT
P110
451
PAGES SA 14-2, l
451
li!Q
451
_:...2104
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
12129025
32-WAY F MICRO-PACK 100SERIES
NAT
CONNECTOR ASSEMBLY BREAKDOWN

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129022 (CLRI
12146093
12129030
12129025
POWERTRAIN CONTROL MODULE (PCM) (V6 VIN S)
**CAVITIES NOT LISTED ARE NOT USED

CAVITY
WIRE COLOR
CKT
DESCRIPTION
BLK
452
MAP, IAT, A/C REFRIGERANT AND A/C EVAPORATOR TEMPERATURE

SENSORS GROUND REFERENCE
DTC(s) 22, 23, 33, 71
DKGRN/WHT
762
A/CREQUEST
SECC10
DKBLU
732
A/C EVAPORATOR TEMPERATURE SIGNAL
DTC(s) 71, 73
RED/BLK
380
A/C REFRIGERANT PRESSURE SIGNAL
DTC(s) 66, 70
GRY
120
FUEL PUMP SIGNAL
DTC54
DKGRN/WHT
465
FU El PUMP RELAY CONTROL
DTC54
11
LTGRN
1222
1-2 SHIFT SOLENOID CONTROL
SECC8
12
YEL/BLK
1223
SECC8
15
TAN/BLK
422
TORQUE CONVERTER CLUTCH ENABLE
SEC CB, DTC 90
16
WHT
687
SEC CB
17
BLK
470
SENSOR GROUND FOR ECT AND TP SENSORS
DTC(s) 15, 21, 22, 58,

59
18
LT BLU/BLK
583
BRAKE SIGNAL
DTC37
21
PNK
1224
RANGE SIGNAL "A"
DTC28
22
22
DKBLU
GRY
1225
48
RANGE SIGNAL "B"

CLUTCH ANTICIPATE SWITCH (MIT)
SECC8
23
RED
1226
RANGE SIGNAL "C".
DTC28
29
LTGRN
432
MAP SENSOR SIGNAL
DTC(s) 33, 34, 44
30
DKBLU
417
TP SENSOR SIGNAL
DTC(s) 21, 22
31
YEL
410
ECT SENSOR SIGNAL
DTC(s) 14, 15
32
YEL/BLK
1227
TRANSMISSION FLUID TEMPERATURE SENSOR SIGNAL
DTC(s) 58, 59
6E3 REFERENCE
20 - 9
0GGGGGGGGGGGGGGG
808888880G808GGG
12129025
32-WAY F MICRO-PACK 100 SERIES
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLK)
12146093
12129030
12129025
POWERTRAIN CONTROL MODULE (PCM) (VG VIN S)

CAVITY
WIRE COLOR
CKT
DKGRN
335
SECC12
BRN
436
SECONDARY AIR INJECTION SYSTEM AIR BYPASS SOLENOID
SECC6
DKGRN/WHT
428
EVAP CANISTER PURGE SOLENOID VALVE CONTROL
SECC3
DKGRN/WHT
459
A/C COMPRESSOR CLUTCH RELAY CONTROL
DTC68
BRN/WHT
419
MIL (SERVICE ENGINE SOON) INDICATOR CONTROL
CHART A-1
11
LTBLU
697
EGR #1 CONTROL
DTC75
12
BRN
698
EGR #2 CONTROL
DTC76
13
RED
699
EGR #3 CONTROL
DTC77
14
ORN
340
BATTERY (KEEP ALIVE MEMORY)
CHART A-3
15
ORN
340
BATTERY (KEEP ALIVE MEMORY)
CHART A-3
16
BLKIWHT
451
PCM GROUND
CHART A-1
18
DKBLU
1493
2ND GEARSTART MODE INDICATOR LAMP CONTROL - PERFORMANCE
SECC8
19
TAN
800
SERIAL DATA
CHART A-1
20
BLK/WHT
351
LEFT 025 GROUND
DTC(s) 13, 44, 45
21
PPLIWHT
1665
LEFT 025 SIGNAL
OTC(s) 13, 44, 45
22
PPL
1666
RIGHT 025 SIGNAL
DTC(s) 63, 64, 65
23
BLKIWHT
351
RIGHT 025 GROUND
DTC(s) 63. 64, 65
24
LTGRN/WHT
1749
IAC COIL "B" HIGH
DTC35
25
LTGRN/BLK
444
IAC COIL "B" LOW
DTC35
DESCRIPTION
6E3 REFERENCE
SA - 20- 10 ELECTRICAL DIAGNOSIS

CAVITY
WIRE COLOR
CKT
26
LTBLU/BLK
1748
IAC COIL "A" LOW
DTC35
27
LTBLU/WHT
1747
IAC COIL "A" HIGH
DTC35
28
DKGRN/WHT
817
BUFFERED SPEED OUTPUT (4000 PULSES/MILE)
DTC24
29
PPL
401
VSS INPUT LOW
DTC(s) 24, 72
30
YEL
400
VSS INPUT HIGH
DTC(s) 24, 72
31
GRY
416
5 VOLT REFERENCE, MAP, TP AND A/C PRESSURE SENSORS
DTC(s)22,34,66,67,70,71, 73
32
BLK/WHT
451
PCM GROUND
FIG A-1
DESCRIPTION
6E3 REFERENCE
GGGG0GG0G00GGG0G
8808080088888888
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129023 (BLU)
12146093
12129028
12129025
POWERTRAIN CONTROL MODULE (PCM) (V6 VIN S)

CAVffY
WIRE COLOR
CKT
TAN/WHT
551
PCM GROUND
FIG A-1
DKGRN
59
A/CCLUTCH STATUS
DTC(s) 68, 69
PNK
439
IGNITION FEED
OTC (s) 53, 96
RED/BLK
1228
PRESSURE CONTROL SOLENOID HI
DTC93
LTBLU/WHT
1229
PRESSURE CONTROL SOLENOID LO
DTC93
10
LTBLU
553
2ND START MODE SWITCH SIGNAL- PERFORMANCE
SECC8
12
PNK/BLK
1746
INJECTOR DRIVER CYLINDER #3
CHART #A-3
13
LTGRN/BLK
1745
CHART #A-3
.14
BLK
1744
CHART #A-3
15
YEL/BLK
846
CHART #A-3
16
BLK/WHT
845
CHART #A-3
DESCRIPTION
6E3 REFERENCE

CAVITY
WIRE COLOR
CKT
17
TAN!WHT
551
~CM GROUND
FIG A-1
18
PNK/BLK
632
REFERENCE LOW CAMSHAFT AND CRANKSHAFT SENSORS
SECC4
20
DKBLU
496
KNOCK SENSOR SIGNAL
DTC43
21
LTBLU!WHT
1800
24X REFERENCE SIGNAL
DTC36
23
DKBLU
229
FUEL ENABLE SIGNAL
DTC46
25
BRN!WHT
633
CAMSHAFT POSITION SENSOR SIGNAL
DTC17
27
WHT
423
IGNITION CONTROL
DTC41
28
TAN/BLK
424
IGNITION CONTROL BYPASS
OTC 42
29
TAN
472
IAT SEJ\ISOR SIGNAL
DTC(s) 23, 25
30
LT BLU/BLK
647
3X REFERENCE HIGH
DTC82
31
RED/BLK
453
3X REFERENCE LOW
SECC4
32
LT BLU/BLK
844
CHART#A-3
COMPONENT
NC Evaporator
Temperature Sensor
DESCRIPTION
LOCATION
Mounted in Evapo~ator Core
6El REFERENCE
201-PG
FIG.
CONN
20 ... 37
NC Refrigerant Pressure
Sensor ................ . Above RH Shock Tower, forward of NC Compressor
Low Pressure Cut Off Switch . . . . . . . . . . . . . . . . . . . . . . 19 . . . 35
Brake Switch Assembly ... Mounted in lower hole of brake pedal bracket (2 conn
with Automatic), (l conn with Manual)
same switch for both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . l
Brake Transmission Shift
42
Interrupt (BTSI) Solenoid In console, under PRNDL Display . . . . . . . . . . . . . . . . . . . 22
In front top of Engine Block, between Intake and
24
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch Anticipate/
(all V6 Manual) ........ . Mounted in clutch pedal bracket (4 cavity conn) . . . . . . 0 . . . . l ...
HI Resolution ......... . Lower front of Engine Block, pigtail comes out
LH side of crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20
LO Resolution . . . . . . . . . . Lower RH side of Engine Block, has no pigtail . . . . . . . . 28
54
Data Link Conn (DLC) . . . . Mounted to I/P Tie Bar, below and right of
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature
(ECT) Sensor . . . . . . . . . . . Mounted in front top of Engine, under plenum
(EV AP) Canister Purge
Solenoid Valve . . . . . . . . . Left side of Engine, mounted to Intake Plenum . . . . . . . 13 . . . 24
Signal Solenoid Valve . . . Right side of Engine, mounted to Manifold . . . . . . . . . . . 12 . . . 23 . .
Fuel Injectors . . . . . . . . . . . . Mounted on Intake Manifold, part of Fuel Rail
202-20
202-11
202-20
SA -
20 - 12

COMPONENT
201-PG FIG.
LOCATION
Fuel Pump Prime Conn . . . Top rear of RH Shock Tower, 1 way conn out of Harn
15 . . . 28
Fuel Pump Relay . . . . . . . . . Forward of LH kick panel, mounted to foot rest bral'.!ket
under carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 13
Fuel Tank Unit . . . . . . . . . . Under rear of vehicle
Fusible Links . . . . . . . . . . . Above RH shock tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . 19
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Idle Air Control (IAC) Valve Right front on Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . 29
56
Ignition Control
Module (ICM) ......... . Left front of Engine ...... . . . . . . . . . . . . . . . . . . . . . . . . . 27
52
Instrument Cluster ...... . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature
(IAT) Sensor .......... . Mounted on air duct, in front of Intake Manifold ..... . 24 ... 45
Isolation Diode (BTSI) ... . Sealed in Harn, approx 6 cm from DERM breakout
Knock Sensor ........... . In bottom RH side of Engine Block ................. . 28,40 54,72
Manifold Absolute Pressure
(MAP) Sensor ......... . Mounted to RH side of Intake Manifold ............. . 12,26 23,50
24
Oxygen Sensor, LH ...... . Mounted in left Exhaust Manifold .................. . 13
23
Oxygen Sensor, RH ...... . Mounted in right Exhaust Manifold ................ . 12
(PCM) ................ . In Engine Compartment, rearward of RH Shock Tower
19
35
21
Pump Assembly . . . . . . . . Front LH Frame Rail, in Engine Compartment ...... . 11
Theft Deterrent Module . . . In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15
Throttle Position (TP) Sensor Mounted to right front side of intake ................ . 14, 29 27, 56
42
Switch ................ . Under console, on base of shift control lever ......... . 22
U nderhood Electrical Center LH side of Engine Compartment, forward
36
of wheelhouse ................................... . 19
ClOO (10 cavities)
Engine to Forward Lamp Harn, behind LH wheelhouse,
28
attached to PCM bracket ......................... . 15
12
Cl 10 (10 cavities) ....... . Engine to Injector Harn, top center of Intake Manifold
22
C200A (17 cavities)
49
C200D (48 cavities)
Part ofl/P Harn, between LH kick panel and
Steering Column ................................ . 25
49
37
37
37
C270 (2 cavities) ........ . 1/P Harn to Clutch Jumper Harn, near brake/clutch
pedal bracket ................................... . 1
2
C405A (4 cavities) ...... . Part of Pass Thru Conn, forward of rear axle, to
Fuel Tank Unit ................................. . 5
9
C405B (10 cavities) ..... . Part of Pass Thru Conn, forward of rear axle, to
Pass Thru Panel ................................ . 5
9
Gl04
of Engine, 1 stud in head, 1 stud in Intake Manifold .. 29
56
G106
Near top LH side ofradiator, in top ofT-Bar ......... . 19
35
CONN
202-21
202-23
202-22
202-22
202-23
202-25
202-18
202-28
202-28
202-0
202-1
202-2
202-2
202-19
202-6
202-7
202-8
202-8
ELECTRICAL DIAGNOSIS 8A ':'
COMPONENT
LOCATION
201-PG
G305 ................... . Bolted to Floor Pan Bar #2, under Driver's Seat
without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . .
Injector Jumper Harn, approx 7 cm from LH
8103
Branch breakout
8104
Injector Jumper Harn, approx 9 cm from Injector 6
8106
Engine Harn, approx 25 cm from PCM Connectors
8107
Engine Harn, approx 30 cm from CllO breakout ..... . 12
11
8108
Engine Harn, approx 4 cm from braided ground strap
8110
Engine Harn, approx 7 cm from RH Oxygen
Sensor breakout
8113
Center breakout
8117
PCM breakout
8119
Engine Harn, at RH Oxygen Sensor breakout . . . . . . . . 12
8122
Engine Harn, approx 4 cm from MAP Sensor breakout
12
8125
12
8127
8131
8163
Center breakout
8190
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . .
8205
breakout
8206
breakout
8209
I/P Harn, approx 24 cm from Convenience Center breakout
8215
I/P Harn, approx 30 cm before DLC breakout
8225
8234 (Automatic) ....... . I/P Harn, approx 4 cm from G201 breakout
8235 ................... . I/P Harn, approx 7 cm from G200 breakout . . . . . . . . . . . 7 . . . .
8238 (Automatic) ....... . I/P Harn, approx 7 cm from Center Console breakout
8280 ................... . Engine Harn, approx 14 cm from C220 breakout
SYSTEM DIAGNOSIS
Refer to SECTION 6E3 for diagnosis.
FIG.
11
35
22
20
23
23
23
68
13
20 - 13
CONN
SA -
SEQUENTIAL MULTIPORT FUEL INJECTION: VS VIN P

DATA LINK, GROUND AND POWER
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
--~-----------,!.Lf
r---SEE POWER
FUSE
SEE POWER
DISTRIBUTION
PAGE SA 103
I DISTRIBUTION
I PAGE SA-10-1
I
I
GAGES
FUSE 9
10AMP
I BLOCK
I
I
I
IGN
(NOT USED)
_______ J
L---.8 ORN
340
.5 PNK
439
.8 PNK
39
f ----~
1
+,-----------~
SEE FUSE
BLOCK DETAILS
PAGESA-117
.SORN
SEEFUSE
BLOCK DETAILS
PAGE8A-115
340
I
I
II
C210
S20S -
.35PNK
39
DATALINK
CONNECTOR (DLC)
-----;;l
(CHEVY) 013
(PONT) AS
J.,_~INSTRUMENT
CLUSTER
SEE
INSTRUMENi
CLUSTER
PAGE8A813
.35TAN
J.
(!)
---
(MIL) "SERVICE
ENGINE
SOON"
INDICATOR
800
ms- - ..I
I
I
I
I
L__________ J
.35 TAN
800
SEE DATA LINK

CONNECTOR
PAGE SASOO
(PONn A4
(CHEVY) CS
.8 ORN
.8 : : :
340
340
.5 PNK
.8 ORN
340
.SS.;::
15 ~ - - - - 2 1
PO~~R,r~:~~
MODULE
(PCM)
Ir
I
i::-=:t39
3 0 ~ ~-
~ ;;,;- ;;,;- 7GN;;O;INPUT
---
.35 BRN!WHT
439
3l
448
-z ~-:.;~--ri:
S TAN
20
_____
ENGINE SOON"
INDICATOR
-=-rONTROL
BATTERY
INPUTS
':' ~ I
~ I
I
.35 WHT/BLK
-IG-;;;T~ INPUT
419
POWER
GROUND
(NOT
USED)
_32
SV
OUTPUT,
FIELD SERVICE
ENABLE
-=REDUNDANT
GROUND
00
POWER
GROUND
=l
SERIAL
DATA
LINE
L__r___t __ J___ 1:___________________ ~ __ J

18
32
Q
SEE GROUND
DISTRIBUTION
PAGE SA-140
.8 TAN/
WHT
.8 BLK1
WHT
551
.STAN/
WHT
551
45~
r
I
<;
.8 BLK,
WHT
451
SEE GROUND
DISTRIBUTION
PAGE SA-14-1
5109
- - ...
.8 BLK1
WHT
451
__a2103
LT1
A
B
C
D
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAY
32WAY
32WAY
32WAY
ELECTRICAL DIAGNOSIS BA-
21 - 1

IGNITION
I SEE POWER
DISTRIBUTION
I PAGE 8A-10-3
HEI COIL WIRE
.8PNK
C2
239
5107
A
.---~-+~~~)B---8-PNK/BLK----(
(
1846
I
SEC
I
COIL
I
D
.8WHTIBLK
)A
11
IGNITION
INPUT
1
I
PRIMARY
COIL
DRIVER
B
'.8 WHTI 423
3
GROUND
'
. .- 450- - - - - - 5108
LOW
RESOLUTION
SIGNAL
DISTRIBUTOR
IGNITION
I
I
II
-~--J
14
.35::L'
WHT
___ J
.35 REDIBLK
.35 RED/BLK
4:0 ___
453
____
___ D
.35 RED
453
32WAY
32WAY
32WAY
32WAY
1.:5~::16:2
BLK
631
.35 RED
B

RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
TACH
OUTPUT
.G.
HIGH
RESOLUTION
SIGNAL
L~~--~~--~~~
REFERENCE LOW
DISTRIBUTOR
GROUND
I
II
SEE GROUND
DISTRIBUTION
PAGE 8A-14-0
13
IGNITION
CONTROL (IC)
.-1
1 BLK
(!
r - - - - - - - - - - - - - - -
I
(PCM) I
A
B
C
D
121
450
POWERTRAIN
CONTROL
MODULE
LT1
.8WHT
.8 WHT1 :::
cy
.8 BLK
(NOT
USED)
IGNITION
COIL MODULE
IGNITION
CONTROL (IC)
SIGNAL
1847
,-
239
G YC100
___
____
..
.8PNK
239
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
- , UNDERHOOD
ELECTRICAL
CENTER
IGNITION
COIL
.8 PNK
____ ....
~~~~~-.
IGNITION
FUSE 11
10AMP
TO AUTOMATIC:15
PNK
TRANSMISSION
PAGE 8A-39-0
239
.........
.35 PPU
WHT
430
c140
631
.35 PNK
BLK
632
OPTICAL SENSOR GENERATES

BOTH HI AND LOW RESOLUTION
SIGNALS BY SENSING A ROTA TING
NOTCHED WHEEL DRIVEN BY THE
CAMSHAFT.
LOW RES
SIGNAL
HI RES
SIGNAL
IGN
VOLTAGE
REF
LOW
SOLID STATE
#5 CYLINDER
CYLINDER #4
SPARK
PLUG WIRES
(PASSENGER
SIDE)
#6
FIRING ORDER
1-8-4-3-6-5-7-2
#3
#8
#7
#2
#1
SPARK
PLUG WIRES
(DRIVER
SIDE)

FUEL PUMP, HVAC AND PASS-KEYII INPUT
f" -
I
I
I
THEFT
DETERRENT
I MODULE
L--.J
SEE HVAC COMPRESSOR CONTROLS

PAGE 8A-64-1
A3
.35 DK BLU
.35 DK GRN/
WHT
25
229
.35 DK GRN/
WHT
SEE FUSE
BLOCK DETAILS
PAGE8A-11-5
459
762
I
I
AIC
REQUEST
INPUT
AIC CLUTCH
RELAY
CONTROL
439
~ -
5205
A.
B C
D
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAY
32 WAY
32 WAY
32 WAY
21
r- - - - - - - - - - - - - - - - - - - ,
FUEL
ENABLE
INPUT
,-
59
LT1
.35 DK BLU
.. !JP
FUSE
BLOCK
___ .
.5 PNK
.5 DK GRN
1
I
~----
229
AIC CLUTCH
STATUS
POWERTRAIN
CONTROL
I MODULE
I {PCM)
14!~
I
I
I
I
FUEL PUMP
RELAY
I
I
1 PNK
L---------------~~~-J
7
.35 DK GRNIWHT
P110
439
Jg
c220
465
.8 DK GRNIWHT
465
C2
- - - - - - - - - . FUEL
PUMP
RELAY
- ------All'
SEE INSTRUMENT
CLUSTER
PAGE 8A-81-2
1GRY
_....
A2y
120
.8 BLKIWHT
451
5215----,
I
I
.s BLKIWHTJ:51
8
.s
c:,o
BLKIW*
FUEL
PUMP
o!!
P110
_.......
5109. -
WITH AC3 OR AQ9

SEE GROUND
DISTRIBUTION
PAGE SA-14-11
3 BLK
1450
C405A
C405B
.8BLKIWHT
451
_u10L
1
SEE GROUND
DISTRIBUTION
PAGE SA-14-1
"
4h~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
ELECTRICAL DIAGNOSIS 8A- 21 - 3

CONTROLLED DEVICES AND INJECTORS
2
RUST
FUSIBLE
LINK K
'
5 RED 502
5163.
5 RED
502
r-------J--,
HOT AT ALL TIMES
HOT IN RUN
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
I
I
.s BRN
5 RE~502
: _----------30
'I Ell
E4
8~ -
441
86
ijES
PUMP
IAIR
"~'
r-----------------------~
~~~~~~~~~~~~~~~~~--4---~~---11~SEEPOWER
I
I
I
I
AIR
PUMP
FUSE 7
20 AMP
UNDERHOOD
ELECTRICAL
CENTE.R
:
j
I
.8PNK
5 PNK
639
.5 PNK
639
436
839
.5 PNK
E
C100
.5 PNK
SEE POWER
DISTRIBUTION
PAGE 8A 10 1
ll
'"
839
----.J 106
,.:
845
.5 OK BLU/
WHT
:~K
878 ,
ll
.s
"'
INJECTOR #3 INJECTOR #5
CONTROL
CONTROL
COIL,, A"
L- - - - - - - - - - - - - - .!!' - - -
L~ -
INJECTOR #4
CONTROL
INJECTOR #6
CONTROL
A
B
C
0
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAV
32WAV
32WAV
32WAV
.35 LT BLU/
WHT
1747
.35 LT BLU,
BLK
IDLE AIR
.3S LTGRN/
WHT
1748
1749
.35 LT GRN1
BLK
COIL B
STEPPER
MOTOR
CONTROL
MODULE (PCM)
~
444
..,.o....,,...__....,...,......._....,;.....,.,..----.,...-
CONTROL (IAC)
---VALVE
INJECTOR #7
CONTROL
846
AI
.5 RE01BLK
877
-,
I
COIL "B"
COIL "B"
I
...!!'- - - .;2 - - - - -POWERTRAIN
- - J
INJECTOR #8 INJECTOR #1
CONTROL
CONTROL
COIL" A"
LT1
1744
A l .5 ::LiBLK
.5 LT BLU/
844
BLK
-INJECTOR #2
CONTROL
II
ll
AI
.: BLK/
.5 PNK/ 1746 WHT
BLK
I
I
I
SEE PAGE 8A-30

FOR MEASURING
ANO HANDLING
PROCEDURES
.5PNK
839
:~~y~::. "'G:~ ~ f ~ ~ ~~i

r"=~!"~'t~-z;_~r;_~-lr~r-~--,~-~-,;~-r:_ 1
"'"'""'
1745
3 ;::, : -
.5 PNK
639
639
______ _.
L-
~1--.---.
.35 BRN
..~:r..
DISTRIBUTION
PAGE 8A-103
INJECTOR
FUSE 9
7.5 AMP

ENGINE DATA SENSORS
.35GRV
416
---B~"':ll:~-,:156GRV
c' '
B' \
TEMP
INTAKE AIR
TEMPERATURE
(IAn SENSOR
'
1,
/
5V
REF
REF
LO
SV, ,
REF
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
REF
LO
r.,rn,
B
452
A/C EVAPORATOR
TEMPERATURE
SENSOR._...i11...;.;;..;;.;...,.;i'--'
A1
.35 BLK
~~473
GRV5416
AiC
REFRIGERANT
PRESSURE
SENSOR
~
------------------------.35 BLK
452
5119
.35 TAN
472
.35 LTGRN
- - - .A.
rI
~ I
I
I
.35 BLK
452
.35 RED/BLK
380
.35 DK BLU
732
.35 GRV
__ !3...
<;
IAT
SENSOR
INPUT
!!
16
MAP
SENSOR
INPUT
12
-=-
sv
KNOCK
SENSOR
INPUT
--------~
SENSOR
GROUND
REF
A/C
REFRIGERANT
PRESSURE
SENSOR
TP
ti:i~R
-=-
22
.35
DK BLU
.35 DK BLU
417
sv
SENSOR
GROUND
REF
2 8 r - - - - - - -6
.35 GARV
474
SV
REF
h
sv
INPUT
SV
REF
!!
29
A/C EVAPORATOR
TEMPERATURE
SENSOR
INPUT
------------- -------------22
_35 BL K
4: 0
ECT
INPUT
25IC
.35 VBEL
4~0
-----ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
496
A
B
C
D
I
I
I
I
I
-------- J
LT1
SEE PAGE SA-30

FOR MEASURING
AND HANDLING
PROCEDURES
416
-r----r----------1----r----------,
214 ' - - - - - -
CONTROL
POWERTRAIN
MODULE (PCM)
432
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAV
32WAV
32WAV
32WAV

CONTROLLED DEVICES, ENGINE DATA SENSORS
SEE GROUND DISTRIBUTION
PAGE 8A-14-0
I
I
I
I
I
I
I
I
------=f-____.
UNDERHOOD
ELECTRICAL
CENTER
.8 BLK
r SEE- POWER
- - - - - - - - ,
I DISTRIBUTION
- - PAGE BA-10-3
1
I
I
I
.5 BRN
I
FANSIACTR
FUSE
6
10AMP
541
____ .J
L----
450
-.Ill....
BLK
5190
F
.8
.8
PPL/
WHT
.8
TAN,
WHT
1665
541
EVAPORATIVE~
EMISSION (EVAP).
CANISTER
PURGE
SOLENOID
VALVE
21.8 Q
1667
19
r - -:: LO
<;
----------
HIGH/ -
'\. LO
BANK #1
H02S
~H / -
BANK #2
H02S
..,...
...,.......
SEE FUSE
BLOCK DETAILS
PAGE8A-11-12
_A.
541
C100
[QTIEXHAUSTGAS
RECIRCULATION
(EGR) VACUUM
CONTROL SIGNAL
~SO=L~E~N~O=ID~V=A=LV~E:;__ _ _ _ _ _ ___,
LT1
,...,,
Bl
.35 GRY 435
!!
10
-
: : :~~CK (BLK)
C . CLEAR (CLR)
!~ ::~
D BLUE (BLU)
32 WAY
-zE;:P~N;TE-;;-lEG~A~U;;COOTWL PURGE SOLENOID

SIGNAL SOLENOID VALVE
VALVE CONTROL
CONTROL
COOLANT FAN
"""'"'""
JI
.35 B:N"'541
Bl
.35 DK GRN/WHT 428
20
--
-----
A
1666
11
.8 TAN
BR.N.:======~====3=5=BRN.I :::,
.8
PPL
1653
ir.-
.35 BRN
I
I
n""n
32 WAY
I
I
I
l__ -------------~:~~'"~"~ -~;:~ --~ -~~il_ ~~J_ --_J

19
..-:---I
SEE POWER
DISTRIB_UTION
PAGE 8A-10-3
.5 PNK
,1/PFUSE
BLOCK
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-5
I
I
L----
.35 DK GRN
.35 YEL
---..1
439
11
P110
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE BA-11-5
492
439
VOLTAGE
APPLIED
}
SEE GROUND
DISTRIBUTION
PAGE 8A-14-1
IGNITION
AIR
FLOW
SENSE
.......__
,,.-- -
SOLID
STATE
OUTPUT
SIGNAL
JUU1.
GND
REF
.35 BLK,W:T 'r:51 -

-
-5109
1.;;-
.8 BLK, WHT
__A.J103
------1
0
A
-
POWERTRAIN
CONTROL
MODULE (PCM)
335
.35 DK BLU
473
SA-

AUTOMATIC TRANSMISSION CONTROLS (M30), TRACTION CONTROL (NW9)
ANDVSS
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
------,1/P
FUSE
I BLOCK
I
IGN
(NOTUSED)
L.-------- _
_J
... --g_~
SEE FUSE
BLOCK DETAILS
PAGE8A-11-5
.8 PNK
39
.35 PNK
I 19
BAc:_2
,-------~~----~~-----,~------,BRAKE
BRAKE
TCC'SHIFT
SWITCH
BRAKE LIGHT
DEPRESSED
INTERRUPT
ASSEMBLY
CRUISE RELEASE
---~-------
SWITCH
(NORMALLY
OPEN)
SWITCH
(NORMALLY
CLOSED)
SEE ELECTRONIC TRANSMISSION CONTROLS

PAGE 8A-39-0
-35 LT BL:fS::
BLK
,,----------------------"'-------------------._
1
.
.35 LT BLU/BLK
::::1583. .583. . . . . . . . . . . .
.35 LT
BLU
.35 DK
BLU
.5 DK
BLU
553
.S PNK
1493
1225
1224
.5 RED/
BLK
.5 RED
1228
1226
.5 LT
GRN
.5 LT
BLU 1
WHT
.5 WHT
1222
.5 YEL/
BLK
1229
687
1223
BLU,BLK
227
.5 YELi
.STAN/
422BLK
BLU1B
(BTSI) SOLENOID
P110
15
r P';;F~M"'."'
I ANCE
INDICATOR
I CONTROL
I
13
c:_
28
- 3_9
16
12
I!
13
11
--
'"'i-:3 -
Q 1
~:~~~SOR
: ~=~D
~ s ~ o - ~S~l-p';!.M,!!;; 2!!T~T _11<:!!_A';_ -R~U;.!; 31
.35 PPL
32
401
.35 DK GRN/
WHT
.35 YEL
400
I!
12
23
.35 ORN!
aK
817
.]STA.Ni
BLK
464
I
I
I ""
I ~
TCS
PARK/NEUTRAL
!!;T~ -
!!"u.!. - - - - - - - .....
11
463
15
C:
.35 ORN/
aK
.35 LTBLU
C:
B BLACK (BLK)
C - CLEAR (CLR)
D - BLUE (BLU)
ISOLATION
~l~~Ep\BTSI)
SEE HATCH RELEASE
434
PA.GE BA.-135-0
816
.8 ORNIBLtK34
---~,---------...........
.35 ORNIBLK
A - RED
_35 TAN/
WHT
832

PAGE 8A-33-0
LT1
SOLENOID TCS
4000 PULSE
c:_
PERH;R.;.' -RAAGE 7ANGE -R;;;GE , HI

Lo7 -1-2 T-2- -Tcc i'h- ~RAKE, POWERTRAIN
ANCE
SIGNAL
SIGNAL
SIGNAL
SHIFT
SHIFT
SHIFT
SOLENOID SIGNAL
SIGNAL CON.TROL
"A"
"B"
"("
PRESSURE
SOLENOID SOLENOID SOLENOID CONTROL
MODULE
MODE
INPUT
CONTROL
CONTROL CONTROL CONTROL
(PCM)
I
L -
30
.35~C:lO S ~ ~ ~ - : ~ [ Q J B
BLK
2
C lO
832
32WAY
32WA.Y
32WAY
32WAY
TRA.NSM!SSION
POSITION
s_wlTCH
5234
434
.35 ORN/BLK
434
.35 ORNIB:Kl434
r - - - - - - -
I
I
I
L.--
____ ...J
'"w*
~---~
~---------- ..
SEE GROUND
DISTRIBUTION
PAGE 8A-14-1
P110
_LGl0 3
ELECTRICAL DIAGNOSIS SA-
21 - 7

MANUAL TRANSMISSION CONTROLS (MN6), TRACTION CONTROL (NW9) AND VSS
'-----
--...J
.5 BRN
541
S190---l
TO INSTRUMENT
CLUSTER
PAGE 8A 81-3
.35 BRN
541
.35 BRN
.5BRN
[qJ
r - -B
I
1
I
I
AI
IL - -
.35 GRY
I
I
15
- -.... -
I
I
~C~E- 11
.35 LT
!;
;... -
832
BLU
!_G~L -
.35 ORN/
BLK
REVERSE
LOCKOUT
SOLENOID
I
-- ,
I
----31l--32l~
-
~~
35 PPL
~ '!.,
401
35 VEL
(MN6-)- -
- - - ~I
1652
D
.--- -
-,
POWERTRAIN
. CONTROL
I MODULE
I (PCM)
4000 PULSE
_'.'E~E.!!: -
-----;
464
- - - , I TRANSMISSION
MANUAL
REVERSE
LOCKOUT
SOLENOID
CONTROL
!~!RK
RETARD
-
.t
541
AI
IL - -
.35 LT GRN
SKIP SHIFT
50.LENOID
CONTROL
12
.35 TANI
BLK
I
I
I
I
- - - ~I
EBTCM
TP SENSOR
res
&... -
r - -B
MANUAL
TRANSMISSION
I (MN6)
I
I
I
~1!'_5_HIFT
~LENOID
[qJ
.35 BRN
587
13
SKIP SHIFT
INDICATOR
CONTROL
541
- - - ,
541
.~ __
375
.35 WHT
SEE FUSE
BLOCK DETAILS
PAGE BA-11-12
I ' .-~
I ~
!,;R~L~U~Ul.J
Bl!!
.35 DK GRN,
400
WHT
817
463
PAGE BA-33-0
l T1
.35 LT
832
BLU
A
B
C
D

32WAV
RED
32WAY
BLACK (BLK)
32WAY
CLEAR (CLR)
32WAY
BLUE (BLU)
A16
...
___________ ..
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
SA-
21 -8 ELECTRICAL DIAGNOSIS
12129025
32-WAV F MICRO-PACK 100 SERIES
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129024 (RED)
12146093
12129028
12129025
POWERTRAIN CONTROL MODULE (PCM) (VS VIN P)

CAVITY
WIRE COLOR
CKT
BLK/WHT
451
PCM GROUND
SECTION B
BLK
1744
FUEL INJECTOR #1 CONTROL
OTC 18
LT BLU/BLK
844
OTC 18
YElJBLK
846
OTC 18
RED/BLK
877
FUEL INJECTO~ #7 CONTROL
OTC 18
DKGRN/WHT
465
FUEL PUMP RELAY CONTROL
CHARTA-5
GRY
435
EGR VACUUM CONTROL SIGNAL SOLENOID VALVE CONTROL
OTC 27, SECTION C7
10
DKBLU
473
SECONDARY COOLANT FAN RELAY CONTROL (WITH C60 EARLY

PRODUCTION) OR COOLANT FAN RELAY #2 AND #3 CONTROL (WITH
C60 LATER PRODUCTION)
SECTION C12
11
DKGRN
335
PRIMARY COOLANT FAN RELAY CONTROL (EARLY PRODUCTION) OR

COOLANT FAN RELAY #1 CONTROL (LATER PRODUCTION)
OTC 27, SECTION C12
12
TAN/BLK
464
EBTCM TP SENSOR SIGNAL
REFER TO SECTION 5E2
13
WHT
121
TACH OUTPUT
DTC99
14
BRN
436
AIR PUMP RELAY CONTROL
OTC 29, SECTION C6
15
DKBLU
1493
PERFORMANCE INDICATOR CONTROL
SECTIONC8
18
TAN/WHT
551
PCM GROUND
SECTION B
19
LTGRN/BLK
1745
OTC 18
20
BLK/WHT
845
OTC 18
21
PNK/BLK
1746
OTC 18
22
DKBLU/WHT
878
OTC 18
23
ORN/BLK
463
TRACTION CONTROL SYSTEM SPARK RETARD REQUEST
REFER TO SECTION 5E2
25
DKBLU
229
FUEL ENABLE SIGNAL
DTC46
31
-
PPL
401
VSSGROUND
DTC(s) 24, 72
32
YEL
400
VSS SIGNAL
DTC(s) 24, 72
DESCRIPTION
6E3 REFERENCE
ELECTRICAL DIAGNOSIS 8A - 21
-9
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLK)
12146093
12129028
12129025

CAVITY
WIRE COLOR
CKT
DKGRN/WHT
762
A/CREQUEST
SECTION C10
RED/BLK
453
DTC 16, SECTION C4
PNK/BLK
632
DISTRIBUTOR REFERENCE LOW SIGNAL
SECTIONC4
WHT
423
IGNITION CONTROL (IC)
DTC(s)41,42,
SECTION C4
BLK
470
TP SENSOR, ECT GROUND REFERENCE
DTC(s) 58, 59
LTGRN
1222
DTC82
DKGRN/WHT
817
VSS OUTPUT (4000 PPM)
DTC97
12
YEL/BLK
1223
DTC81
13
GRY
WHT
587
687
SKIP SHIFT SOLENOID CONTROL

DTC84
14
RED
631
DISTRIBUTOR IGNITION FEED
SECTION C4
15
ORN
340
BATTERY FEED
CHART A-1
16
BLK
452
IAT, MAP, A/C REFRIGERANT, A/C EVAP TEMP SEN,SORS GROUND REFERENCE
DTC(s) AFFECTED
19
YEL
492
MAFSIGNAL
DTC48
20
PPL/WHT
430
HIGH RESOLUTION SIGNAL
DTC36
21
DKGRN
59
A/CCLUTCH STATUS
DTC 69, SECTION C10
28
GRY
474
+ 5 VOL TS REFERENCE
DTC(s) AFFECTED
29
GRY
416
+ 5 VOL TS REFERENCE
DTC(s) AFFECTED
30
PNK
439
IGNITION FEED
CHART A-1
31
ORN
340
BATTERY FEED
CHART A-1
DESCRIPTION
6E3 REFERENCE
SA- 21-10 ELECTRICAL DIAGNOSIS
SEQUENTIAL MULTIPORT FUEL INJECTION: V8 VIN P
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129022 (CLR)
12146093
12129030
12129025

(VS VIN P)

DESCRIPTION
6E3 REFERENCE
CAVITY
WIRE COLOR
CKT
LTBLU/WHT
1747
IAC COIL "A" HIGH
SECTIONC2
LTBLU/BLK
1748
IACCOIL "A" LOW
SECTIONC2
LTGRN/BLK
444
IAC COIL "B" LOW
SECTION C2
LTGRN/WHT
1749
IAC COIL "B" HIGH
SECTION C2
TAN
1667
BANK #2 H02S LOW
DTC63
PPL
1666
BANK #2 H02S HIGH
DTC(s) 63, 64, 65
11
LTBLU
832
TRACTION CONTROL SYSTEM ACTIVE
DTC74
13
LTBLU
553
PERFORMANCE MODE INPUT
SECTION CB
14
LT BLU/BLK
583
BRAKE SIGNAL
DTC(s) 37, 38
15
ORN/BLK
434
PNPSIGNAL
CHARTC-1A
16
RED/BLK
1228
PRESSURE CONTROL SOLENOIO HIGH
DTC73
19
TAN/WHT
1653
BANK #1 H02S LOW
DTC13
20
PPL/WHT
1665
BANK #1 H02S HIGH
DTC(s) 13, 44, 45
21
TAN
472
IATSIGNAL
DTC(s) 23, 25
22
DKBLU
417
TP SENSOR SIGNAL
DTC(s) 21, 22
23
LTGRN
432
MAP SIGNAL
DTC(s) 33, 34
25
YEL
410
ECT SIGNAL
DTC(s)14, 15
28
PNK
1224
RANGE SIGNAL "A"
DTC28
29
DKBLU
1225
RANGE SIGNAL "B"
SECTION CB
30
RED
1226
RANGE SIGNAL"("
DTC28
32
BLK/WHT
451
PCM GROUND
SECTION B
ELECTRICAL DIAGNOSIS BA - 21
- 11
12129025
NAT

- 12129023 (BLU)
TPA
- 12146093
SEAL
STRAIN RELIEF 12129030
- 12129025
CONNECTOR

CAVITY
WIRE COLOR
CKT
TAN/WHT
551
LTBLU/WHT
DESCRIPTION
6E3 REFERENCE
PCM GROUND
SECTION B
1229
PRESSURE CONTROL SOLENOID LOW
DTC73
PNK
439
IGNITION FEE_D
OTC (s) 50, 53, 75
LTGRN
1652
REVERSE LOCKOUT SOLENOID CONTROL
OTC 83, SECTION CS
DKGRN/WHT
459
OTC 70, SECTION C10
BRN/WHT
419
MIL (SERVICE ENGINE SOON) INDICATOR CONTROL
CHARTS A-1, A-2
10
DKGRN/WHT
428
EVAP CANISTER PURGE SOLENOID VALVE CONTROL
DTC 26, SEC:TION C3
11
TAN/BLK
422
TCC SOLENOID CONTROL
DTC90
12
RED/BLK
380
A/C REFRIGERANT PRESSURE SENSOR SIGNAL
DTC(s) 66, 67
15
WHT
375
SKIP SHIFT INDICATOR CONTROL
DTC91
20
WHT/BLK
448
OUTPUT/FIELD SERVICE ENABLE TERMINAL
CHART A-2
22
DKBLU
496
KNOCK SENSOR SIGNAL
DTC43
24
DKBLU
732
A/C TEMPERATURE SENSOR SIGNAL
DTC (s) 66, 67
28
YEL/BLK
1227
TRANSMISSION FLUID TEMPERATURE SENSOR SIGNAL
DTC58,59
30
TAN
800
SERIAL DATA
CHART A-2
SA 21 -12 ELECTRICAL DIAGNOSIS

COMPONENT
201-PG FIG.
LOCATION
NC Evaporator
20 ... 37
Temperature Sensor
Mounted in Evaporator Core
NC Refrigerant Pressure
Sensor ................ . Above RH Shock Tower, forward of NC Compressor
Low Pressure Cut-off Switch . . . . . . . . . . . . . . . . . . . . . . 19 . . . 35
Brake Switch Assembly . . . Mounted in lower hole of brake pedal bracket (2 conn
same switch for both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
Brake Transmission Shift
Interrupt (BTSI) Solenoid In console, under PRNDL Display . . . . . . . . . . . . . . . . . . . 22 . . . 42
Data Link Conn (DLC) .... Mounted to 1/P Tie Bar, below and right of
Steering Column ............................................... .
Distributor ............. . In front center of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . 74 ..
Control Module (EBTCM) Under 1/P, next to LH hinge pillar,just above
Pass Thru Grommet .............................. 8 . . . . 14
(ECT) Sensor . . . . . . . . . . Front of Engine, mounted in water pump . . . . . . . . . . . . 24 . . . 45
Solenoid Valve .. . . . . . . . . Right center of Engine, mounted to Manifold . . . . . . . . . 26 . . . 50
Exhaust Gas Rec{rculation
Signal Solenoid Valve
Left rear of Engine, mounted to Intake Ple.num ...... . 24
44
Fuel Injectors ...... , ... . Mounted on Intake Manifold, part of Fuel Rail ..... , .. 24
44
Fuel Pump Prime Conn .. . Top rear of RH Shock Tower, 1 way conn ollt of Harn .. 15
28
Fuel Pump Relay ........ . Forward of LH kick panel, mounted to foot rest bracket
under carpet ......................... ........... . 7 .... 13
FuelTank Unit ......... . Under rear of vehicle
Fusible Links ........... . Above RH Shock Tower ........................... . 10
19
Bank #1 . . . . . . . . . . . . . . . Mounted in left Exhaust Manifold .................. . 24
44
Bank #2 . . . . . . . . . . . . . . . Mounted in right Exhaust Manifold ................ . 40
72
I/P Fuse Block ... ,. . . . . . . . LH side ofl/P Carrier, on the side ...... : ........... . 8 .... 15
Idle Air Control (IAC)
Valve . . . . . . . . . . . . . . . . . . Right front on Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . 14
27
lgnition Coil . . . . . . . . . . . . . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29
Ignition Coil Module . . . . . Front LH side of Engine ............... , . . . . . . . . . . . . 16
29 ..
Instrument Cluster . . . . . . . LH side of I/P ................................................... .
Intake Air Temperature
(IAT) Sensor . . . . . . . . . . . Mounted on air duct, in front of Intake Manifold . . . . . . 24 . . . 45
Isolation Diode (BTSI) . . . . Sealed in Harn, approx 6 cm from DERM breakout
Knock Sensor . . . . . . . . . . . . In bottom RH side of Engine Block . . . . . . . . . . . . . . . . . . 28, 40 54, 72
Manifold Absolute Pressure
(MAP) Sensor . . . . . . . . . . Mounted to RH side oflntake Manifold . . . . . . . . . . . . . . 12, 26 23, 50
45
Mass Air Flow (MAF) Sensor Mounted on air duct, in front of Intake Manifold . . . . . . 24
(PCM) . . . . . . . . . . . . . . . . In Engine Compartment, rearward of RH Shock Tower 19
35
CONN
202-11
202-20
202-13
202-21
202-22
202-22
202-23
202-22
202-22
202-23
202-26
ELECTRICAL DIAGNOSIS SA- 21 -13
COMPONENT
Reverse Lockout Solenoid
(Manual) . . . . . . . . . . . . . . .
Pump Assembly . . . . . . . .
Skip Shift Solenoid . . . . . . .
Theft Deterrent Module .. :
Switch . . . . . . . . . . . . . . . . .
ClOO (10 cavities)
C140 (4 cavities)
C200A (17 cavities)
C200D (48 cavities)
C210 (4 cavities) . . . . . . . . .
C220 (10 cavities) . . . . . . . .
C230 (10 cavities) . . . . . . . .
C405A (4 cavities) . . . . . . .
C405B (10 cavities) ..... .
G102
Gl03
G106
G305
P110
8101
8102
8106
8107
8108
8109
8113
LOCATION
201-PG
Rear LH side of Transmission . . . . . . . . . . . . . . . . . . . . . . . 26
FIG.
CONN
51
Front LH Frame Rail, in Engine Compartment ...... .

Center LH side of Transmission .................... .
In 1/P,just right of Radio, attached to Air Bag Bracket .
Mounted to right front side of intake ................ .
21
26
51
8 .... 15
14,29 27,56
Under console, on base of shift control lever ......... .

LH side of Engine Compartment, forward
of wheelhouse ................................... .
attached to PCM bracket ......................... .
Right side oflntake Plenum, attached to Evaporator
Solenoid Valve .................................. .
and Steering Column ............................ .
Steering C~lumn ................................ .
Under RH side ofl/P, behind RH kick panel ......... .
Under RH side ofl/P, behind kick panel ............. .
Part of Pass Thru Conn, forward ofrear axle, to
Fuel Tank Unit .. : .............................. .
Part of Pass Thn,1 Conn, forward ofrear axle, to
Pass Thru Panel ................................ .
Front of LHcylinder head
(3 rings, 3 wires and braided strap) ................ .
RH side of Engine Block, just above Starter
(1 ring, 1 wire) .................................. .
Near top LH side ofradiator, in top ofT-Bar ......... .
without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Harn, between Injectors 4 and 6 breakouts . . . .
Engine Harn, approx 5 cm from Injector 3 breakout
PCM breakout
Engine Harn, approx 7 cm from main breakout at
right rear of Engine
Engine Harn, approx 17 cm from Injector 3 breakout . .
Engine Harn, approx 4 cm from: main branch and
PCM breakout
Center breakout
22
42
202-28
19
36
202-28
15
28
202-0
26
50
202-19
25
49
202-2
25
20
20
20
49
37
37
37
202-2
202-19
202-6
202-7
202-8
202-8
16
29
40
19
72
35
11
202-18
6 . . . . 11
19
26
24
35
50
44
24 . . . 44
SA - 21 -14 ELECTRICAL DIAGNOSIS

COMPONENT
LOCATION
201-PG
. . . . . . . . . . . . . . . . . . . Engine Harn, approx 5 cm from clip near PCM and

main branch
8119
PCM breakout
8122
Engine Harn, approx 25 cm from main branch and PCM
breakout
8127
Engine Harn, approx 8 cm from left clip, on Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8132
Engine Harn, approx 2 cm from clip near PCM and
main branch
8133
Engine Harn, approx 11 cm from Injector 3 breakout ..
8163
Center breakout
8190
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8205
breakout
8206
breakout
8209
breakout
8215
8225
8234 (Automatic) ....... . 1/P Harn, approx 4 cm from G201 breakout
8235 ................... . 1/P Harn, approx 7 cm from G200 breakout .......... .
8238 (Automatic) ....... . 1/P Harn, approx 7 cm from center console breakout
FIG.
Sl 17
SYSTEM DIAGNOSIS
24 . . . 44
24 ... 44
36 . . . 68
7 .... 13
CONN
ELECTRICAL DIAGNOSIS SA - 21 -15
BLANK
--------------------------------------------------------------------1
FUSIBLE
LINKE
1 RUST
102
5RED
...
s200---p
5 RED 102 102
-1-----,,.,.,.
I
sAc2
r- I
I
I
I
see POWER
DISTRIBUTION
PAGE SA-10-3
SWITCH
ACCV ,
LOCK....
OFF
L- -
SEE POWER
DISTRIBUTION
PAGE 8A 102
- - -
1-I
/~START I
_ ...... auLB
I
RUN TEST
J
-
If
5:ooB
--------------------..
SYEL
C2000
5 YEL
5 YEL
r-
1
I
I
L...
.8 PPL
S223
CRANK
FUSE16
__
3AMP
-,1/P
ruse
BLOCK
I
l-_.I
806
MANUAL
AUTOMATIC
B'l
TO DIAGNOSTIC
ENERGY RESERVE
MODULE
PAGE SA-47-0
5 YEL
CLUTCH[]
START
SWITCH
(CLOSED WITH
CLUTCH PEDAL
_
DEPRESSED)
TRANSMISS;' 1,a
POSITION
SWITCH
--
e'l - - ,
r- - -
I p
1
I \R
1 I
2
I e., N @ 0 )I I
L _____
J
,....-~r
l
'~--------~v~----------/
.35 YEL
.35 Y~169
---JJ ,~. .
C2'):
C1
269
2:--------------------
r- - -, THEFT
Y
_
A2
CI STARTER I DETERRENT
MODJLLE
I ENABLE I
-
A1 ---s.ve.L,.BLK--Al(4
6
._ _.
625
SPPL
3 PPL (V6 VIN SI

5 PPL (VS VIN Pl
see PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint

(SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and
the SIR Component and Wiring Location view in Section 9J before
performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.
...
- - ..... - - i!!!
FUSE
~E;;O;E;- -
BRED
I DISTRIBUTION
I PAGE SA-10-1
+
30 .i 1
BLOCK
IGN
,-(NOTUSED)
GAGES
FUSE 9
10AMP
BATTERY
I
_.J
.8 ORN
340
SEE FUSE
BLOCK DETAILS
PAGE SA-11-7
19 BLK
50
13 BLK
50
PAGESA-11-5
5206
::i:~;f~ ----- --------~~i' "
_J
r- -
I
.. I
I
BRED
19BLK
SEE FUSE
BLOCK DETAILS
t.
SEE GROUND
DISTRIBUTION
PAGE SA-14-4
1
39
.8 PNK
- - - - - - - - - - -
BATTERY
souD
Q
470
- ;;;,:;-T~M-;T,
(!} . ~=
~~::KsA-81-t
STATE
I
I
L---.---- ... INSTRUMENT

CLUSTER
GAGES"
INDICATOR
- - - - - - -- - - - - .
~
GENERATOR
BATT
DC VOLTAGE
SENSING
INP.UT
AC VOLTAGE
BATT
~---+-->-tsENSING
~
INPUT
....J""1...I"1. -
-
RECTIFIER
BRIDGE
I
I
I
I
I
CLOSES WITH LOW (11.2V) OR

HIGH VOLTAGE (16.SV) OR
STOPPED GENERATOR
RfGULATOR
(SOLID STA TE)
3 PPL (V6 VIN 5)

S PPL (VS VIN P)
STARTER
SOLENOID
HOLD-IN
COIL
SEE PAGE 8A3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
30 - 2

COMPONENT
Battery ................ .
Battery Junction Block .. .
Clutch Start Switch ..... .
201-PG FIG.
CONN
LOCATION
RH front of Engine Compartment . . . . . . . . . . . . . . . . . . . 19
35
Top of RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . 19
Mounted to clutch pedal bracket, behind
Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
Above RH Shock Tower ........ , . . . . . . . . . . . . . . . . . . . 10 . . . 19
RH front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 29 26, 56 202-21
LH side of 1/P Carrier, on the side . . .. . . . . . . .. .. . . . . . 8 . . . . 15 . . 202-23
Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . 63 . . 202-23
LH side of I/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-23
Bottom of RH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . 28, 40 54, 72
Bottom of RH side of Engine, above Starter Motor . . . . . 28, 40 54, 72
In I/P,just right ofRadio, attached to Air Bag Bracket . 8 . . . . 15
202-18
Mounted to right side of SIR Bracket, behind I/P . . . . . . 22
41
202-27
Fusible Links ........... .

Generator .............. .
I/P Fuse Block .......... .
Ignition Switch ......... .
Instrument Cluster ...... .
Starter Motor ........... .
Starter Solenoid ........ .
Theft Deterrent Relay ... .
Switch ................ . Under console, on base of shift control lever ......... .
C200B (18 cavities)
C200D (48 cavities)
Steering Column ................................ .
C210 (4 cavities) ........ . Under RH side ofl/P, behind RH kick panel ......... .
C220 (10 cavities) ....... . Under RH side ofl/P, behind kick panel ............. .
GlOO (L32) ............. . Bolted to Belt Tension Bracket Bolt, lower RH front
of Engine (1 ring, 1 wire) ......................... .
GlOO (LTl)
Bolted to RH side of Engine Block, same bolt used for
NC Compressor if equipped (1 ring, 1 wire) ........ .
GlOl
Top of RH Shock Tower (3 rings, 5 wires) ............ .
PlOO
Compartment ................................... .
PllO
Compartment ................................... .
8200
Forward Lamp Harn, approx 5 cm from EBCM
breakout ....................................... .
8206
breakout
8209
breakout
8223
22
42
202-28
25
49
202-2
25
20
20
49
37
37
202-2
202-19
202-6
13
25
39
10
69
19
19
36
19
35
8 .... 14
(Perform before beginning
Diagnosis)
STARTER
System
1. Visually inspect the hydrometer (built into

Battery).
Green eye - Battery is charged.
Dark eye - Charge and load test Battery, refer
to SECTION 601. If Battery passes load test,
refer to System Diagnosis, page SA-30-3.
. Clear or light yellow eye - Battery electrolyte
is low. Replace Battery.
2. Always note condition of "SECURITY" Indicator if
Engine does not crank. If the indicator stays "ON"
or flashes continuously, refer to "Theft Deterrent
System," page SA-133-0.
3. Check that Starter Solenoid terminals "S" and "B"
and Battery connections are clean and tight.
4. Check that Fusible Link E is undamaged. If
Fusible Link E is open, check for a short to ground
through CKT 5 or CKT 6.
5. Check that G 100 and G 101 are clean and tight.
continuity/voltage che~k with a system
integrity of other systems (see "Troubleshooting
Procedures," page SA-4-0).
2. Check Gages Fuse 9 for open.

3. Check that the Generator connector and Generator
"BAT" terminal are both clean and tight.
4: Check that the Battery connections are clean and
tight.
5. Check Generator belt.
SYSTEM DIAGNOSIS
rn
rn
CHARGING SYSTEM
1.
Visually inspect the hydrometer (built into

Battery).
Green eye - Battery is charged.
Dark eye - Charge and load test Battery, refer
to SECTION 601. If Battery passes load test,
refer to System Diagnosis, page SA-30-3.
Clear or light yellow eye - Battery electrolyte
is low. Replace Battery.
Important:
The following tests are designed for engines and
batteries at normal operating temperatures and
assumes that there are no engine symptoms
which would cause a no-start symptom. The
Battery must be in a charged state before doing
diagnosis. To use the tests under other
conditions could result in misdiagnosis.
Important:
Perform the On-Board Diagnostic System Check
described in SECTION 6E3 to be certain no
trouble codes are stored in PCM memory which
may lead to misdiagnosis, specifically Diagnostic
Trouble Code (DTC) 46, indicating a problem in
the PASS-KeyII Fuel Enable circuit.
Always note condition of "SECURITY" Indicator
if Engine will not crank. If the indicator stays
"ON" or flashes continuously, refer to "Theft
Deterrent System," page SA-133-0.

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Engine does not crank, Starter Solenoid does not click.
Chart #1
8A-30-4
Starter Solenoid clicks, but Engine cranks slowly or not

at all.
Chart #2
8A-30-6
Battery is undercharged or overcharged.
Chart #3
8A-30-7
"CHECK GAGES" Indicator on at all times.
Refer to page SA-81-1.
"CHECK GAGES" Indicator inoperative.
Refer to page SA-81-1.
Slower or no crank only after extended periods of

vehicle non-use.
See Parasitic Load Test. Refer to SECTION 6D1.
CHART #1
rn
ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK

IMPORTANT:
BATTERY MUST BE IN A CHARGED STA TE TO AVOID MISDIAGNOSIS. FOR BATTERY CHARGING OR TESTING, REFER
TO SECTION 601.
IF "SECURITY" INDICATOR STAYS "ON" OR FLASHERS CONTINUOUSLY, REFER TO "THEFT DETERRENT SYSTEM,"
PAGE BA-133-0 (NORMAL BULB CHECK IS APPROXIMATELY 5 SECONDS.
TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.
DISCONNECT THEFT DETERRENT RELAY.

ATTACH A TEST LIGHT BETWEEN THEFT DETERRENT RELAY CONN TERM "A1" ANDB +.
. WHILE OBSERVING TEST LIGHT, TURN IGNITION SWITCH TO "START."
----------------~
: REFER TO "THEFT DETERRENT:
:
: SYSTEM PASS-KeyIr,
I SECTION BA-133, CHART #1. 1
r-'"--~~~~~~~~~~~~~~~~~~~~~~~~~~~~--,,-
CONNECT A TEST LIGHT BETWEEN THEFT DETERRENT RELAY CONN TERM "C1" AND GROUND.
WHILE OBSERVING TEST LIGHT, TURN IGNITION SWITCH TO "START."
'--.--~~~~~~~~~~~~~~~~~~~~~~~~~~~~--'~------------------~
CONNECT A TEST LIGHT BETWEEN THEFT DETERRENT RELAY

CONN TERM "C2" AND GROUND.
WHILE OBSERVING TEST LIGHT, TURN IGNITION SWITCH TO "START."
rn
IMPORTANT:
DO NOT ALLOW STARTER TO CRANK LONGER THAN 1 S

SECONDS OR DAMAGE TO THE STARTER MAY OCCUR.
ATTACH A 30 AMP FUSED JUMPER BETWEEN THEFT

DETERRENT RELAY CONN TERM "C1" AND TERM "A2".
TRANSMISSION IN "PARK" OR "NEUTRAL" (AUTO TRANS)
OR WITH CLUTCH PEDAL DEPRESSED (MANUAL TRANS).
IGNITION SWITCH TO "START."
DOES ENGINE CRANK?
CHECK FOR OPEN IN CKT 5 OR

OPEN IN POWER FEED CKT 102
INCLUDING IGNITION SWITCH AND
FUSIBLE LINKE.
30 - 5
CHECK FOR POOR

CONNECTION TO RELAY.
IF OK, REPLACE THEFT
DETERRENT RELAY.
ALSO CHECK CKT 6 TO THE
STARTER SOLENOID FOR A
POSSIBLE SHORT. A SHORT
MAY HAVE CAUSED THE
RELAY TO FAIL
FUSED JUMPER STILL CONNECTED.

INSTALL.A TEST LIGHT FROM STARTER SOLENOID
TERM "S" TO GROUND. ,
.
TRANSMISSION IN "PARI(" OR "NEUTRAL" (AUTO
TRANS) OR WITH CLIJ1'CH f>EDAL DEPRESSED
(MANUAL TRANS).
.
rWITH A TEST LIGHT TO GROUND, BACKPROBE C210

TERM ;,A''..
TRANS,MlSSION IN "PARK" OR "NEUTRAL" (AUTO
TRANS) OR WITH CLUTCH PEDAL DEPRESSED
(MANUAL TRANS).

ATC210TERM "A".
, IF OK, REPAIR OPEi'{ iN. CKT. 6
BETWEEN (210 AND THEFT
DETERRENT .RELAY TERM" A2".
MANUAL TRANSMISSION
CHECK FOR OPEN IN CKT 269

FROM THEFT DETERRENT
RELAY TERM "C2" TO
CLUTCH START SWITCH
TERM "A".
CHECK FOR POOR
CONNECTIONS AT OR FOR
AN OPEN IN THE CLUTCH
START SWITCH.
FROM CLUTCH START
SWITCH TERM "B" TO 5223.

FROM THEFT DETERRENT RELAY
TERM "C2" TO TRANSMISSION
POSITION SWITCH TERM "F".
CHECK FOR POOR
CONNECTIONS AT OR FOR AN
OPEN IN THE TRANSMISSION
POSITION SWITCH.
CHECK FOR OPEN IN CKT 5 FROM
TRANSMISSION POSITION
SWITCH TERM "E" TO 5223.
:
I
:
:
I
----------------1
CHECK FOR POOR

:
CONNECTION AT STARTER I
SOLENOID TERM "S''..
1
IF OK, REPLACE STARTER :
SOLENOID.
1
L------------------~

ATC210TERM "A".
IF OK; REPAIR OPEN IN CKT 6
BETWEEN C210 AND STARTER
SOLENOID.
30 - 6
SA -

CHART #2
STARTER SOLENOID CLICKS BUT ENGINE CRANKS SLOWLY
OR NOT AT ALL
rn
IMPORTANT:
THE FOLLOWING TESTS ARE DESIGNED FOR ENGINES AND BATTERIES AT
NORMAL OPERATING TEMPERATURES AND ASSUME THAT THERE ARE NO
ENGINE SYMPTOMS WHICH WOULD CAUSE A NO-START SYMPTOM. TO USE
THE TESTS UNDER OTHER CONDITIONS COULD RESULT IN MISDIAGNOSIS.
BATTERY MUST BE IN A CHARGED STATE TO AVOID MISDIAGNOSIS. FOR
BATTERY CHARGING OR TESTING, REFER TO SECTION 601.
BATTERY IS FULLY CHARGED.

IGNITION SWITCH IN "START."
MEASURE THE VOLTAGE AT THE BATTERY WHILE CRANKING THE ENGINE.
CRANK ENGINE AND READ VOLTAGE AFTER 15 SECONDS, THEN REMOVE LOAD.
GREATER THAN 9.5 VOL TS
LESS THAN 9.5 VOL TS
MEASURE VOLTAGE BETWEEN NEGATIVE BATTERY

TERMINAL AND THE ENGINE BLOCK WHILE
CRANKING.
GREATER THAN
0.5VOLTS
MEASURE THE VOLTAGE BETWEEN

THE POSITIVE BATTERY TERMINAL
AND THE STARTER SOLENOID,
TERM "B" WHILE CRANKING.
REPLACE NEGATIVE BATTERY

CABLE.
r- ----------' ----,
REMOVE STARTER
I
MOTOR ASSEMBLY
:
FOR REPAIR.
:
_________________
REFER TO SECTION 602. J
---------------,
LOADTESTBATTERY.
:
REFER TO SECTION 601. 1
L-
---------------~
BATTERY OK
REPLACE POSITIVE BATTERY

CABLE.
BATTERY NOT OK
r-
---------------~ .----~~~~--.
:
:
REMOVE STARTER
:
ASSEMBLY FOR REPAIR. :
REFER TO SECTION 602. 1
GREATER THAN
0.5VOLTS
:
:
r-
REPLACE BATTERY.
CHART #3
BATIERY UNDERCHARGED OR OVERCHARGED
DISCONNECT GENERATOR CONNECTOR.

ENGINE "OFF."
CONNECT VOLTMETER (SET AT DC SCALE) BETVVEEN GENERATOR
CONNECTOR TERM "L" AND GROUND.
BATTERY VOLTAGE
CHECK FOR OPEN OR POOR CONNECTIONS IN

CKT 225 BETWEEN GENERATOR TERM "L" ANO
INSTRUMENT CLUSTER TERM "C12".
CHECK FOR OPEN FUSE 9 OR OPEN IN CKT 39 TO
INSTRUMENT CLUSTER (IF FUSE 9 OR CKT 39 ARE
. OPEN, THE INSTRUMENT CLUSTER WILL NOT BE
OPERA TING CORRECTLY).
IF OK, SERVICE INSTRUMENT CLUSTER.
MOVE VOLTMETER LEAD FROM TERM "L" TO

"BATT" TERM ON GENERATOR (RED WIRE).
BATTERY VOLTAGE
CHECK FOR OPEN IN CKT 1 BETWEEN GENERATOR

"BATT" TERMINAL AND BATTERY.
RECONNECT GENERATOR CONNECTOR.

ENGINE RUNNING AT FAST IDLE.
ALL ACCESSORIES TURNED '.'OFF.",
CONNECT VOL'TIVIETER (O<; SCALE) ACROSS BATTERY
TERMINALS
AND
.
. ,, NOTE V()J. TAGE. '
,,
BETWEEN 13.5-15.5 VOLTS
UNDER 13.5 VOLTS

OR OVER 15.5 VOL TS
- - - - - - - - - - - - - - - - - .----------------~ r- - - - - ~ - - - - - - - - - - - - - - - - ,
PERFORMGENERATORLOADTEST. REFERTO
: : REPAIR OR REPLACE GENERATOR. :
SECTION 603.
.
: 1 REFER TO SECTION 603.
1
IF GENERATOR IS OK, PERFORM BATTERY LOAD TEST. 1 ._ ___ - - - - - - - - - - - - - - - - - - --...1
:
:
30 - 7
SA~
30- 8 ELECTRICAL DIAGNOSIS

CIRCUIT OPERATION
BATTERY
Refer to SECTION 601.

CHARGING (ALSO REFERENCE SECTION 603)
The Generator provides voltage to operate the

vehicle's electrical system and to charge its Battery. A
magnetic field is created when current flows through
the Rotor. This field rotates as the Rotor is driven by
the Engine, creating an AC voltage in the Stator
windings. The AC voltage is converted to DC by the
Rectifier Bridge and is supplied to the electrical
system at the Battery terminal.
The Generator's Regulator uses digital techniques
to supply the Rotor current and thereby control the
output voltage. The Rotor current is proportional to
the width of the electrical pulses supplied by the
Regulator. When the Ignition Switch is placed in
"RUN," voltage is supplied to terminal "L", turning on
the Regulator. Narrow width pulses are supplied to
the Rotor, creating a weak magnetic field. When the
Engine is started, the Regulator senses Generator
rotation by detecting AC voltage at the Stator through
an internal wire. Once the Engine is running, the
Regulator varies the field current by controlling the
pulse width. This regulates the Generator output
voltage for proper Battery Charging and Electrical
System Operation.
The Digital Regulator controls the Charge
Indicator light with a Solid State lamp driver. The
lamp driver turns "ON" the light whenever an
undervoltage, overvoltage or stopped Generator is
detected.
STARTER (ALSO REFERENCE SECTION 602)
When the Ignition Switch is moved to the

"START" position, voltage is supplied to the normally
open contacts of the Theft Deterrent Relay. Voltage is
also supplied through, either the Transmission
Position Switch (Automatic Transmission) when in
"PARK" or "NEUTRAL," or Clutch Start Switch
(Manual Transmission) when the clutch pedal is
depressed, .to the Theft Deterrent Relay Coil. The
Theft Deterrent Module energizes the Theft Deterrent
Relay by grounding one side of the Relay Coil only
when the Theft Deterrent System has not been
activated (See "Theft Deterrent System," page
SA-133-0).
When the Theft Deterrent Relay is energized, the

normally open contacts close, completing the circuit to
the Starter Solenoid. When the Starter Solenoid
circuit is completed, both the Hold-In and Pull-In
Windings are energized. The circuit through the Pullin Winding is completed to ground through the Starter
Motor. The windings work together magnetically to
pull in and hold in the Plunger. The Plunger moves
the Shift Lever. This action causes the Drive
Assembly to rotate as it engages the Flywheel ring
gear on the Engine. At the same time, the Plunger
also closes the solenoid switch contacts in the Starter
Solenoid. Full battery voltage is then applied directly
to the Starter Motor and it cranks the Engine.
As soon as the Solenoid Switch contacts close,
voltage is no longer applied to the Pull-In Winding
since battery voltage is applied to b9th ends of the
windings. The Hold-In Winding remains energized
and its magnetic field is strong enoNgh to hold the
Plunger, the Shift Lever and the Drive Assembly
Solenoid Switch contacts in place to continue cranking
the Engine.
When the Ignition Switch is released from the
''START" position, battery voltage is removed from the
PPL wire and the junction of the two windings.
Voltage is applied through the motor contacts to both
windings to ground at the enq of the Hold-In
Windings. However, the direction of current flow
through the Pull-In Winding is ..now opposite the
direction of the current flow when the winding was
first energized. The magnetic fields of the Pull-In and
Hold-In Windings now oppose one another. This
action of the windings, with the help of the Return
Spring, causes the Drive Assembly to disengage and
the Solenoid Switch contacts to open simultaneously.
As soon as the contacts open, the starter circuit is
turned "OFF."
BLANK
30 - 9
SA - 31
-0
COOLANT FANS
V6 VIN SOR VS VIN P (WITH C41)
1 RUST
FUSIBLE
LINK C
r- -
HOTIN RUN
.._ ... -
SEE POWER
DISTRIBUTION
PAGEBA-10-3
--W UNDERHOOD
FANSIACTR
~
ELECTRICAL
CENTER
,---
lOAMP
3 RED
I
I
I
I
I
I
I
402
- - - - - - - - . . . , . ~ COOLANT
FAN
---
---
.5 BRN
lLTBLU
.35BRN
409
::.~[]
B
541
------ ...
541
5190
.35 DK GRN
SEE FUSE
BLOCK DETAILS
PAGE SA-11-12
---,
335
.35 G:V"'416
AIC
REFRIGERANT
PRESSURE
SENSOR
11
5v '
REF
3B:KJ5o
SEE GROUND
.......__
DISTRIBUTION
PAGE SA-14-6
.....- -
~~~~~~~~~~~~3BLK
rn
5113
150
.35 GRV
.35 DK GRN
416
PRESS

WITH COLORED TPAs.
A CLEAR (CLRI
B BLACK (BLKI
C BLUE (BLU)
- 32 WA V
32 WA V
- 32 WAY
A RED
B BLACK (BLKI
C CLEAR (CLR)
D - BLUE (BLUI
32WAV
32WAV
32WAV
32WAV
r - - - COOLANT
!~
11
2
!!
!!
5V
REF
FAN
CONTROL
12
5
SEE PAGE BA-3-0

FOR MEASURING
ANO HANDLING
PROCEDURES
rn
.35 BL~~52
I
__.......
380
5119-__......
.35 BLl452
1
D
B (VB VIN Pl
~
- - - - A (V6 VIN SI
A/C
PRESSURE
SENSOR
GROUND
REFERENCE
SENSOR
INPUT
=t
-=-
h
5
SENSOR
GROUND
REFERENCE
POWERTRAIN
I CONTROL
MODULE
I (PCMI
ECT
INPUT
vss
LO
vss
HI
L------ --------------~
29
31
- - - - - ENGINE
COOLANT
TEMPERATURE
(ECTI SENSOR
IMPORTANT:
C1101SONLVONV6 VINS.
CKTS 410 ANO 470 ARE
PART OF ENGINE HARNESS
ONVB VINP.
A
.35 BLKIPNK
470
30
32
401
l
SEE SEQUENTIAL
FUELINJECTION
PAGE BA-20-4
I
I~
I
-=-
.35 PPL
"2w~
-z--------1----. -,
.35 RED!BLK
I
I
I
I
I
REF
LO
:I
CI
IMPORTANT:
REFER TO SECTION 6E3 AND
CHECK FOR DTCs BEFORE
DIAGNOSING COOLANT FAN
SYSTEM OR REPLACING PCM.
".I
'I/
335
--.J106
LT1
II
I
.35 VEL
B (V6VIN S)
~ (V8 VIN Pl
400
31 -1
COOLANT FANS
VB VIN P (WITH C60) EARLY PRODUCTION VEHICLES
1 RUST
3 RED
FUSIBLE
LINK C
~----------------
- , UNDERHOOD
,-
I ELECTRICAL
SEE POWER
DISTRIBUTION
PAGE SA-10-3
4021
I
I
CENTER
3 RED
F4
F2
~It:~
...
--
F1
.5 BRN
.35 BRN
541
F:i _----
.35 DK
flLU
1
I
I
I
I
I
I
I
I
rn
IMPORTANT:

DIAGNOSlf':IG COOLANT FAN
SYSTEM OR REPLACING PCM .
473
...-.-.......................
+ ..---------- - -,
.35 BRN
541
541
YC100
5190
.3S DK GRN
3 LTBLU
HS
409
illl'
.35G:YJt6
SEE FUSE
BLOCK DETAILS
PAGE SA-11-12
5V
REF
3 BRN
504
B
COOL~N:.
PRIMARY
(DRIVER
SIDe)
~
.M
~ ~?c~:~:::N,
Al
3BLK.
150
~BLK
I
I
I,~
.
- '
COOLANT
FAN
CONTROL
-;f
32
32
32
32
REF PR.ES SURE

SENSOR
' CONTROL
380
INPUT
.35 BLK'
PAGESA-21-4
O~ - ' : , . ; ; GROUND
REFERENCE
L. -
!F~N~ - - - - - - - - - - !2 - - - !!! - -
WAY
WAY
WAY
WAY
.35 BLK
T,O THROTTLE
POSITION SENSOR ............_

AND AUTOMATIC ...........- TRANSMISSION
PAGE SA-21-4
470
vss
INPUT
vss
32
.3S:B:1L~O
.lS::L
- - - -. . E_NGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
S~
A_)'.
.35 BLK . .
4.70_ _ _ _
401
FUEl
INJECTION
452
= I." "'
GROUND
LT1 PCMCON~TORIDENTIFICATION
RED
BLACK (BlK)
CLEAR (CLR)
BLUE (BLU)
COOLANT
FAN
I
I
I
LO
A"'
.35 BLK 452 _...... SEE
S119--..... SEQUENTIAL
I .i
Rff
i ~"''"
__.._~
A
B
C
D
473
35 DK BLU
r!ll
~~~-.}!z~:..:.,-;; :,I
150
;5113
~~;:~}1!~: _... -
416
.35 REDIBLK
A
'
L'
3BLK
.35 GRY
(PASSENGER
SIDE)
A/C
REFRIGERANT
PRESSURE
SENSOR
.lSY EL
SEE VEHICLE
SPEED SENSOR
PAGE SA-33-0
4:
-,;=~"'
I
MODULE
I (PCM)
I
i~
I
...I
SA - 31 - 2 ELECTRtCAL DIAGNOSIS
COOLANT FANS
VS VIN P (WITH C60) ALL OTHER VEHICLES
1 RUST
FUSIBLE
LINK C
HOTINRUN
r - - - - - - - - - - - - SEE
- POWER
- - .... - - - - - - - - - - - ,
3REO
402
DISTRIBUTION
PAGE SA-10-3
I
I
I
I
I
I
FANS/ACTR
FUSE 6
.10AMP
UNDERHOOD
ELECTRICAL
CENTER
SEE FUSE
BLOCK DETAILS
PAGE aA-11-12
L..~~~~-5B_R_N~~~~--llllll. . . . . . . .
541
3REO
r--~~=-~---.lr-~----11--~--
.35 BRN
402
541
.35 BRN
541
.35 BRN'
541
01
05
F4
JS
J4
COOLANT
RELAY #1
.
04
~~! ,------~------,
COOLANT
FAN
RELAY #3
J3
02
J1
f2
B~~ I '
J2
504
409
3 BLK
.35 DKGRN
------
3 BRN
504
B
COOLANT[2]
FAN,
L.EFT
:
(DRIVER
.-.
SIDE)
M. t
.350K
-150
5117
.,.
416
3 BLK
SEE GROUND
DISTRIBUTION
PAGE SA-14-6
...__ _ ____.
IJ,.-
PRESS
,vLO
_,,.'.','!'.,, .:......111 m
CI
3 BI.K
532
i
-
..,
50
~1
3 BLK
ill1
150
...L~
l T1
A
B
C
D
--f
.1
5119---..... SEQUENTIAL
r-z- ---z----..-- --:i----
35 OK
. GRN
11
Ar
I
I
I
REF
,.,.
..3.SGRY
-,
REFRIGERANT
PRESSURE
SENSOR
REF
C100
AIC
sv' I'
.,
REFER TO SECTION 6E3 ANO

CHECK FOR OTCs BEFORE
DIAGNOSING COOLANT FAN
. .- - - - - - - - . .3SGRY~416
GER SIDE),
IMPORTANT:
473
BLU
!~:, . _ _______
- - - - .J ._____s_Ys_T_E_M_o_R_R_EP_L_A_CI_N_G_Pc_M_......
335
I
I
473
L-3LTBLU
.35 OK BLU
rn
>:
3
y504 .35 ~~r473
3 BRN
5167
BLU
,,.._ _ _ _ _
-;;;.-;:;
s166
I
I
1
1
1
335
.35 OK BLU
_____ .:..;..!..0
-1
COOLANT
FAN RELAY
#1
CONTROL
-1
SV A/C
REF PRESSURE .
SENSOR
.-
INPUT
SENSOR
ECT
GROUND
INPUT
PCM CONNECTOR IOE_NTIFICATION

RED
32 WAY
BLACK (BLl(I
32 WAY
CLEAR (CLR)
32 WAY
BLUE (BLUI
32 WAY
~5
-17 ----
.35 YBEL
.35 BLK
__
.35 BLK
.35 BLK
410
!!
16
470
I.____
_
5122
470
1.
1
vss
401
I
I
1
SENSOlf --,POWERTRAIN
CONTROL
GROUND
MODULE
REFERENCE
(PCMI
vss
31 ~ "'! .:"! ~;~
.35 PPL
FUEL
INJECTION
PAGEBA-214
452
!:~~ --
L.. -
.380
,;
12
!!
29
COOLANT
FAN RELAY
#2 ANO 3
CONTROL
.35 REOtBLK
-=-1+5v.-.-,
-=-
I
I
TOTHROTILE
POSITION SENSOR .........__
_
AND AUTOMATIC ~ TRANSMISSION
PAGE BA-21-4
473
.35 YEL
-; -
400
I
I
...
ELECTRICAL DIAGNOSIS 8A-
31 - 3
COOLANT FANS
COMPONENT
A/C Refrigerant Pressure
Sensor . . . . . . . . . . . . . . . . .
Coolant Fans . . . . . . . . . . . .
(ECT) Sensor (V6 VIN S)
(ECT) Sensor (VS VIN P)
Fusible Links .......... ,. .
(PCM) (V6 VIN S) . . . . . .
(PCM) (VS VIN P) . . . . . .
U nderhood Electrical Center
ClOO (10 cavities) . . . . . . . .
CllO (10 cavities) (L32) , .
Gl06 . . . . . . . . . . . . . . . . . . . .
Sl 13 . . . . . . . . . . . . . . . . . . . .
8117 (L32)
Sll7 (LTl)
8119 (L32)
Sll9 (LTl)
8122 (L32)
8122 (LTl)
8190 . . . . . . . . . . . . . . . . . . . .
LOCATION
201-PG
CONN
Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 35

Behind radiator
Mounted in front top of Engine, under plenum
.
Front of Engine, mounted in water pump ........... . 24
Above RH Shock Tower ........................... . 10
45
19
ln'Engine Compartment, rearward of RH Shock Tower
19
35 ..
202-25

of wheelhouse ................................... .
attached to PCM bracket ......................... .
Engine to Injector Harn, top center oflntake Manifold
Near top LH sie ofradiator, in top ofT-Bar ......... .
Center breakout
Eri:gine Harn, approx 5 cm from main branch and
PCM breakout
Engine Harri, approx 5 cm from clip near PCM and
main branch
Engine Harn, at RH Oxygen Sensor breakout ....... .
PCM breako~t
breakout
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
35 ..
202-26
19
36
202-28
15
12
19
28 ..
22
35
202-0
202-1
For a Service Part Cross Reference List and Information, refer to SEQTION SA-200.
SYSTEM DIAGNOSIS
FIG.
For Diagnosis, refer to SECTION 6E3.
12 ... 23
12 ... 23
36 . . . 68
SA -
32 - 0
ENGINE COOLANT HEATER: (KOS)
ENGINE COOLANT
HEATER CORD
(18i3 TYPE HPN)
BLACK
ENGJNEr-----------------,
BLOCK
ENGINE COOLANT
HEATER .
ORANGE
CONNECTOR
(HEATING ELEMENT)
L-----------------J
COMPONENT
(V6 VIN S) . . . . . . . . . . . . .
(VS VIN P) . . . . . . . . . . . .
Cord (V6 VIN S) . . . . . . .
LOCATION
201-PG
RH side, middle bottom of Engine, in block
FIG.
28 ... 54
LH side of Engine Block, near Oil Level Sensor

Routed from RH side of Engine to positive Battery cable,
strapped on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 35

Cord (VS VIN P) . . . . . . . Routed from rear of Engine Compartment, strapped to
hood release cable, near U nderhood Electrical Center
For a Service Part Cross Reference List and Information, refer to SECTION SA-200.
CIRCUIT OPERATION
The Engine Coolant Heater is inserted into the
Engine Block where there would normally be a Freeze
Plug. The Engine Coolant Heater is not connected to
the vehicle's 12 volt electrical system. For on-vehicle
Service, refer to SECTION 9E.
19 . . . 36
32 - 1
CONN
SA -
33 - 0
I"" -
I
I
I
I
ksv
""'I CRUISE
I"" -
I. MODULE
CONTROL
,r:::l
--.
""'I INSTRUMENT
: CL;ER
___ ,_.
...
----1
INPUT
(CHEVY) 01
(POND 812
817
.35 DK GRN/WHT
.35 DK GRN/WHT
. .VEHICLE I ~
SPEED
I
I .
I
VEHICLE.~
SPEED
INPUT
...
: IGkNITION
..-------------.----
817
5242
.35 DK GRNtWHT
LT1
817
A
B C D

RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAY
32WAY
32WAY
32WAY

WITH COLORED TPAs.
. 35 DK GRN/WHT
817
28
8
A - CLEAR (CLR)
B - BLACK (BLK)
C BLUE (BLU)
B (BLK) (V6 VIN S)

VIN P)
B (BLK) (VB
r - - - .;.. - - - - - - , I
~
4000 PULSES
I PER MILE. SPEED OUTPUT

I
I
VEHICLE SPEED
I
L - - - _!.N~T !1 - 29
31
.35 PPL
CONTROL
MODULE (PCM)
~
VEHICLE SPEED
l~UL!!I -
- - - - - -30
32
401
POWERTRAIN'
.35 YEL
..J
B (BLK)(V6 VIN S)
~ (RED)(V8 VIN P)
400
1----...------'7""--""'I VEHICLE
SPEED
SENSOR
PERMANENT
MAGNET
GENERATOR
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
32 WAY
32 WAY
32 WAY
12129025
CONNECTOR ASSEMBL V BREAKDOWN

NAT
POWERTRAIN CONTROL MODULE {PCM) {VS VIN P)
TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129022 (CLR)
12146093
12129030
12129025
GGGGGGGGGGGGGG0G
800008888G0GGGGG
12129025
CONNECTOR ASSEMBL V BREAKDOWN

NAT
POWERTRAIN CONTROL MODULE {PCM) {V6 VIN S)
TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLK)
12146093
12129030
12129025
C16
01
01
I I
II
016
12045575
12065803

BLK

BLK
INSTRUMENT CLUSTER {CHEVY)
INSTRUMENT CLUSTER {PONT)
33,- 1
SA -
33 - 2

COMPONENT
Cruise Control Module
Instrument Cluster . . . . . . .
(PCM) (V6 VIN S) . . . . . .
(PCM) (VS VIN P) . . . . . .
(M30 Automatic) . . . . . . .
(M49 or MM6 Manual) ..
C200A (17 cavities)
LOCATION
201-PG FIG.
Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36 . .
LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN
19
35
202-25
19
35
202-26
16, 26
30,51
25
49
202-2
25
20
49
37
202-2
202-6
19
36
19
35
202-11
202-23
Rear LH side of Transmission
Rear LH side of Transmission . . . . . . . . . . . . . . . . . . . . . . .

C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C220 (10 cavities) ....... . Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8242
I/P Harn, approx 26 cm from Instrument Cluster Conn
For a Service Part Cross Reference List and Information, refer to SECTION BA-200.

Diagnosis)
System
Check for a broken. (or partially broken) wire


Procedures," page BA-4-0).
SYSTEM DIAGNOSIS
Refer to the Symptom Table for the appropriate
diagnostic procedures.
SYMPTOM TABLE
SYMPTOM
Speedometer inoperative. DTC 24 set.
Speedometer and Cruise <;:ontrol inoperative; DTC 24
not set.
PROCEDURE
PAGE NUMBER
Refer to SECTION 6E3.

Chart #1
8A-33-3
Speedometer inoperative. DTC 24 not set. Cruise Check for open in CKT 817 between 5242 and
Control operates.
Instrument Cluster Connector. Also check for poor
connection at terminal "812". If OK, service
Instrument Cluster.
CHART #1
SPEEDOMETER AND CRUISE CONTROL INOPERATIVE; CODE 24 NOT SET
DISCONNECT PCM CONN B (V6 VIN S) OR

CONN B (VB VIN P).
CONNECT SIGNAL GENERATOR 1/P TESTER
J 33431-B TO PCM CONN B (V6 VIN S)
TERM "28" OR CONN B (VB VIN P) TERM "8".
CONNECT J 33431-B ~ROUND TERMINAL TO
A GOOD CHASSIS GROUND.
SET SIGNAL GENERATOR 1/P TESTERJ 33431-B
T054mph.
DOES SPEEDOMETER READ 54 mph?
CHECK FOR OPEN, SHORT TO GROUND OR SHORT

TO VOLTAGE ON CKT817.
CHECK FOR POOR CONNECTION AT INSTRUMENT
CLUSTER CONN (PONT) TERM "812" OR (CHEVY)
TERM "01".
IF OK, SERVICE INSTRUMENT CLUSTER.
CIRCUIT OPERATION
The Vehicle Speed Sensor is a gear-driven
Permanent Magnet Generator housed in the vehicle's
Transaxle. This sensor generates a sine wave output
with a frequency proportional to vehicle speed. The
PCM converts this signal to an output that is switched
to ground at a frequency of 4000 pulses per mile at the
DK GRN/WHT wire (CKT 817), which feeds the
Instrument Cluster and Cruise Control Module.

AT PCM CONN B (V6 VIN S) OR
CONN B (VB VIN P).
IF OK, REPLACE PCM.
33 .. 3
SA -
34 - 0. ELECTRICAL DIAGNOSIS

.35 PNK
(CHEVY) 013
(PoNn AS
1 ; --39
1 CLUSTER
INSTRUMENT
TO OTHER
I
INDICATORS I ~
I t'r\
I,,.~
I ~ "LOWTRAC" , ~
INDICATOR
I 4,
I
L------J
r -.
~~
~E;;O;;R-
GAGES
DISTRIBUTION
PAGE SA-10-3
FUSE 9
IO AMP
IGN
(NOT USED)
L------
.SPNK 3.9. . . . . . . . . . . . . . . . . . . . . .. .
(PoNn A161
(CHEVY) 016
.35 DK BLU
1537
A9
C200D
ii'C200A
.35 DK BLU
I
I
I
AIC-
1537
139
5165
I Iv I
WITH NW9
BS
C2
WITHOUT NW9
.8 PNK
=SfTC~,
I
I
ACTIVE
I
I
.35 DK BLU
MANUAL
ELECTRONIC
BRAKE,TRACTION
CONTROL MODULE
I '
B IC250
.35 PNK
AUTOMATIC
L __ J
(EBTCM)
1537 (WITH NW9)
I
I I
I
/~...!;;:;;;;;;;;;;;;;;.,_A_,;=;;;;~
V6 VIN S
CLUTCH ANTICIPATE/
CRUISE RELEASE SWITCH
(4 CAVITY DUAL SWITCH)
(OPEN WITH
CLUTCH PEDAL
DEPRESSED)
PAGE SA-20-7
139
.35 PNK
I
I
r-\ ,
B
I
I
VS VIN P
I
I
-1J
RIA
I
I
L--
379
-Al
86
A1il Q
'
OFF - .. ON
ON
SEE FUSE
BLOCK DETAILS
PAGESA-11-15
I
I
I
I
DEPRESSED)
CRUISE RELEASE/[]
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
.35 BRN
139
-~
---...----:----,
RIA
I
I
I
I
I
I
CRUISE
RELEASE'
CLUTCH
SWITCH
(2 CAVITY)
(OPEN WITH
CLUTCH PEDAL
AI
.35 BRN/W:T
C250
I CRUISE
I SWITCH
--,
MULTl-FUNCTION
LEVER
139 (WITHOUT NW9)
DISTRIBUTION
PAGE 8A-10-3
C215
7EE-;O;;R-
139
S2781
.....
153~----::a..
.35 DK BLU
_______ J
.8PNK
139
CRUISE
FUSE12
20AMP
.8PNK
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE SA-11-5
I 1537 _35 DK BLU
__
B
[ ] CRUISE RELEASE/
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
Al
.35 BRN
.JS DK BLU
.35GRY
84
.8 PNK
.35 GRYiBLK
397
139
87
86
A1il Q
. .fr.-------_:_ -,,i"'""---------,,"'""--------..-..;,.............................,.
CRUISE r"'............-,""'........................................""'...................
BRAKE
CONTROL
INPUT
ll.10DULE
rn
IMPORTANT:
THE "SET TO GET CRUISE" FEATURE REQUIRES THE OPERATOR TO SET AN INITIAL SPEED BY USING THE ""SET/COAST"
BUTION BEFORE THE "'RESUME,ACCE.L" SLIDER SWITCH WOULD BE ACTIVE.
THE "'BRAKE BEFORE CRUISE" FEATURE REQUIRES THE CRUISE MODULE TO SEE BRAKE INPUT AT TERMINAL "D" TO
CHANGE STATES ONCE EACH IGNITION CYCLE BEFORE ALLOWING CRUISE TO OPERATE. (LATER PRODUCTION VEHICLES
REQUIRE BRAKE INPUT AT EITHER TERMINAL "D" or "G").
ELECTRICAL DIAGNOSIS 8A- 34- 1
----,k'.e:
LT1
FUSE
STOP/HAZARD
FUSE 6
20AMP
A
B
C
D
I BLOCK
I
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAV
32WAV
32,WAV
32WAV

WITH COLORED TPAs.
A - CLEAR (CLR)
B BLACK (BLK)
C - BLUE (BLU)
BRAKE LIGHT
CRUISE RELEASE
SWITCH
(NORMALLY
OPEN)
r" -
c
.8 VEL
L----.J
28
20
.35 DK GRN/WHT
TO CENTER
rn
817
TO TURN/HAZARD
SWITCH ASSEMBLY
PAGES 8A1100, 1
220
....s.v.EL
.......... HIGH MOUNTED
STOP LIGHT (CHM SL)
820
PAGE SA-1101
52 4 3
~--------------,
B (BLK)(V6 VIN S)
~ (BLK) (VS VIN P)
8,
TO AUTO TRANS
SA-21-6 (VS VIN P)
NOT USED WITH
MANUAL TRANS
820
POWERTRAIN
CONTROL
I MODULE
I (PCM)
,A.
I ~
4000 PULSES
PER MILE,
SPEED
OUTPUT
.SLTBLU
- - "1
32WAV
32WAV
32WAV
.35 DK GRN/WHT
817
IMPORTANT:
BRAKE SIGNAL INPUT MUST BE
PULLED LOW THRU CENTER HIGH
MOUNTED STOPLAMP BULB OR
CRUISE CONTROL WILL NOT WORK
5242
.....
1P
_iii.3IIISIIID.K GRN!W
. .HIIT_ _
11111111111
.35 DK GRN/WHT1817 817
.8 VEL
Tel INSTRUMENT
CLUSTER
PAGE SA-81 0
820
.:r:------------------~.~~:.:~ .::
.8 VEL
qlJl!Q
A1
....
S271 - - - ...
VEHICLE SPEED
SENSOR INPUT
BRAKE
INPUT
STEPPER~
MOTOR
12V
SV
.8 BLK
I
I
I
I
I
16SO
SEE GROUND
DISTRIBUTION
PAGE BA-142
MECHANICAL
LINK (CABLE)
TO THROTTLE BODY
SEE PAGE 8A-30
FOR MEASURING
AND HANDLING
PROCEDURES
SA -
12065425
BLK

CAVITY
WIRE COLOR
CKT
GRY
397
DKBLU
DESCRIPTION
PAGE
CRUISE CONTROL SWITCH - ON
8A-34-0
84
CRUISE CONTROL SWITCH - SET/COAST
8A-34-0
GRY/BLK
87
CRUISE CONTROL SWITCH - RESUME/ACCEL
8A-34-0
BRN
86
CRUISE RELEASE/BRAKE SWITCH OUTPUT
8A-34-0
BLK
1650
GROUND
8A-14-0,2
PNK
139
POWER FEED FROM A/C-CRUISE FUSE #12
8A-34-0
YEL
820
BRAKE DEPRESSED INPUT
8A-34-1
DKGRN/WHT
817
VEHICLE SPEED SIGNAL
8A-34-1
12129025
32-WA Y F MICRO-PACK 100 SERIES
NAT

(V6 VIN S) AND (VS VIN P)
V6 VIN S
CONNECTOR ASSEMBLV_IIREAKDOW_I\!
TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLKI
12146093
12129030
12129025
VS VIN P
TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLK)
12146093
12129028
12129025
C215
fr
- - ~PIN IMIL IK I J lolH IG IF
34 - 3
~ FORWARD LAMP
le 1~J ~~~~~SJ ~~iJ~~~ING
06294509
11 WAY F PACK-CON I
BLK
COMPONENT
LOCATION
Mounted in lower hole or brake pedal bracket (2 conn

same switch for both ............................. . 0 ....
201-PG
FIG.
CONN
1
Clutch Anticipate/
(all V6 Manual) . . . . . . . . . Mounted in clutch pedal bracket (4 cavity conn) ..... . 0 .... 1 . .. 202-20
Cruise Control Module . . . . Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse ................................... . 19 ... 36 . . 202-11
Cruise Release/Brake Switch
(all withK44) .......... Mounted in upper hole of brake pedal bracket
(2 cavity conn) .................................. . 0
1
Cruise Release/Clutch Switch
(VS Manual with K34t . . Mounted in chitchpedal bracket (2 cavity conn)
0
1
Ehictronic Brake/Traction
Control Module (EBTCM) Under I/P, next to LH hinge pillar, just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14 .. 202-13
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 .. 202-23
Instrument Cluster ...... . LH side ofl/P ................................................... . 202-23
53
Multi-Function Lever ... . Left Arm on Steering Column . . . . . . . . . . . . . . . . . . . . . . . 27
(PCM) (V6. VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower
19
202-25
35
19
(PCM) (V8 VIN P) ..... . In Engine Compartment, rearward of RH Shock Tower
35 .. 202-26
of wheelhouse ................................... . 19
36
202-28
C200A (17 cavities)
49
202-2
C200D (48 cavities)
Steering Column ................................ . 25
49
202-2
64
202-4
C220 (10 cavities) ....... . 'Under RH side'ofl/P, behind kick panel ............. . 20
202-6
37
C250 (2 cavities) ........ . Forward Lamp Harn to Clutch Jumper Harn or Switch,
near brake/clutch pedal bracket .................. . 0, 1 .. 1, 2
Bolted to left front frame rail (2 rings, 1 wire and
G109
braided strap) ................................... . 11
21
PlOO . . . . . . . . . . . . . . . . . . . Left side in dash panel, Engine to Passenger
Compartment ................................... . 19
36
PllO
Compartment ................................... . 19
35
S165
Center breakout
S206
breakout
I/P Harn, approx 26 cm from Instrument Cluster Conn
S242
I/P Harn, approx 14 cm from Fuel Pump Relay breakout 7
13
S243
Forward Lamp Harn, approx 19 cm from breakout
S271
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14
Forward Lamp Harn, approx 9 cm from EBCM breakout
S278
~
SYSTEM DIAGNOSIS
For Diagnosis, refer to SECTION 9B.
SA -
39 - 0
ELECTRONIC TRANSMISSION CONTROLS

.
-
,UNDERHOOD
ELECTRICAL
IGNITION
CENTER
FUSE 11
10AMP
r;E;;O;E;- -
I DISTRIBUTION
f PAGE 8A-10-3
I
f
I
- _ .J
L----
rn
.8 PNK
239
LT1
FROM PERFORMANCE/TRACTION
CONTROL SWITCH PAGE SA-39-1
A
B
C
D

32WAV
32WAV
32WAV
32WAV
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
IMPORTANT:

.
WITH COLORED TPAs.
ON CHEVROLET ONLY,
CKTS 553 AND 1493 TO
THE PCM ARE PRESENT
BUT NOT USED ON THE
ENGINE HARNESS.
A CLEAR (CLR)
B
BLACK (BLK)
C BLUE (BLU)
.35 DK BLU
1493
.35 LT BLU
553
32 WAY
32 WA V
32 WAY
...
POWERTRAIN
CONTROL
MODULE
~
(PCM)
~
I!
18
15
10
~ (V6 VIN S)
13
C (V8 VIN P)
J .. _&
~--------------~----~------------~
A
PERFORMANCE
INDICATOR CONTROL
rec
f SOLENOID
3-2
CONTROL
SOLENOID
2-3
SHIFT
SOLENOID
...:0!,!"R_! _;0!,!'R_! (V8 VIN P) .8 PNK

(V6 VIN S) .35 PNK
239
239
11
15
D
~
C~T~L -
13
16
PRESSURE
CONTROL '
SOLENOID
~
1223
SOLID STATE
RANGE
SIGNAL
RANGE
SIGNAL
RANGE
SIGNAL
;2 - -_ _. I!!,_ - - 2 - - - ".!!.:, - ~ .. -
_!0_'.!!R~ 7
11
12
12
.5 VEUBLK
1-2
SHIFT
. SOLENOID
PERFORMANCE
MODE INPUT
16
.SLT BLU/
2:8
!;
.5 PNK
1229
30
23
29
22
21
1224
.5 RED
TFT
SENSOR
28
32
6
17
1226
WHT
SEE FUSE
BLOCK DETAILS
PAGESA-11-15
.5 WHT
687
.5 LTGRN
1222
.5 RED/BLK
1228
.5 DK BLU.
1225
.,1!G~L- .!!!O~D..,j
.5VEU
BLK
1227
.35BLK
B(VBVINP)
~ (V6 VIN S)
SEE
SEQUENTIAL
FUEL
INJECTION
PAGE SA-21-4
(VS VIN P)
PAGE 8A-20-4
(V6 VIN S)
470
s122e_5e~K1470
TCC
SOLENOID
CONTR~frrJ
SOLENOID~
-------'y
I
IIJ]
;m,~i:![j.
1_2 [ ] ] PRESSURE
SHiFT
CONTROL
SOLENOID
---
11
SOLENOID
(PCS)
TRANSMISSION FLUID
TEMPERATURE (TFT)
TRANSMISSION RANGE (TR)
SENSOR
PRESSURE SWITCH ASSEMBLY.__ _ _ _ _ _ _ _
_ _ (INTERNAL)
_ _ __
AUTOMATIC
TRANSMISSION
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
rn
IMPORTANT:
INFORMATION ON
THIS PAGE IS SPECIFIC
TO PONTIAC.
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
TO INTERIOR LIGHTS
DIMMING
PAGESA-117-2
.8BRN
141
+--S207
.35BRf41
Gl _
"7tt_J,:_____________________
A__
PERFORMANCE/ _ _
TRACTION
CONTROL
SWITCH
PONT WITH M30
ANDNW9
ILLUMINATION
LAMPS
<D <D..
.
,..."T_R_A_CTI_O_N__ _._P_E_RF.,ORM"
.35 BRN/
WHT
MOMENTARY
CONTACT
1571
.35 PPL!
WHT
TOANTILOCK
BRAKES/
TRACTION
CONTROL
PAGE 8A-44-4
~
TO POWERTRAIN CONTROL
MODULE (PCMI
PAGE SA-39-0 (PONT ONLYI
1572
TOANTILOCK
BRAKES/
TRACTION
CONTROL
PAGE SA-44-4
TO INTERIOR LIGHTS
DIMMING
PAGE SA-117-2
'":t
~
.35 BLK,'WH:r:51
1~
--S215
.----..a....--5..,BLKWHT
iEE GROUND
DISTRIBUTION
PAGES SA-14-1, 3
&.~
SEE PAGE 8A3-0
FOR MEASURING
AND HANDLING
PROCEDURES
t.
iCZlO
P110
.5 BLKWHT
451
S109 (V8 VIN Pl
VIN SI
5110 (V6
.8 BLK,WHT
14:-
G 103 (VS VIN Pl

__AJ1104 (V6 VIN SI
~
TO POWERTRAIN CONTROL
MODULE (PCMI
PAGE 8A39-0 (PONT ONL YI
39 - 1
SA -
39 - 2
ELECTRONIC TRANSMISSION CONTROLS

COMPONENT
Automatic Transmission
Conn . . . . . . . . . . . . . . . . . .
1/P Fuse Block . . . . . . . . . . .
Control Switch ........ .
Performance Switch ..... .
(PCM) (V6 VIN S) ..... .
(PCM) (V8 VIN P) . . . . . .
ClOO (lOcavities) ....... .
C210
C220
C230
0103
(4 cavities) ........ .
(10 cavities) ....... .
(10 cavities) ....... .
(LTl) ............. .
0104 (L32)
PllO ................... .
8107 (L32)
8107 (LTl)
8109 (LTl)
SllO (L32)
Sl22 (L32)
8122 (LTl)
S207
8215
LOCATION
FIG.
CONN
RH center of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . 73
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
202-10
202-23

42 ... 79
202-24
202-24
19
35
202-25

of wheelhouse ............... , . . . . . . . . . . . . . . . . . . . .
attached to PCM bracket . . . . . . . . . . . . . . . . . . . . . . . . . .
RH side of Engine Block,just above Starter
(l ring, 1 wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Harn, approx 30 cm from Cl 10.breakout . . . . . .
Engine Harn, approx 7 cm from main breakout at
right rear of Engine
PCM breakout
breakout
breakout
1/P Harn, approx 4 cm ~efore DLC breakout
1/P Harn, approx 30 cm before D LC breakout
19
35
202-26
19
36 ..
202-28
15
20
20
20
28 ..
37 ..
37
37
202-0
202-19
202-6
202-7
40
72
29
56
19
12
35
22
SYSTEM DIAGNOSIS
201-PG
12 ... 23
BLANK
39 - 3
SA.:,140- 0 ELECTRICAL DIAGNOSIS
HORNS
------,~
FUSE
CIGAR/HORN
BATT
FUSE 1~ (NOT USED)
25 AMP
L---------
I BLOCK
I
f
J
.8 ORN
540
A
1 ORN
I"" -
540
-,CIGAR
LIGHTER
PAGES8A-114-0, 1
I
I
I.. -
Ill
-
..I
- - - - - - - - - - - - - - _.. - - -, CONVENIENCE
: ~i-------- -- ---- - -Q
II
1 DK GRN
29
.35 BLK
II CENTER
__ .JI
L.-
rn
HORN
RELAY
28
IMPORTANT:
WHEN REPLACING HORNS, BE SURE
TO REPLACE WITH THE SAME
SOUNDING HORN. THERE IS ONE "A"
NOTE (450 Hz) AND ONE .. F.. NOTE
(360 Hz). HORNS ARE MARKED WITH
EITHER AN "A" OR .. F. NEAR THE
HORN OPENING.
HORN BRUSH
SLIP RING
. .- - - - - - 5 1 5 8
1 DK GRN
29
SPRING
IT-r1 ,o,.,
IJ-lJ
HORN #1
WHEEL
-~
&
-:=-
HORN #2
(F NOTE)
(BOTH HORNS ON RIGHT FRONT SIDE OF VEHICLE)
tit.
SEE PAGE SA-3-0
FOR PROPER
HANDLING
PROCEDURES
-----+-+----RED
RED
HORN SWITCH
(INCLUDES 2 SWITCHES
& WIRING)
-
-~1--------sTEERING
WHEEL
- - - - INFLATOR MODULE
,..
PLATE (CASE
GROUNDS TO
STEERING WHEEL
WHEN DEPRESSED)
jf:. 4
BLK

i@H1 K 1,f"r't;J)
F-CONN
M-TERM
12004147
11-WAY F PACK-CON I
BLK
1/P HARNESS TO STEERING COLUMN HARNESS
COMPONENT
LOCATION
Cigar Lighter ........... . Mounted on front of console . . . . . . . . . . . . . . . . . . . . . . . . .
1/P Carrier ..................................... .
Horn #1 (A note) ....... . RH side, front of vehicle directly below Headlamps ... .
Horn #2 (F note) ........ . RH side, front of vehicle directly below Headlamps ... .
Horn Switch ............ . In Steering Wheel ................................ .
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side .................. .
C200A (17 cavities)
C200D (48 cavities)
Part ofl/P Harn, between LHkick panel and
Steering Column .................. : ............. .
C216 (11 cavities) ....... . Attached to base of Steering Column .... '. .......... .
Compartment ................................... .
8158
on horn branch
CONN
43 . . . 81
8 ....
19 ...
19 ...
2
8 ....
15
35
35
3
15
202-23
25
49
202-2
25
34
49
63
202-~
202-5
19
36
202-20
(Perform before beginning System
Diagnosis)
Check Fuse 7. An accessory plugged into the Cigar
Lighter may have caused an overload.

electronic equipment wh_ich may affect the
SYSTEM DIAGNOSIS
diagnostic procedure(s).
HORNS
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Chart #1
BA-40-2
Horns inoperative from switch(es).

Horns inoperative from one switch only (Chevrolet).
Check for open in BLK or RED wire leading to

inoperative switch. If OK, replace Horn Switch as
necessary.
One Horn inoperative.
Remove connector from inoperative Horn. Attach one

end of a fused jumper to B +. Momentarily touch the
other end to the Horn. If the Horn sounds, repair
open in CKT 29. If the Horn does not sound, check the
Horn for a clean and tight ground at its case. If OK,
replace Horn.
Horns "ON" at all times.
Chart #2
BA-40-3
CHART #1
HORNS INOPERATIVE FROM SWITCH(ES)
CHECK FUSE 7.
IS FUSE 7 OPEN?
REMOVE HORN RELAY.

CONNECT A TEST LIGHT FROM CONVENIENCE
CENTER TERM "L" TO GROUND.
DID TEST LIGHT COME "ON"?
CONNECT A TEST LIGHT FROM THE

CONVENIENCE CENTER TERM "L" TO TERM "M".
PRESS HORN SWITCH.
REPAIR OPEN IN CKT 540 OR POWER FEED TO FUSE 7.
RECONNECT HORN RELAY.

BACKPROBE CONVENIENCE CENTER TERM "N"
WITH A TEST LIGHT TO GROUND.
PRESS HORN SWITCH.
CHECK FOR A SHORT TO GROUND THROUGH CKT 540 OR CKT 29, REPAIR
AS NECESSARY. IT IS POSSIBLE THAT AN ACCESSORY PLUGGED INTO
THE CIGAR LIGHTER MAY HAVE CAUSED THE OVERLOAD.
REPLACE FUSE 7.
DISCONNECT C216.
CONNECT A TEST LIGHT FROM CONVENIENCE CENTER TERM "L"
TO (216 TERM "G" (STEERING COLUMN SIDE).
PRESS HORN SWITCH.
REPAIR OPEN IN CKT 28

BETWEEN C216 AND
HORN RELAY.
CHECK FOR OPEN IN BLK WIRES ATTACHED

TO HORN BRUSH SLIP RING AND FOR
CONTACT AT THE SLIP RING, OR CHECK FOR
CLEAN AND TIGHT GROUND AT CASE OF
HORN SWITCHES (CHEVY) OR CONNECTION
AT INFLATOR MODULE (PONT).
IF OK, REPLACE HORN SWITCH(ES) AS
NECESSARY.
CHART #1 (continued)
CHART #2
HORNS INOPERATIVE FROM BOTH SWITCHES
HORNS "ON" AT ALL TIMES
REMOVE HORN RELAY.

ARE HORNS "ON"'?
DISCONNECT EITHER HORN

CONNECTOR.
CONNECT A TEST LIGHT FROM
CONN TERM "B" TO GROUND.
PRESS HORN SWITCH.
DOES TEST LIGHT COME "ON"?
CHECK FOR POOR

CONNECTION AT
TERM "N".
IF OK, REPLACE
HORN RELAY.
CONNECT A TEST
LIGHT FROM
CONVENIENCE
CENTER TERM "L"
TOTERM"M".
IS TEST LIGHT "ON"?
CHECK HORNS FOR GOOD

GROUNDS AND GOOD
CONNECTIONS.
IF OK, REPLACE HORNS AS
NECESSARY (HORNS
INOPERATIVE COMPLAINTS
MAY NOT ARISE UNLESS
BOTH HORNS FAIL).
CHECK FOR POOR

CONNECTION Af
TERM "N".
IF OK, REPAIR
OPEN IN CKT 29.
CHECKFORSHORTTO
GROUND IN CKT 28.
IF OK, REPAIR OR
REPLACE HORN
SWITCHES AS
NECESSARY.
CIRCUIT OPERATION
CHEVROLET
Battery voltage is applied at all times to the Horn

Relay at terminal "L". When a Horn Switch is pressed,
it provides a ground to the Horn Relay Coil. The Horn
Relay contacts close, applying battery voltage to the
horns. The horns continue to sound until the Horn
Switch is released.
PONTIAC
Battery voltage is applied at all times to the Horn

Relay at terminal "L". A ground path is provided
through a spring loaded plate to energize the Horn
Relay, whenever the lnflator Module is pressed. The
Horn Relay contacts close, applying battery voltage to
the horns. The horns continue to sound .until the
Inflator Module is released.
SA -
41 ~ 0 ELECTRICAL DIAGNOSIS
r----I
I
sEE POWER
DISTRIBUTION
PAGE SA-10-3
------,~
FUSE
GAGES
FUSE9
10AMP
IGN
(NOT USED)
L---------.8 PNK
SEE FUSE
BLOCK .DETAILS
PAGE SA-11-5
I BLOCK
I
I
I
_..J
39
.---5206
.3SPNK139
(CHEVY) 013
(POND AS
f':'.
- - -~ INDICATORS,
I GAGES
I
I
I
I
~
w
CHEVY
I I I
-, CLUSTER
INSTRUMENT
I~
"BRAKE"
I~
(G)) CG)) I
PONT
"BRAKE"
SYMBOLFORZ49:
(G)) {G))
INDICATOR
---
.3STAN/WHT
(PONn A10
(CHEVY) C10
.35 TAN/WHT
RELEASE RELAY
PAGE SA-135-0
I
I
~---- 1---------~
INDICATOR
TO HATCH
MANUAL
TRANSMISSION
.35TAN/WHT
33
.35 TAN/WHT
33
33
WITH
DAYTIME
RUNNING
LIGHTS (DRL)
AS 1C200D
yc200A
-J-,
___
.35 TAN/WHT 133

5273 - - - - - - - - -. .
.35 TAN/WH:r33
.35 TAN/WHT
33
~~Cl
DAYTIMEr"' RUNNING
LIGHTS (DRL) I
MODULEI
._
I
PARK
BRAKE
INPUT
.....
"'"~}:
.35 TAN/WHT
HYDRAULIC
MODULATOR
ASSEMBLY
33
I
A
PARK BRAKE
SWITCH
CLOSED WITH
PARK BRAKE ON
PARK B R A K E [ ]
SWITCH
CLOSED WITH
PARK BRAKE ON
[ ]
._
BRAKE
COMBO
VALVE
(ABS)
__ _ ____ ...
.8 BLK/WHT
I
I
I
1-cE_Bc_M_>~1 WITH NW9
5 BLK,WHT
Q.
84
"BRAKE"
INDICATOR
CONTROL
-:_i_
"'- -
-W ELECTRONIC
BRAKE
CONTROL
I MODULE
-=:-
.J ELECTRONIC
BRAKE/
TRACTION
CONTROL
MODULE
(EBTCM)
651
651
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
r-z---
~--- ------, I
I
SEE GROUND
DISTRIBUTION
PAGE SA-14-4
__ J
ELECTRICAL DIAGNOSIS BA --41
-1
FRONT VIEW
A1
81
12110113
12065803
DK RED
BLK
ELECTRONIC BRAKE CONTROL MODULE (EBCM)

OR
ELECTRONIC BRAKE/TRACTION CONTROL MODULE (EBTCM)
INSTRUMENT CLUSTER
COMPONENT
LOCATION
201-PG
FIG.

Part of Hydraulic Modulator Assembly, inward side . . 39 . . . 68
(DRL) Module . . . . . . . . . . Mounted behind Radio and HV AC Controls, left of
1/P Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 12 . .
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14 ..
Control Module (EBTCM) UnderI/P, next to LH hinge pillar,just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14 ..
Hydraulic Modulator
Assembly ............. . Front left of Engine Compartment . . . . . . . . . . . . . . . . . . 39 . . . 68
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . .. . . . . . . . 8 . . . . 15 ..
Instrument Cluster ...... . LH side of I/P ................................................... .
Park Brake Switch ...... . In console, at base of Park Brake Lever . . . . . . . . . . . . . . 43
81
C200A (17 cavities)
and Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
49 ..
C200D (48 cavities) ..... -:' Part of 1/P Harn, between LH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
49 ..
Top of RH Shock Tower (3 rings, 5 wires) . . . . . . . . . . . . . 10
19
GlOl
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
Slll
Assembly breakout
8206
breakout
8228
S273
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14
CONN
202-20
202-13
202-13
202-23
202-23
202-2
SA - .41 - 2 ELECTRICAL DIAGNOSIS

Diagnosis)
System
Check for Antilock Brake or Traction Control

DTC(s).
Check for an open GAGES Fuse 9.

SYSTEM DIAGNOSIS
Perform the Sysiem Check and refer to the

procedures.
SYSTEM CHECK
ACTION
NORMAL RESULTS
(1)
(2)
(3)
Park Brake released .

Turn Ignition Switch to "RUN" position .
"BRAKE" Indicator lights for approximately 3 seconds

then goes "OFF."
Ignition Switch in "RUN."

Apply Park Brake .
"BRAKE" Indicator lights.
Release Park Brake .
"BRAKE" Indicator does not light.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
"BRAKE" Indicator remains on with Ignition Switch in

"RUN" and Park Brake released.
Chart #1
8A-41-3
"BRAKE" Indicator does not turn on for only one

condition.
Chart #2
8A-41-4
ELECTRICAL DIAGNOSIS SA- 41
CHART #1
"BRAKE" INDICATOR REMAINS ON WITH IGNITION SWITCH IN "RUN"
AND PARK BRAKE RELEASED

DISCONNECT BRAKE COMBO VALVE CONNECTOR.
DID "BRAKE" INDICATOR GO OUT?
DISCONNECT PARK BRAKE SWITCH.

r-
----------------------------,
:
'
:
REFER TO SECTION 5.
:
REPAIR OR REPLACE MECHANICAL PARTS OR I
BRAKECOMBO VALVE AS NECESSARY.
:
L------------------------------~
DISCONNECT ELECTRONIC BRAKE

CONTROL MODULE (EBCM) OR
ELECTRONIC BRAKE/TRACTION
CONTROL MODULE (EBTCM)CONN C2.
IS VEHICLE EQUIPPED WITH DAYTIME

RUNNING LIGHTS (DRL)?
r- - - - - - - - - - - - - - - - - - - - - ,
: REFER TO SECTION SE1 (E~CM) OR :
I SE2 (EBTCM).
1
L----------------------J
CHECK FOR SHORT TO GROUND

THROUGH CKT 33, INCLUDING
HATCH RELEASE RELAY IF
EQUIPPED WITH A MANUAL
TRANSMISSION.
CHECK FOR MECHANICAL INTERFERENCE.

IF OK, REPAIR OR REPLACE PARK BRAKE
SWITCH AS NECESSARY.
DISCONNECT DRL MODULE CONN C1.

CONNECT A JUMPER WIRE AT DRL

MODULE CONN C1 FROM TERM "D" TO
TERM "E".
IF LIGHT COMES ON, REPAIR SHORT TO
GROUND IN CKT 1134.
IF LIGHT STA VS OFF, CH ECK FOR
SHORTED TERMINALS IN CONNECTOR.
IF OK, REPLACE DRL MODULE.
-3
SA -
41 - 4

CHART #2
"BRAKE" INDICATOR DOES NOT TURN ON FOR ONLY ONE CONDITION
WHICH COMPONENT DOES NOT TURN "BRAKE" INDICATOR ON?
PARK BRAKE SWITCH
BRAKE COMBO VALVE
EBCM OR EBTCM
.-- -------.
DOES VEHICLE
HAVE DRL?

DISCONNECT BRAKE COMBO VALVE (ABS CONN C4).
CHECK FOR BATTERY VOLTAGE AT CONN C4TERM "A".
IS BATTERY VOLTAGE PRESENT?

BETWEEN BRAKE COMBO
VALVE AND 5228.

CHECK FOR BATTERY
VOLTAGE AT PARK BRAKE
SWITCH CONNECTOR.
- IF NO VOLTAGE, REPAIR
OPEN IN CKT 33 BETWEEN
SWITCH AND 5228.
- IFBATTERYVOLTAGE,
CHECK FOR POOR
CONNECTION AT SWITCH
OR FOR MECHANICAL
INTERFERENCE.
IF OK, REPLACE SWITCH.
~--------...1
CONNECT A FUSED JUMPER

ACROSS HARNESS CONN FROM
TERM "A" TOTERM"B".
IS "BRAKE" INDICATOR ON?
REPAIR OPEN
IN CKT651.
: REFERTO
:
I SECTION 5E1 1
: (CODE A087). :

CHECK FOR BATTERY VOLTAGE AT PARK BRAKE SWITCH.
DISCONNECT DRL MODULE

CONN C1. CHECK FOR BATTERY
VOLTAGE AT TERM "D" ON
HARNESS CONNECTOR.

BETWEEN DRL
MODULE AND 5228.

TO BRAKE COMBO VALVE.
IF OK, REPLACE BRAKE COMBO
VALVE.
CHECK FOR POOR

CONNECTION AT PARK BRAKE
SWITCH, OR FOR MECHANICAL
INTERFERENCE.
CHECK FOR OPEN IN CKT 1134,

OR FOR POOR CONNECTION
TO DRL MODULE.
CIRCUIT OPERATION
When the Ignition Switch is tQrned to "RUN,"
"BULB TEST" or "START," voltage is applied to the
Instrument Cluster through CKT 39 from Gages
Fuse 9. The ''BRAKE" Indicator receives a ground
through CKT 33 by any one of three components: the
Park Brake Switch, Brake Combo Valve, Electronic
Brake Control Module (EBCM) or the Electronic
Brake/Traction Control Module (EBTCM).
When the Ignition Switch is' turned to "RUN,"
CKT 33 is grounded through the Electronic Brake
Con.trol ModuJe (EBCM) or Electrqnic Brake/;fraction
Control Module (EBTCM), illuminating the "BRAKE"
Indicator for approximately 3 seconds. When th~ Park
Brake is set, the Park Brake Switch closes, grounding
CKT 33 through the Park Brake Switch. For a better
understanding of when the ;B,rake Combo Valve,
Electronic Brake Control Module (EBCM) or the
Electronic B.rake/Traction Control Module (EBTCM)
will ground CKT 33, refer to SECTION 5El.
41 - 5
SA -
44 - 0
ANTILOCK BRAKES {WITHOUT NW9)
HOT AT ALL TIMES
------------------------------,~
rsE;;O;;R- -
I DISTRIBUTION
PAGE 8A-10-3
I
I
GAGES
FUSE 9
10AMP
SEE POWER
DISTRIBUTION
PAGE 8A-lO-l
IGN
(NOTUSED)
FUSE
I BLOCK
--
STOP/HAZARD
FUSE 6
20AMP
L-------.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE BA-11-5
.SORN
39
~--5206
.35PN139
J ,.&
(CHEVY) 013
(PONn AS
INSTRUMENT
~
CLUSTER
~~RU=~-~----1--------~---,
lcLusTER
@"BRAKE"
PAGES8A-81-1, 3
INDICATOR
@"LOW
TRAC"
INDICATOR
~----l ____ J____

(PONn A10
(CHEVY) C10
SOLID
STATE
@"ABSINOP"
INDICATOR
II
cyc1
.8 YEL 1820
1537
A4~C200D
'j"C200A
A9
.8 YEL 1820
.35 TAN/WHT
33
.
.
TO CENTER HIGH
.8YEL
5 2 4 3 - - - -. . .~ MOUNTED STOP LIGHT
820
PAGE 8A-110-1
.8 YEL.820
A16
016
.35 DK BLU
TCC/SHIFT
INTERRUPT
SWITCH
(NORMALLY
. CLOSED)
.8YEL
.s;: ~t~:
.35 DK BLU
TO CRUISE
CONTROL MODULE
~ PAGE8A-34-1
5271 - - -. . .
820
867 ________________________
85.........________....;......;;....__________________________________~B~RA-K~E~--------------------------,
ELECTRONIC,_
f-5228
BRAKE ABS ACTIVE

ABS WARNING
CONTROL LAMP CONTROL LAMP CONTROL
MODULE
SV
SERIAL
(EBCM)
DATA
LINE
SOLID STATE
TO BRAKE
WARNING
PAGE 8A-41-0
.35 TAN/
WHT
33
GROUND
C200D
A5r~
SWITCH
INPUT
Q.
A11
.35 TAN
800
"BRAKE"
INDICATOR
CONTROL AND
MONITOR
B4F __________
.35 TAN/WHT
LEFT FRONT
SOLENOID
CONTROL
81
RIGHT FRONT
SOLENOID
CONTROL
33
.35TANlWHT
--------5273
33
A12
C200A
C200D
SEE DATA LINK

CONNECTOR
PAGE 8A-SO-O
.35TAN
800
5 BLK/WHT
651
BRAKE.-~~----------~
COMBO
NORMALLY
OPEN
VALVE
CLOSED WITH
UNEQUAL
BRAKE
PRESSURE
[j [j
ABS
BRAKE
PRESSURE
VALVE
SOLENOID,
L!.
L--S225
"~~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
.8 BLK,WHT
651
.8BLK,WHT
.8 BLK/WHT
.35T:Nl800
DATA LINK
CONNECTOR
(DLC,
SEE GROUND
DISTRIBUTION
PAGE 8A-14-4
651
651
ABS
BRAKE
PRESSURE
VALVE
SOLENOID,
'!!
WHEEL SPEED
SENSOR,
RIGHT FRONT
SEE POWER
DISTRIBUTION
PAGE 8A102
.5WHT
rsETi>o';E;- -
I DISTRIBUTION
ABSIGN
FUSE 5
SAMP
PAGE 8A101
I
I
I
I
I
I
I
I
I
1 RUST
S RED
102
FUSIBLE
LINKE
.5 BLK
5RED
5 RED
302
302
.SWHT
.35 DK
GRN
.35TAN
.5 BLK
C130
872
833
L---UNDERHOOD
ELECTRICAL
CENTER
.5 ORN
440
.35 PNK
.35 BRN
641
3 RED
1632
5 RED
WHEEL SPEED
SENSOR
LEFT FRONT
1633
1633
5 2 7 2 - - -. .
5 RED 11633
gDA9.
810
BATTERY
INPUT
IGNITION
RUN
INPUT
ABS
ENABLE
RELAY
CONTROL
ABS
SWITCHED
BATTERY
LEFT FRONT
WHEEL SPEED
INPUT
SOLID STATE
~
RIGHT FRONT
WHEEL SPEED
INPUT
REAR
WHEEL SPEED INPUT
~
LO
C200A
C200D
---~,,..----~!"-.. .
____,,______...____!!'.lllii...---~...
C405B
C405C
CZ
----HYDRAULIC
MODULATOR
ASSEMBLY
RIGHT FRONT
MOTOR
LEFT FRONT
MOTOR
rn
IMPORTANT:
TO PROTECT AGAINST INTERFERENCE,
SENSOR WIRES ARE TWISTED
APPROXIMATELY 9 TIMES PER FOOT.
REAR
MOTOR
.5 BLK
.5WHT
8A - 44 - 2 ElECTRICAL DIAGNOSIS

HOT AT ALL TIMES
------------------------~-~--,~
rsE;;O;;E;- -
I DISTRIBUTION
PAGE SA-10-3
I
I
GAGES
FUSE 9
10AMP
SEE POWER
DISTRIBUTION
PAGE SAl0-1
IGN
(NOTUSED)
STOP/HAZARD
FUSE 6
20AMP
FUSE
IBLOCK
-
L--------
TO CRUISE
CONTROL MODULE
PAGE SA-34-1
TO BRAKE
WARNING
PAGE 8A-41-0
.8 LT BLU
1284
1289
3 ORN
BRAKE.-------COMBO
NORMALLY
VALVE
OPEN
CLOSED WITH
UNEQUAL
BRAKE
PRESSURE
.8 BLK.WHT
5 BLKI
WHT
651
rn rn
A
ABS
g_
.8 BLK,WHT
651
651
SEE GROUND
DISTRIBUTION
PAGE SA-14-4
BRAKE
PRESSURE
VALVE
SOLENOIO,
651
AIIS
~~.........."1""_ _ _"""_.-....,..!""'"---,"'"---"""~ABS
BRAKE
PRES SU Rf
VALVE
SOLENOID,
R_F_
1285
MOTOR
PACK
LEFT FRONT
MOTOR
RIGHT FRONT
MOTOR
REAR
MOTOR
HYDRAULIC
MODULATOR
ASSEMBLY
SEE POWER
DISTRIBUTION
PAGE SA-10-2
E=I
- - 7ee-;'o~R - - - - - - - ,
rs;-P~E;- DISTRIBUTION
PAGE SA-10-1
DISTRIBUTION
PAGE SA-10-3
I
I
I
I
I.
I
I
I
I
1 RUST
I
I
FUSIBLE
LINKE
5 RED
FUSIBLE
LINK B
r--_,....
1.021111111. . . .111111115REDIIIIIII. . . . . ., ,
302
5 RED
302
., UNDERHOOD
ELECTRICAL
CENTER
,I
.35 BRNl641
GS
ABS~~"'~~~..,..~-.
RELAY
.35 BRN
1
I
I
I
30
641
DATA LINK
CONNECTOR (DLC)
. .~.J~
L----
5225--~
5 1 8 0 - - -. .
. 5 ORN
440
.35 PNK
.35 BRN
1632
641
.35 TAN
3 RED
5 RED
.35 PPL
1633
800
5 RED/
BLK
1633
SEE DATA LINK

CONNECTOR
PAGE 8A-SO-O
563
C2000
C200A
A1~
-t
5272 . . . . . . . . ..
5 RED
.35 TAN
5RED/
BUC
1633
..,,,
562
800
563
r--~~~-~~;-~:-~:-------~--~-------- -----*!'---,I
I
810
Bll
-----_B~
Q.
A11
5V
INPUT
RUN
INPUT
I
\
ENABLE
RELAY
CONTROL
SWITCHED
BATTERY
ENABLE
RELAY
CONTROL
SWITCHED
BATTERY
- - - - - - .SERIAL
DATA
SOLID STATE
\
\
TCS ADJUSTER
ASSEMBLY MOTOR
LEFT REAR
TCS MOTOR
RIGHT REAR
TCS MOTOR
TRACTION
CONTROL
ACTIVE
~ ~ ~
HI
1.- -
LO
HI
LO
HI
LO
- - ~ - - - : : ~ -~=:"' - : : : : - ~-"":!' -
_ _ ..., -
RECEIVED
THROTTLE
POSITION
LINE
SPARK
RETARD
REQUEST
--:1:-r- --=-- - -:y;
-A;6-
I
I
I
I
I
I
I
~
T:-----------T.
PlOO
3WHT
JLT BLU
560
564
3 LTGRN
.35LTBLU
P,100
AS
832 .35TAN/BLK~464
566
D I (100
3 GRY
3 DK BLU
561
565
3 DK GRN
"~"~'ci
~C2~0- - - - - - -fC2:~10
567
.35LT BL~
832
.35 TAN/BLK
464
11
~
12
~
POWERTRAINr- -- --CONTROL TCS
EBTCM TP
MODULE (PCM) ACTIVE
SENSOR
SIGNAL
,-
ADJUSTER~
- - - ...
LEFT REAR
MOTOR
A2A C200A
C200D
.350RN/BL~J:~
RIGHT REAR
MOTOR
I
I
.3~ ORNIBLK
463
23
A
---,
TCS
SPARK
RETARD
REQUEST
~I
L--~-----------.J
LT1
A RED
B - BLACK (BLK)
C - CLEAR (CLR)
D - BLUE (BLU)
32WAY
l2WAY
32WAY
32WAY
SEE PAGE BA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
BA - 44 - 4 ELECTRICAL DIAGNOSIS
".8 BRN
__ ....
141
SEE FUSE
BLOCK DETAILS
PAGE8A-116
~ ~ ILLUMINATION
\.i;,I ~ LAMPS
WHTr
CHEVY
5215--i.
.5 BLK,1451
WHT
1572
...-----~
SEE GROUND
DISJ:RIBUTION
P110
TO POWERTRAIN
CONTROL MODULE (PCM)
PAGE 8A-39-0
(PONTIAC ONL YI
PAJGE8A-141
A 13
.8 BLK/1451
WHT
.35PPUWHT
1572
r - - - - - - - - - - - -
I
I
SOLID STA TE
: : _LC:_~_
----
-Tes eNAeU -
815
- - - - - - - - -rCSINOlcAToR - - ,
SWITCH SIGNAL
LEFTFRONT
WHEEL SPEED INPUT
RIGHTFRONT
WHEEL SPEED INPUT
I!_:__-"-~.:- !!!. .:. -------;3 -- ~~~

3
_ TAN
35
833
ELECTRONIC
BRAKE/
TRACTION
CONTROL
MODULE
(EBTCM)
C200D
C200A
1571
.35 BRN/WHT
A15
LAMP CONTROL
LEFT REAR
WHEEL SPEED INPUT
- ..: .35R:~.
L~
RIGHT REAR
WHEEL SPEED INPUT
I
I
~ - !!!_:.. - - :.. .};_0_ :_ _H'.._'_ j
8~~-Ai-----~;J~T
8
GRN
1572
C200D
C200B
C4
.35 BRN/WHl1571
5109--
--.J103
.35 PPL/WHT
'~-----.v~-----_,,1
C210
-
.S!
TO INSTRUMENT
CLUSTER
PAGE BA-44-2
A
TRACTION - - - - - - - - - - - - .
CONTROL
SWITCH
.3SBL~51
TO INTERIOR
~ 3GRY
5
LIGHTS DIMMING
PAGE 8A117-1
8
.35 BLK
A10
---
884
1Q
88~--A
.35 BRN
C200A
C200D
--
Al 4
.35WHT
884
A15
----
882
C200A
C200D
-882
[I] IMPORTANT:
TO PROTECT AGAINST
INTERFERENCE, SENSOR
WIRES ARE TWISTED
APPROXIMATELY
9 TIMES PER FOOT.
WHEEL
SPEED
SENSOR,
RIGHT
FRONT
WHEEL
SPEED
SENSOR,
LEFT REAR
WHEEL
SPEED
SENSOR,
RIGHTREAR
C1
C2
12110626
12110113
8-WA Y F METRI-PACK 280 FLX LK
LTGRY
DK RED

OR
CONTROL MODULE (EBTCM)

OR
C3 (WITH NW9)
12129088
8-WA Y F METRlPACK 280 SERIES FLX LK
.BLK.
ELEC:TRONIC BRAKE/TRACTION
CONTROL MODULE(EBTCM)

CAVITY
DESCRIPTION
PAGE
WIRE COLOR
CKT
BLK
1280
LEFT FRONT ABS MOTOR FEED
8A-44-1, 2
PNK
1281
LEFT FRONT ABS MOTOR RETURN
8A-441,2
DKGRN
1284
REAR ABS MOTOR FEED
8A-441,2
RED
1633
ABS RELAY OUTPUT- SWITCHED TO BATTERY
8A-441,3
BLKIWHT
651
GROUND
8A-440,2
ORN
1285
REAR ABS MOTOR RETURN
BA-44-1,2
PPL
1282
RIGHT FRONT ABS MOTOR FEED
8A-44-1,2
BLK
1283
RIGHT FRONT ABS MOTOR RETURN
8A-44-1,2
C1

CAVITY
WIRE(:OLOR
CKT
A1
BLK
884
LEFT REAR WHEEL SPEED SENSOR SIGNAL (WITH NW9)
SA-44-4
A2
RED
885
LEFT REAR WHEEL SPEED SEN~OR RETURN (WITH NW9)
SA-44-4
Al
TAN
833
RIGHT FRONT WHEEL SPEED SENSOR RETURN
SA-44-1,4
A4
DKGRN
872
RIGHT FRONT WHEEL PEED SENSOR SIGNAL
SA-44-1.4
AS
AS
WHT
WHT
883
883
REAR WHEEL SPEED SENSOR RETURN

RIGHT REAR WHEEL SPEED SENSOR RETURN (WITH NVli9)
SA-44-1
SA-44-4
A6
A6
BRN
BRN
882
882
REAR WHEEL SPEED SENSOR SIGNAL

RIGHT REAR WHEEL SPEED SENSOR SIGNAL (WITH NW9)
SA-44-1
SA-44-4
A7
YEL
873
LEFT FRONT WHEEL SPEED SENSOR RETURN
SA-44-1,4
AS
LTBLU
830
LEFT FRONT WHEEL SPEED SENSOR SIGNAL
SA-44-1,4
A9
LTBLU
1289
RIGHT FRONT SOLENOID FEED
SA-44-0,2
A11
TAN
800
SERIAL DATA SIGNAL
SA-50-0
A14
TAN/BLK
464
THROTTLE POSITION SENSOR SIGNAL (WITH NW9)
SA-44-3
A15
BRN/WHT
1571
TRACTION CONTROL SYSTEM ENABLE SWITCH SIGNAL (WITH NW9)
SA-44-4
A16
LTBLU
832
TRACTION CONTROL ACTIVE (WITH NW9)
SA-44-3
81
DKGRN
1288
LEFT FRONT SOLENOID FEED
SA-44-0,2
82
LTGRN
867
ABS WARNING INPUT TO INSTRUMENT CLUSTER (SOLID STA TE)
SA-440, 2
83
PNK
1632
ABS ENABLE FEED TO RELAY
SA-44-1,3
84
TANIWHT
33
"BRAKE" INDICATOR LAMP (SWITCHED GROUND)
SA-44-0,2
85
DKBLU
1537
"LOW TRAC" INDICATOR LAMP CONTROL
SA-44-0,2
810
ORN
440
POWER FEED FROM ABS BAT FUSE #1
SA-44-1,3
811
BRN
641
POWER FEED FROM ABS IGN FUSE #5
SA-44-1,3
812
YEL
820
SA-44-0,2
814
ORN/BLK
463
SPARK RETARD REQUEST(WITH NW9)
BA-44-3
815
PPL/WHT
1572
"ASR" (CHEVY) OR "TCSOFF" (PONT) INDICATOR LAMP CONTROL(WITH NW9)
BA-44-2,4
PAGE
DESCRIPTION
C2
C3 (WITH NW9)
;,
LTGRN
566
RIGHT REAR TCS MOTOR FEED
SA-44-3
PPL
562
TCS ENABLE FEED TO RELAY
SA-443
RED/BLK
563
TCS RELAY OUTPUT - SWITCHED TO BATTERY
SA-443
GRY
561
THROTTLE RELAXER MOTOR RETURN
SA-443
WHT
560
THROTTLE RELAXER MOTOR FEED
SA-44-3
LTBLU
564
LEFT REARTCS MOTOR FEED
F
G
H
DKBLU
565
LEFT REAR TCS MOTOR RETURN
DKGRN
567
RIGHT REAR TCS MOTOR RETURN
SA-44-3
-
--~
--
----
SA--443SA-44-3
---~ 1--
COMPONENT
Solenoid, LF ........... .
Solenoid, RF .......... .
ABS Motor Pack ........ .
Adjuster Assembly ...... .
Brake Switch Assembly ...
Data Link Conn (DLC) ....
LOCATION
201-PG
Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 39
FIG.
CONN
68

68
68
LH top center of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
75
Part of Hydraulic Modulator Assembly, inward side
39
68
Mounted to 1/P Tie Bar, below and right of
Steering Column ............................................... .
202-19
202-11

Module (EBCM) . . . . . . . . Under 1/P, next to LH hinge pillar,just above
Pass Thru Grommet .............................. 8 . . . . 14 . . 202-13
202-13
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14
Fusible Links ........... . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
19
Hydraulic Modulator
Assembly . . . . . . . . . . . . . . Front left of Engine Compartment . . . . . . . . . . . . . . . . . . 39
68
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
202-23
Instrument Cluster . . . . . . . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-23
202-24
79
Control Switch . . . . . . . . . Mounted in center console behind shifter . . . . . . . . . . . . . 42
202-26
(PCM) (VS VIN P) . . . . . . In Engine Compartment, rearward of RH Shock Tower
19
35
202-25
19
35
Traction Control Motor
Pack . . . . . . . . . . . . . . . . . . . Mounted to left front frame rail, below Hydraulic
202-28
70
Modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
78
Traction Control Switch . . Left side of upper console . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
36
202-28
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel Speed Sensor,
Left Front . . . . . . . . . . . . . . Middle ofleft front steering knuckle . . . . . . . . . . . . . . . . . 25
47
Wheel Speed Sensor,
Left Rear . . . . . . . . . . . . . . Mounted to rear backing plate of wheel disc . . . . . . . . . . 28
55
38
Wheel Speed Sensor, Rear . Top of Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel Speed Sensor,
47
Right Front . . . . . . . . . . . . Middle of right front steering knuckle . . . . . . . . . . . . . . . 25
Wheel Speed Sensor,
55
Right Rear . . . . . . . . . . . . . Mounted to rear backing plate of wheel disc . . . . . . . . . . 28
ClOO (10 cavities) . . . . . . . . Engine to Forward Lamp Harn, behindUi wheelhouse,
202-0
28
attached to PCM bracket ..... , . . . . . . . . . . . . . . . . . . . . 15
Cl20 (2 cavities) . . . . . . . . . LH Wheel Speed Sensor Pigtail, mounted to LH
Frame Rail
BA -
44 - 8
ANTILOCK BRAKES/TRACTION CONTROL (NW9}

COMPONENT
C130 (2 cavities)
C200A (17 cavities)
C200B (18 cavities)
C200D (48 cavities)
C210 (4 cavities) ........ .
C220 (10 cavities) ....... .
C405B (10 cavities) ..... .
C405C (4 cavities) ...... .
GlOl ................... .
G103 (LTl) ............. .
PlOO
PllO
8109 (LTl) ............. .
Slll
8175
8180
8206
8207
8215
8225
8228
8243
8271
8272
8273
8278
LOCATION
201-PG
RH Wheel Speed Sensor Pigtail, mounted to RH
Frame Rail
Steering Column ................................ . 25
Under RH side ofl/P, behind RH kick panel ......... . 20
Under RH side ofl/P, behind kick panel ............. . 20
Pass Thru Panel ................................ . 5
Speed Sensor (ABS) ............................. . 5
Top of RH Shock Tower (3 rings, 5 wires) ............ . 10
(1 ring, 1 wire) .................................. . 40
Compartment ................................... . 19
Compartment ................................... . 19
PCM breakout
Assembly breakout
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
breakout
1/P Harn, approx 14 cm from Fuel Pump Relay breakout 7
inboard of PlOO .................................. 8
inboard of P 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
inboard of PlOO . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Forward Lamp Harn, approx 9 cm from EBCM breakout
SYSTEM DIAGNOSIS
Refer to SECTION 5El or 5E2 for Diagnosis.
FIG.
CONN
49
202-2
49
202-2
49
37
37
202-2
202-19
202-6
202-8
9
19
202-8
72
36
35
68
68
13
14
14
14
BLANK
SA- 47 - 0 ELECTRICAL DIAGNOSIS
FUSE
BLOCK
GAGES
FUSE9
10AMP
AIR BAG
FUSE 1
15AMP
IGN
(NOT USED)
.__
.8 PNK
~~~~----~------~
39
.35 PNK
39
.8 PPL
806
1
I
__.
.......................,,
5206
SEE FUSE
BLOCK DETAILS
PAGE 8A11-5
._
---------------~~
- - - SEE POWER
DISTRIBUTION
PAGE 8A103
.8 YEL
~139
5204
.8 VEL
1139
.8 YEL
.)
1139
1139
810
82
A9
DIAGNOSTlc-----------------------------------ENERGV RESERVE
CRANK
REDUNDANT
SV
IGNITION 1
IGNITION 1
MODULE (DERM)
INPUT
INDICATOR
IGN1
1.t:. ~
SERIAL
DATA
"" I
SIR INDICATOR
"Low (MONITOR
AND CONTROL)
B1
(CHEVY) 013
(PONT) AS
rJ----,
I
I
Ir- - ..., I
II
INSTRUMENT
CLUSTER
.8 BRN
358
,------------,
IMPORTANT:
WHENDERM
CONNECTOR IS
DISCONNECTED, A
SHORTING BAR IS
CLOSED SHORTING
TERMINAL "A1"
TO TERMINAL "B1"
ILLUMINATING
THE INDICATOR.
.35
BLK/
WHT
.8 BLK
650
3 BLK
650
IE
I I ____.I...II
._.,..
SEE DATA
LINK CONNECTOR
PAGE 8A-500
rn
REDUNDANT
INDICATOR
GROUND
A2
rAuolo- ,
ALARM
MODULE
SHORTING
BAR
L~----'
--.--~
SEATBELT
SWITCH
SIGNAL
811
,. . ""
I ~"AIRBAG" I
I ~INDICATOR I
I y
I
(PONn A7
(CHEVY) C16
SOLID STATE
CONVENIENCE
CENTER
.35BLKi'NHT
~~
.8 TAN
800
- - - - .5225
.35T~Ni8:DATA LINK
CONNECTOR (DLC)
SEE GROUND
DISTRIBUTION
PAGE 8A-14-8
...__
...-- -
3 BLK
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
Jiw.~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
5216
650
SEE GROUND
DISTRIBUTION
PAGE 8A-14-7

47 - 1
.SYEL
1139
.8 PNK
1401
8
----.....,pi,,------~----------T""'""------,ARMING
.8 YEL/BLK
SENSOR,
DUALPOLE
CLOSED WITH
RAPID LOW
LEVEL VELOCITY
CHANGES
236
2490
.8 WHT
347
.8 WHTi
BLK
1403
.8 LT GRN, WHT
1837
A3
(36 VLR) 36 VOLT
LOOP RESERVE
PASSENGER
36VLR
DRIVER
36VLR
DRIVER
SOURCE
SENSE
PASSENGER
SOURCE
SENSE
SOLID STATE
PASSENGER
SIDE
"HIGH"
Y..n,
A7
.8 WHT/BLK . : : . . . . . .
SHORTING
BAR
.8WHT
347
SIR COIL ASSEMBLY
.8 BlK/
WHT
1751
)
SHORTl~J
BAJ
I
I
I
I
I
I
I
I
J.~.
(""" 8: t="
R
TO PREVENT ACCIDENTAL
DEPLOYMENT, SHORTING BARS CLOSE
TO SHORT CONNECTORS WHEN
CONNECTORS ARE SEPARATED .
.8 DK GRN
.8 DK GRN
348
.8 BLK/
WHT
1751
- - - . . - - . . . - - - -.. DISCRIMINATING
SENSOR, PASSENGER
COl'iPARTMENT ...
.8 BLK/
WHT
1751
CLOSED WITH
DEPLOYMENT
LEVEL VELOCITY
CHANGES
- - - - - . - - - - . DISCRIMINATING
SENSOR, FORWARD
CLOSED WITH
DEPLOYMENT
8450
LEVEL VELOCITY
Q
CHANGES
SEE GROUND
DISTRIBUTION
PAGE 8A14-4
12092689
YEL
DIAGNOSTIC ENERGY RESERVE MODULE (DERM)

CAVITY
WIRE COLOR
CKT
A1
BLKJWHT
1751
GROUND
SA-14-4
A2
BLK
650
GROUND
8A-14-8, 9
A3
PNK
1401
DUAL ARMING SENSOR FEED- PASSENGER- 36 VOLT
SA-47-1
A4
YEL/BLK
236
DUAL ARMING SENSOR FEED- DRIVER- 36 VOLT
8A-47-1
AS
LTGRN
1400
DUAL ARMING SENSOR SIGNAL - DRIVER
SA-47-1
A6
LTGRN/WHT
1837
DUAL ARMING SENSOR SIGNAL - PASSENGER
SA-47-1
A7
WHT/BLK
1403
INFLATOR FEED- PASSENGER
8A-47-1
A9
YEL
1139
POWER FEED FROM AIR BAG FUSE #1
SA-47-0, 1
A10
YEL
1139
8A-47-0, 1
A12
BLKJWHT
1751
GROUND
S'A-14-4
81
BRN
358
AIR BAG INDICATOR LAMP FEED
8A-47-0
82
PNK
39
POWER FEED FROM GAGES FUSE #9
SA-11-5
BS
BLKJWHT
238
SEATBELT SWITCH SIGNAL
SA-47-0
87
DKGRN
348
SIR INFLA TOR OUTPUT
8A-47-1
BS
DKGRN
348
SIR INFLA TOR OUTPUT
SA-47-1
89
WHT
347
INFLATOR FEED - DRIVER
SA-47-1
810
PPL
806
POWER FEED FROM CRANK FUSE #16
SA-11-9
811
TAN
800
SERIAL DATA SIGNAL
SA-50-0
DESCRIPTION
PAGE
12092761
YEL
ARMING SENSOR, DUAL POLE
201-PG
FIG.
CONN
COMPONENT
LOCATION
Arming Sensor, Dual Pole

Convenience Center ..... .
43 . . . 81
202-19
Mounted to Floor Tunnel Bracket, under console
Left of Steering Column, mounted to bottom of
1/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 15
202-20
Steering Column ..................................... , . . . . . . . . . . 202-11

202-12
Module (DERM) . . . . . . . . Snapped in bracket, behind RH side of 1/P Compartment 8 . . . . 15
Forward . . . . . . . . . . . . . . . Mounted to center of front end Tie Bar, near hood latch
19 . . . 36
Passenger Compartment
Mounted to upper dash, just right of Steering Column
Support Bracket . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . 38
202-23
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8
15
Inflator Module, Driver .. . Mounted on Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 3
Inflator Module, Passenger Mounted on right side of 1/P
Instrument Cluster ...... . LH side of 1/P ................................................... . 202-23
Seat Belt Switch ........ . Part of Driver's Seat Buckle Assembly . . . . . . . . . . . . . . . 43 . . . 81
SIR Coil Assembly ...... . Top of Steering Column ........................... . 3, 34 . 5,51
C200B (18 cavities)
202-2
49
C200D (48 cavities)
202-2
49
Steering Column ................................ . 25
19
Top of RH Shock Tower (3 rings, 5 wires) ............ . 10
0101
0200
behind kick panel (2 rings, 2 wires) ............... . 9 .... 16
PlOO
Compartment ................................... . 19 ... 36
1/P Harn, approx 10 cm from Steering Column breakout
8204
8206
[IP Harn, approx 18 cm from Convenience Center
breakout
1/P Harn, approx 5 cm from Convenience Center (Pont)
8216
8217
UP Harn, approx 23 cm before DLC breakout
8225
SYSTEM DIAGNOSIS
Refer to SECTION 9J-A for diagnosis.
SA -
50 ..,o

DATA
LINK
CONNECTOR
(DLC,
,m,w,r, ----------- --.~=::. ~ ------------------- "'~'
------~S~:~1-14S5
WHT
800
~----,
WITHOUT
BOSE (U82)
WITH
BOSE (U821
5215----,
B
.5 BLK/WHT
I
I
I
I
.5 BLK/WHTt51
(210
451
I._ &
J..
.:.J}:
5V
SERIAL
--~~DATA
LINE
I_
.3S BLKI
.1455
WHT
I
I
g.
r---,
A
I PROGRAM I
I
.STAN
.35 TAN
.35WHTiBLK
.35 TAN
800
I. -
800
448
A12
(2000
C200A
IMPORTANT:
ON V6 VIN SONLY, CKT 448 TO THE

DLC JS PRESENT BUT NOT USED ON
THE 1/P HARNESS, BUT IS NOT PRESENT
ON THE ENGINE HARNESS.
rr----------,
Q ______ - - -
(VS VIN Pl 20
POWERTRAIN
CONTROL
MODULE
(PCMI
I
''~I
~ I w
5v
OUTPUT,FIELD
SERVICE
ENABLE
I
I
.35 TAN
I
I
I
LINE
L-------~----~
Lf1
A
B
C
D
~CM CONNECTOR IDENTIFICATION
L32_
RED
BLACK (BLK)
CLEAR (CLRI
BLUE .(BLUI
32WAY
32WAY
32WAV
32WAV
~CM CONNECTOR IDENTIFICATION

\l!ltTH.COLORED TeA.s_.__ _
A. CLEAR (CLR)
B . BlACK (BLKI
-C BLUE (BLU)
SEE PAGE 8A30
FOR MEASURING
AND HANDLING
PROCEDURES
SEE PAGE 8A30

FOR PROPER
HANDLING
PROCEDURES
32 WAY
32 WAY
32 WAY
800
I
I
II
HffiAL
DATA
A11
ELECTRONIC r
BRAKE CONTROL
~
MODULE
6~BCM)
WITH NW9
I
I
II'
ELECTRONIC
BRAKE/
TRACTION
CONTROL
MODULE
(EBTCMI
Q
-
I
I
I
-1
KEYLESS
ENTRY
RECEIVER
- - -800
- - - - - ~ 5225
I
I
--~
.
'~--------.v~--------/
B11v
451
I
I
I
I
I
I
____ ....
....
T
.8 BLK/WHT
DIAGNOSTIC
ENERGY RESERVE
MODULE (DERMI
..-------.
~~
-V 5
I
I
SERIAL
1'
DATA
LINE
I
I
I
L_-:_
___ ..J
...
c:;3l ct;] c;u:fil EtrU:tiJ
50 - 1
12020043
~~c:2J~&ct1c2l~

BLK
DATA LINK CONNECTOR (DLC)

CAVITY
WIRE COLOR
CKT
BLK/WHT
451
GROUND
8A-14-1,2,3
WHT/BLK
448
DIAGNOSTIC REQUEST, PCM
8A-20-0,
8A-21-0
BLK/WHT
1455
PROGRAM INPUT, KEYLESS ENTRY RECEIVER
8A-132-1
TAN
800
SERIAL DATA LINE, DIAGNOSTIC ENERGY RESERVE MODULE (DERM),

ELECTRONIC BRAKE CONTROL MODULE (EBCM), ELECTRONIC BRAKE/TRACTION
CONTROL MODULE (EBTCM) AND PCM
.
8A-50-0
DESCRIPTION
PAGE
COMPONENT
LOCATION
Data Link Conn (DLC)
Mounted to 1/P Tie Bar, below and right of

Steering Co 1umn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201-PG

Module (DERM) ....... . Snapped in bracket, behind RH side of 1/P Compartment
Keyless Entry Receiver ... Behind RH side kick panel, in molded pocket ........ .
(PCM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower
(PCM) (VS VIN P)
C200A (17 cavities)
C200D (48 cavities)
Steering Column ................................ .
C210 (4 cavities) ........ . Under RH side ofl/P, behind RH k1ck panel ......... .
C240 (6 cavities) ........ . Under RH side ofl/P, behind kick panel ............. .
C285 (1 cavity) ......... . Under RH side ofl/P, behind kick panel ............. .
G103 (LTl) ............. . RH side of Engine Block,just above Starter
(1 ring, 1 wire) .................................. .
G104 (L32)
of Engine, 1 stud in head, 1 stud in Intake Manifold ..
PllO ................... . Right side in dash panel, Engine to Passenger
Compartment ................................... .
S109 (LTl)
PCM breakout
SllO (L32)
breakout
.
S215
S225
FIG.
CONN
202-11
8 ....
15 ..
202-12
8 ....
14 ..
202-13
8 .... 14
40
71
202-13
202-23
19
35
202-25
19
35
202-26
25
49
202-2
25
20
20
20
20
20
49
37
37
37
37
37
202-2
202-19
202-6
202-7
202-19
40
72
29
56
19
35
BA -
50 - 2

SERIAL DATA LINE DIAGNOSIS
ATTEMPT TO ESTABLISH COMMUNICATION WITH THE SAME SYSTEM ON A DIFFERENT VEHICLE.

CAN COMMUNICATION BE ESTABLISHED?
IGNITION SWITCH "OFF."

CHECK FOR PROPER CONNECTION OF SCAN TOOL TO DATA LINK CONNECTOR.
IS THE CONNECTION GOOD?
IGNITION SWITCH "ON."

ATTEMPT TO ESTABLISH COMMUNICATION WITH THE OTHER TWO
MODULES CONNECTED TO SERIAL DATA LINE.
CAN COMMUNICATION BE ESTABLISHED?
REPAIR DATA LINK CONNECTOR

TERMINAL "M" OR RECONNECT
SCAN TOOL, AS NECESSARY.

DISCONNECT ALL MODULES CONNECTED TO "SERIAL DATA
LINE," DATA LINK CONNECTOR TERMINAL "M".
.
MEASURE RESISTANCE ON DATA LINK CONNECTOR FROM
TERMINAL "M" TO TERMINAL "A" (GROUND).
DOES J 39200 DISPLAY "OL" (INFINITE)?
r-
IGNITION SWITCH "ON."

MEASURE VOLTAGE ON DATA LINK
CONNECTOR FROM TERMINAL "M"
TO TERMINAL "A" (GROUND).
IS ANY VOLTAGE MEASURED?

RECONNECT ONE OF THE MODULES WHICH IS DISCONNECTED.
IGNITION SWITCH "ON." ATTEMPT TO ESTABLISH COMMUNICATION;
WHEN COMMUNICATION CANNOT BE ESTABLISHED REPLACE THE MOST
RECENTLY CONNECTED MODULE.
REPEAT THIS PROCESS UNTIL THE M~LFUNCTIQlll_llll_<i MODULE IS ISOLA TED.
REPAIR SHORT FROM

"SERIAL DATA LINE"
TO GROUND.
-----------------------,
: SCAN TOOL MAY BE MALFUNCTIONING, :

I REFER TO SCAN TOOL INSTRUCTION
I
I
I
I~
MANUAL.
------_________________ J I

DISCONNECT MODULE WHICH WILL NOT
COMMUNICATE AND CH ECK FOR PROPER
CONNECTION AT "SERIAL DATA LINE"
TERMINAL(S). REPAIR AS NECESSARY.
IF OK, THEN MEASURE RESISTANCE FROM
DATA LINK CONNECTOR TERMINAL "M"
TO MODULE HARNESS CONNECTOR
"SERIAL DATA LINE" TERMINAL.
IS RESISTANCE 5.0 Q OR LESS?
REPAIR OPEN IN
"SERIAL DATA
LINE" CIRCUIT
FROMS225 TO
MODULE.
CHECK FOR POWER

AND GROUND TO
THE MODULE.
IF OK, THEN
REPLACE MODULE.

REPAIR SHORT FROM "SERIAL
DATA LINE" TO VOLTAGE.
BLANK
HEATER (C41)
HOTINRUN
r-
1
I
I
..ii
HOT AT ALL TIMES
"""IIIP
FUSE
I BLOCK
HVAC
FUSE3
FUSIBLE
LINK A
1 RUST
1--
__ ....
ZSAMP
3 BRN
SEE FUSE
BLOCK DETAILS
PAGE 8A116
I
I
241
1-
.35BRN
<lllilq..- - - - . S248
241
3 BRN
*BLOWER SWITCH HAS MAKE
BEFORE BREAK CONTACTS.
241
r----------------------c ----~~
I
g
,-CONTROL
ASSEMBLY
VENT
I
I
SELECTOR
OFF ~ T C H
DEF
3 RED
202
;:::::::J::-:-],,____l ____ J
D
B
1 ORN
52
2LTGRN
1 LTBLU
72
I
A1
(1
(2
A2
BLOWER
RESISTOR
.35 BLK
650
3 DK BLU
101
,..----5217
1
SEE GROUND
DISTRIBUTION
....____
,....- -
__
PAGESBA-14-7,8.9
T.._
3BLKl650
3BLK
......_
5216
650
~200
3 PPL
65
COMPONENT
LOCATION
201-PG
FIG.
Blower Motor . . . . . . . . . . . . Under low~; RH side of 1/P, mounted in.UV AC Module

20 . . . 37
Blower Resistor . . . . . . . . . . In HVAC Module,,forward and left ofTertiperature'
Control Cable Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
Blower Switch . . . . . . . . . . . Part of HVAC Control Assembly ............. .'. . . . . . 21
Fusible Links . . . . . . . . . . . . Above.RH Shock Tower ........................... . 10
19
(HV AC) Control Assembly Center of 1/P ..... : ...... : ........................ . 21
40 ..
High Blower Relay . . . . . . . Under 1/P, above left side ofifloor tunnel ............ . 42
77
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................... 8 .... 15
Selector Switch . . . . . . . . . . Part of HV AC Control Assembly" .. ,:' ............... . 21
39
C200B (18 cavities)
Part of Forward Lamp Harn, bet\veen LH kick panel
and Steering Column ... ~ ........................ . 25
49
C200D (48 cavities)
Steering Column ................................ . 25
49
G200 . . . . . . . . . . . . . . . . . . . . Near base of LH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (2 rings,,2 wires) ............... . 9
16
G201 . . . . . . . . . . . . . . . . . . . . Near base of RH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (1 ring, 1 wire) .................. . 9
16
PlOO
Compartment ........... ., ......................... . 19 ... 36
8216
8217
8248
SYSTEM DIAGNOSIS
For Diagnosis, refer to "HV AC Blower Controls

(C60)," page 8A-63-0.
CONN
202-20
202-22
202-23
202-2
202-2
8A-61 0 ELECTRICAL DIAGNOSIS
DEFOGGER (CHEVY)
SEE INTERIOR LIGHTS
DIMMING PAGE BA-117-0
-----,1/P
I"'
I
I
I
SEE POWER
DISTRIBUTION
PAGE BA-10-1
1/PDIMMER
FUSE 13
5AMP
I FUSE
BLOCK
25AMP
----~
...
.5GRY
SEE INTERIOR
LIGHTS
DIMMING
PAGE BA-117-1
,-
HVAC
FUSE 3
--5224
.35GRY
5 ORN
TO DRIVER
POWER SEAT SWITCH
PAGE BA-140-0
3 ORN
3 BRN
1240
241
5248
S252
1240
1240
SORN
.35 BRN
241
TOHVAC
SELECTOR SWITCH
PAGES BA-63-0,
BA-64-0, 1
A4 ,
c', '
E' \
REAR
DEFOGGER
SWITCHfTIMER
, I'
~~
'
ILLIJMINATION@
LAMP
ON~
INDICATOR
BATI
---
ON/OFF
INPUT
SQUD STATE TIMER
DEFOG
ENABLE
RELAY
GROUND
(UD
'I,
5P~LYi93
.35 BLBKJ.so
5315.
BLK
293
3 PPL
lI
((
SEE GROUND
DISTRIBUTION
PAGES BA-14-7, 8. 9
293
.....__
,...- -
-5217
3 BLK
CONVERTIBLE
C320
ON
... _,..
SWITCH
DEFOG
ON INPUT
OFF
650
L---S216
P300
REAR
DEFOGGER
GRID
~I
(330
COUPE
750
....:....2200
"
---,I
I
I
3 BLK 1650
3 BLK
I
I
"/
\
I
COUPE
~.
I
CONVERTIBLE
3 BLK
1150
., ,~
3 BL K
.....-.J320
...............
s42 0
.S BLK
1150
1150
SEE GROUND
DISTRIBUTION
PAGE SA-14- 11
DEFOGGER (PONTIAC)
I
I._
'-tl/P
FUSE
BLOCK
HVAC
FUSE 3
is AMP
___ _
SORN
TO DRIVER POWER
,____ ...
SEE POWER
DISTRIBUTION
PAGESA-10-1
3 BRN
1240
241
3 ORN
SEAT SWITCH
11111-..- - - S2S2
PAGES SA-140-0, ' 1111 1240
SA-141-0
5 ORN
5248-------
'i"
1240
.35 BRN
241
TOHVAC
SELECTOR SWITCH
PAGES 8A-63-0,
8A-64-0, 1
----------,
HVAcr------------r--------------
CONTROL
ASSEMBLY
---
ORN
1240
PNK
I
41'"\
IGN
241
V\~
REAR
DEFOGGER
TIMER/
RELAY
ON/OFF
INPUT
REAR DEFOGGER
SWITCH
--~~~..---~~~~--~~~.....iiiiiiiiiiiiiiiiiiil
GRV
292
ON
INDICATOR
SOLID STATE
GROUND
PNK
DEFOG
ENABLE
BRN
1r~
PPL
293
BLK 650
293
:~:
L----------- --------------------------~
J. ~
S P~L'r:ii
D
.35 BLK
5315.
3 PPL
~-----,
CONVERTIBLE
SEE GROUND
DISTRIBUTION
PAGESSA-14-7,8,9
293
.,jlri----(~1,.---,
1
I
'I
' .
BLK
3PPL
293
~!
-III(..,
IIIP300
COUPE
C330
REAR
DEFOGGER
~
~-
I
I
I
I
I
I
I
\
\
.\
COUPE
>-ml<
CONVER
TIBLE
\
\
650
5216
650
3~
75
3 BLK
,,
I
........_
....- -
3BLK
1150
' G200
--..,~
S
~
3 BLK
,,,,,.
_Jl_Ji320
.SBLK
1150
1150
...
SEE GROUND
DISTRIBUTION
PAGE8A1411
BA .. 61
-2
DEFOGGER
,,
HVAC CONTROL ASSEMBLY.

CONNECTOR DESCRIPTIONS
PAGE
C1
Blower Switch
5-Way Connector'
BA-63-0
C2
Selector Switch
3-Way Connector
BA-63-0, BA-64-0
C3
Illumination Lamps Jumper
2-Way Connector
BA-117-1
PONTIAC ONLY
C4
HVAC Control Assembly to 1/P Harness
4-Way Connector
BA-61-1
cs
Four 1-Way Connectors
BA-61-1
C6
4-Way Connector
C4
;\
BA-61-1
IA IB Ic ID IE I
12015664
12059296
4-W~ Y F METRI-PACK 630 S~RIES
.,
BLK
RED
REAR DEFOGGER SWITCH/TIMER CONNECTOR (CHEVY)
COMPONENT
LOCATION
201.:PG
(HVAC) Control Assembly Center of 1/P ..................................... .
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. .
Rear Defogger Grid . . . . . . . Mounted on rear windshield ....................... .
Rear Defogger Switch . . . . Part of HVAC Assembly .......................... .
Rear Defogger Timer/Relay Part of H VAC. Assembly ............ .............. .
C320 (1 cavity) . . . . . . . . . . Under left Interior Garnish Molding above left rear
wheelhouse
C330 (3 cavities) . . . . . . . . . Hatch to 1/PHarn, center ofroofnear Dome Lamp ....
0200 . . . . . . . . . . . . . . . . . . . . Near base of LH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... .
0310 ........... ,........ . Bolted to .roof, left of Dome Lamp (1 ring, 1 wire) ..... .
0320 ................... . Bolted to body frame above RH rear wheelhouse
P300 .................... . In rear center of roof, near Dome Lamp ............. .
8216 ..............: . . . . . . {IP Harn, approx 5 cm from Convenience Center (Pont)
8217 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 23 cm before DLC breakout
8224 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 4 cm from Instrument Cluster (Pont)
or from RR Defog Switch (Chevy) breakouts
8248 . . . . . . . . . . . . . . . . . . . . 1/.P Harn, approx 4 cm before RR Defog Switch (Chevy)
8252 ................. , . . 1/P Harn, approx 17 cm back from HV AC Controls
8315 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 19 cm from conn C410
8420 . . . . . . . . . . . . . . . . . . . . Hatch Harn, approx 7 cm from P300 ................ .
For a Service Part Cross'il.eference List and Information, refer to SECTION SA-200.
FIG.
CONN
21 ...
8 ....
4 ....
21
37
21
40 . .
15
202-22
202-23
9
4
16
6
7
39
66 ..
39
4 .... 7
202-27

Diagnosis)
l. Check Fuse 3. If open, refer to Chart #2.
2. Check Rear Defogger Grid for opens, refer to
SECTION 10-2.
3. Check that grounds G200, G310 and G320 are
clean and tight.
. jinside of the insulation which could cause system
disconnected .. These circuits may be intermittent
systemoperational (under load).
61- 3

SYSTEM DIAGNOSIS
procedure(s).
SYSTEM CHECK (CHEVY)

NORMAL RESULTS
ACTION
(1)
Switch returns to "REST" position. Rear Defogger

Engine ruhning.
Turn Rear Defogger Control Switch to "ON" and Indicator is "ON" and Rear Defogger Grid becomes
warm. Defogger Grid(s) and Indicator turn "OFF" in
release.
approximately 10 minutes.
[2]
..
After first 10 minute time period, with Engine still Switch returns to "REST" pos1t1on . Indicator and
running, turn Rear Defogger Control Switch to Defogger Grid(s) remain "ON" for approximately 5
minutes and then turn "OFF."
"ON" and release.
SYSTEM CHECK (PONTIAC)

ACTION
NORMAL RESULTS
'
(1)
Engine running.
Press Rear Defogger Switch once and release.
Switch returns to "REST" position. Rear Defogger

Indicator is "ON" and Rear Defogger Grid becomes
warm. Indicator and Rear Defogger Grid turn "OFF"
in approximately 10 minutes.
Switch returns to "REST" position. Indicator and Rear

Defogger Grid remain "ON" for 5 minutes and then
turn "OFF."
(2)
(3)
Indicator and Rear Defogger Grid remain "ON" until

Press Rear Defogger Switch a second time and the Rear Defogger Switch is pressed a second time .
release.
SA -
DEFOGGER
SYMPTOM TABLE (CHEVY)
SYMPTOM
PROCEDURE
PAGE NUMBER
Rear Defogger Grid inoperative, Indicator may or may

not light.
Chart #1
SA-61-5
Indicator inoperative, but Rear Defogger Grid Replace Rear Defogger Switch/Ti mer.
operates normally.
Rear Defogger Grid and Indicator will not cycle Replace Rear Defogger Switch/Timer.
"ON/OFF" for 10 minutes or 5 minutes.
Rear Defogger Control Switch does not return to Replace Rear Defogger Switch/Timer.
"REST" position.
Refer to "Interior Lights," page SA-117-0.
Illumination Lamp inoperative.

Fuse #3 blows when attempting to operate rear
defogger.
SA-61-8
Chart #5
SYMPTOM TABLE (PONTIAC)

PROCEDURE
PAGE NUMBER
Rear Defogger Grid and Indicator inoperative.
Chart #2
SA-61-6
Rear Defogger Grid inoperative but Indicator operates

normally.
Chart #3
SA-61-7
Indicator inoperative but Rear Defogger Grid operates

normally.
Chart #4
SA-61-8
SYMPTOM
Rear Defogger Grid and Indicator operative, but will Replace Rear Defogger Timer/Relay.
not cycle "ON/OFF" for 10 minutes or 5 minutes.
Rear Defogger Switch does not return to "REST" Replace Rear Defogger Switch.
position.
Fuse #3 blows when attempting to operate rear
defogger.
Chart #5
SA-61-8
CHART #1
REAR DEFO(,jGEI\ GRID INOPERATIVE. INDICATOR MAY OR MAY NOT LIGHT.
WITH A TEST LIGHT TO GROUND, BACKPROBE REAR

DEFOGGER SWITCH/TIMER TERM"(".
IS TEST LIGHT "ON"?
TURN IGNITION SWITCH TO "RUN."

WfrH A TEST LIGHTJ() GROUND, BACKPROBE REAR
D~FOGGER SWITCl-fJtiMER TERM "A".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 1240.

CHECK FOR POWER FEED TO CKT BREAKER.
IF OK, REPLACE CKT BREAKER.
WITH A TEST LIGHT, BACKPROBE REAR DEFOGGER

SWITCH/TIMER FROM TERM "C" TO TERM "B".
IS TEST LIGHT "ON"?

CHECK FOR POWER FEED TO FUSE.
IF OK, REPLACE FUSE.
REAR DEFOGGER SWITCH/TIMER TO "ON."

SWITCH TERM "D".
JS TEST LIGHT '.'ON"?
CHECK FOR POOR CONNECTION AT REAR

DEFOGGER SWITCHlTIMER OR G200.
IF OK, REPAIR OPEN IN CKT 650.

REAR DEFOGGER GRID CONN {CKT 293 SIDE).
IS TEST LIGHT "ON"?

DEFOGGER SWITCH/TIMER.
IF OK, REPLACE REAR DEFOGGER SWITCH/TIMER.
-----. -----------. ______
------------,
BE SURE IT HAS NOT BEEN 10 MIN FROM INITIAL TURN ON. :

CHECK THAT REAR DEFOGGER GROUND G310 {COUPE) OR I
G320 {CONVERTIBLE) ARE CLEAN AND TIGHT.
:
CHECK FOR OPEN IN CKT 293 BETWEEN GRID CONN AND
:
~----------------.

TERM "A" (COUPE) OR C320 (CONVERTIBLE).
REAR DEFOGGER SWITCH/TIMER TERM "D"
AND REAR DEFOGGER GRID CONNECTOR.
G~~
I
CHECK WITH TEST LIGHT ACROSS BOTH CONNECTORS. IF : ' - - - - - - - - - - - - - - - - ~
NO LIGHT, CHECK FOR OPEN BETWEEN GRID AND
:
GROUND G310 {COUPE} OR G320 {CONVERTIBLE).
1
IF LIGHT, REPAIR REAR DEFOGGER GRID AS NECESSARY.
:
1
REFER TO STATIONARY WINDOWS SECTION 102.
L--------------------------------------J
-5
SA - 61
-6
DEFOGGER
CHART#2
REAR DEFOGGER GRID AND INDICATOR.:INOPERATIVE
BACKPROBE ORANGE WIRE CONNECTION AT

REAR DEFOGGER TIMER/RELAY WITH A TEST
LIGHT TO GROUND.
TEST LIGHT "ON"?

BACKPROBE CONN C6 TERM "4"
TO GROUND.
TEST LIGHT "ON"?
----------------------- ------ -------------,
CHECK FOR OPEN IN CKT 1240 OR POOR CONNECTION AT CQNN C4

TERMINAL "A".
CHECK CIRCUIT BREAKER.
IF OK, CHECK FOR SHORT TO GROUND THROUGH CKT 1240 CAUSING
BREAKER TO REMAIN OPEN.
CH.ECK POWER FEED TO CIRCUIT BREAKER 12 (RUER TO "POWER
DISTRIBUTION," PAGE SA-10-1).
IF NO SHORT FOUND AND POWER FEED OK, REPLACE CIRCUIT BREAKER.
:
:
:
I
:
I
L-----------------------------------------------
BACKPROBE FROM ORANGE

WIRE CONNECTION (CKT 1240)
TO CONN C6 TERM "1 ".
TEST LIGHT "Ot.1''7
BACKPROBE CONN C6 TERM "3" WITH A

TEST LIGHT TO GROUND WHILE PRESSING
AND HOLDING REAR DEFOGGER SWITCH.
TEST LIGHT "ON"?
REPAIR OPEN IN CKT 650 BETWEEN REAR

DEFOGGER TIMER/RELAY AND GROUND.
CHECK FOR POOR CONNECTIONS AT

REAR DEFOGGER TIMER/RELAY.
IF OK, REPLACE REAR DEFOGGER RELAY.
CHECK FOR POOR CONNECTION AT

CONN C4 TERM "C".
IF OK, REPAIR OPEN IN CKT 241 TO
REAR DEFOGGER TIMER/RELAY.

DEFOGGER SWITCH CONN CS GRY WIRE
CONNECTION.
CHECK FOR OPEN IN GRY WIRE.
IF OK, REPLACE REAR DEFOGGER SWITCH.
CHECK FOR OPEN IN CKT 241 BETWEEN
CONNECTORS C4 & CS.
ELECTRICAL DIAGNOSIS 8A- 61
CHART #3
REAR DEFOGGER GRID JNOPERATIVE BUT INDICATOR OPERATES NORMALL V
DISCONNECT REAR DEFOGGER GRID.

PRESS REAR DEFOG SWITCH ONCE.
CONNECT A TEST LIGHT FROM REAR WDO DEFOGGER
GRID CONNECTOR, CKT 293 SIDE (PPL WIRE) TO GROUND.
TEST LIGHT "ON"?

FROM REAR DEFOGGER
GRID CKT 293 SIDE TO
CKT 1150 (COUPE) SIDE
ORCKT1750
(CONVERTIBLE).
TEST LIGHT "ON"?
BACKPROBE REAR DEFOGGER TIMER/RELAY

(CKT 293 PPL WIRE) CONNECTION TO GROUND.
IS TEST UGHT ON?
CHECK FOR POOR CONNECTIONS OR

OPENS IN CKT 293 BETWEEN REAR
DEFOGGER TIMER/RELAY AND REAR
DEFOGGER GRID.

AT REAR DEFOGGER GRID
CONNECTOR OR OPEN IN REAR
DEFOGGER GRID.
CHECK FOR OPEN OR

POOR CONNECTION IN
CKT 1150 (COUPE) OR
CKT 1750
(CONVERTIBLE).
REPLACE REAR
DEFOGGER
TIMER/RELAY.
-7
8A-
61 - 8
DEFOGGER
CHART #4
INDICATOR INOPERATIVE BUT REAR DEFOGGER GRID OPERATES NORMALLY

PRESS REAR DEFOGGER SWITCH ONCE.
BACKPROBE CONN C6 TERM "2" WITH TEST LIGHT TO GROUND.
TEST LIGHT "ON"?
BACKPROBE CONN CS
(BRN WIRE) TO CONN C5
(BLK WIRE).
TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTIONS AT CONN C5
(BLK) AND CONN C5 (BRN).
IF OK, REPLACE REAR
DEFOGGER SWITCH.
REPAIR OPEN IN BRN WIRE

(CKT 293) OR BLK WIRE
(CKT 650).
CHECK FOR POOR

.CONNECTION AT CONN C6
TERM "2".
IF OK, REPLACE REAR
DEFOGGER TIMER/RELAY.
CHART #5
HVAC FUSE 3 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATIEMPTING.TO USE REAR DEFOGGER
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE REAR DEFOGGER?
TEST REAR DEFOGGER SWITCH/TIMER FUNCTION.

WHEN THE FUSE BLOWS, USE SCHEMATIC TO
DETERMINE WHAT CIRCUIT OR COMPONENT
COULD BE FAILING. USE A TEST LIGHT OR DVM TO
NARROW IN ON SHORT TO GROUND POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL
WHEN TRYING TO CHECK CIRCUITS THAT SHOULD
NOT BE AT A GROUND POTENTIAL.
USE SCHEMATICS AND DVM TO CHECK SUSPECT POWER

CIRCUITS FOR A SHORT TO GROUND POTENTIAL, EITHER
THROUGH A FAULTY COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE TERMINALS.
START BY DISCONNECTING ONE COMPONENT AT A TIME.
IF ALL RELATED COMPONENTS ARE DISCONNECTED AND
SHORT IS STILL PRESENT, LOCATE AND REPAIR SHORT IN
WIRING.
61 -9
CIRCUIT OPE~ATION (CHEVY)
CIRCUIT OPERATION (PONTIAC)
When the Ignition Switch is turned to "RUN,"

voltage is applied from Fuse 3 to the Rear Defogger
Switch. When the Rear Defogger Switch is turned to
"ON," voltage is momentarily applied to the Rear
Defogger Solid State Timer through CKT 241. With
voltage applied to the Rear Defogger Timer On/Off
Input, the Solid State Timer will energize the Internal
Relay which applies voltage to the Rear Defogger Grid.
The Relay remains closed until the defog cycle is
complete or the Rear Defogger Switch/Timer is turned
"OFF."
When the internal contacts of the Rear Defogger
Relay are closed, voltage from Circuit Breaker 12 is
applied to the indicator and to CKT 293.
The Rear Defogger Switch contains an internal
timer to control the time the internal contacts are
closed. When the Ignition Switch is turned to "RUN"
and the Rear Defogger Switch is turned to "ON" for the
first time, the defog cycle lasts 10 minutes. Further
operation will result in 5 minute defog cycles. The
defog cycle is reset to 10 minutes when the Ignition
Switch is turned to "OFF" and back to "RUN."
When the Ignition Switch is turned to "RUN,"

voltage is applied through the HV AC Fuse to the Rear
Defogger Switch and the Rear Defogger Timer/Relay.
When the Rear Defogger Switch is pressed, voltage is
momentarily applied to the Rear Defogger
Timer/Relay through CKT 292. When voltage is
applied to the Rear Defogger Timer/Relay, the Rear
Defogger Timer/Relay will close the internal contacts.
The internal contacts remain closed until the defog
cycle is complete or Rear Defogger Switch is pressed a
second time.
When the internal contacts of the Rear Defogger
Timer/Relay are closed, voltage" is applied to the Rear
Defogger Grid and Indicator.
The Rear Defogger Timer/Relay contains an
internal timer to control the time the internal contacts
are closed. When the Ignition Switch is turned to
"RUN" and the Rear Defogger Switch pressed for the
first time, the defog cycle lasts 10 minutes and further
operation will result in 5 minutes defog cycles. The
defog cycle is reset to 10 minutes when the Ignition
Switch is turned to "OFF" and back to "RUN."
HVAC BLOWER CONTROL (C60)
I
r-
1
I
I
3 BRN
SEE FUSE
BLO(:K DETAILS
PAGE SA-11-6
HOTINRUN
-
HOT AT ALL TIMES
-,1/P
FUSE
BLOCK
,--
HVAC
FUSE3
25AMP
__
FUSIBLE
LINK A
1 RUST
....I
241
.35 BRN
*BLOWER SWITCH HAS .MAKE

BEFORE BREAK CONTACTS.
___ ...., __ _
d=:3___ _
3 REO
DEF
OFF
202
---------...1
B
1 ORN
52
2LTGRN
66
1 LT.BLU
THERMAL
.LIMITERS (NOT
REPLACEABLE I
72
.610
"~E:11-------------::!.=Z"' I
\ t-ww-~_,..,__...
C2
C1
BLOWER
RESISTOR
.35 BLK
650
3 DK BLU
101
...----S217
1
SEE GROUNO
DISTRIBUTION
lillr,,,.__
......- -
PAGESSA-14-7,8,9
3BLK,650
38LK
L.--,
5216
650
~200
3 PPL
65
HVAC CONTROL ASSEMBLY

CONNECTOR DESCRIPTIONS
PAGE
C1
Blower Switch
5-Way Connector
8A-63-0
C2
Selector Switch
3-Way Connector
8A-63-0, 8A-64-0
C3
l.llumination Lamps Jumper
2-Way Connector
8A-117-1
PONTIAC ONLY
C4,
HVAC Control Assembly to 1/P Harness
4-Way Connector
8A-61-1
cs
Four 1-Way Connectors
8A-61-1
CG
4-Way Conne~tor
8A-61-1
C1
12020813
12064752

BLK

BLK
HVAC BLOWER SWtTCH {C1)
BLOWER RESISTOR
EJ El E1
B El B
12110541
6-WAY F METRI-PACK 280 FLX LK
BLK
HIGH BLOWER RELAY
63 - 1
SA -

201-PG FIG.
CONN
COMPONENT
LOCATION
Blower Motor . . . . . . . . . . . . Under lower RH side ofl/P, mounted in .HVAC Module
20 . . . 37
Blower Resistor . . . . . . . . . . In HV AC Module, forward and left of'I'emperature .
Control Cable Attachment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-20
39
Blower Switch . . . . . . . . . . . Part of HVAC Control Assembly . . . . . . . . . . . . . . . . . . . . 21
19
Fusible Links . . . . . . . . . . . . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
202-22
40
(HVAC) Control Assembly Center of I/P . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
High Blower Relay . . . . . . . Under I/P, above left side of floor tunnel . . . . . . . . . . . . . 42
77
202-23
(Ip Fuse Block . . . . . . . . . . . tHside ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Selector Switch . . . . . . . . . . Part of HVAC Control Assembly . . . . . . . . . . . . . . . . . . . . 21 . . . 39
C200B (18 cavities)
C200D (48 cavities)
G200
G201
PlOO
8216
8217
8248
Part of Forward tamp Harn, between tH kick panel

and Steering Columq ............. , . . . . . . . . . . . . . . .
Part ofl/P Harn, between tH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Near base of LH "A" pillar, bolted to I/P Mounting Stud
Near basJ: of RH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (1 ting, 1 wire) . . . . . . . . . . . . . . . . . .
Left sid~ in dash panel, Engine to Passenger
,Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/P Harn, approx 4 cm before RR Defog Switch (Chevy)
25
49
202-2
25
49
202-2
16
16
19 . . . 36
For a Service Part Cross Reference tist and Information, refer to SECTION SA-200.
(Perform before. beginning

Diagnosis)
System
Check HVAC Fuse 3 for open. If open, check for

short to ground through CKT 241.
2. Check Fusible Link A.
3. Check that G201 and G200 are clean and tight.
Check for a broken (or partially broken) wire.
1.

SYSTEM DIAGNOSIS
procedures.
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]

Blower Switch in "LO."
Selector Switch in "VENT."
Blower Motor runs at low speed.
Blower Switch in "M1".
Blower Motor runs faster than in low speed .
Blower Switch in "M2".
Blower Motor runs faster than "M 1" speed .
Blower Switch in "HI."
Blower Motor runs at high speed .
[2]
[3]
[4]
[5]
'
Put Selector Switch in "VENT," "Bl-LEV," "HEAT," Blower continues to run at high speed .
"DEFOG" and "DEF."
[6]
Put Selector Switch in "OFF."
Blower Motor stops ..
SYMPTOIVLTABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Blower Motor does not operate in "HI," but does

operate in "LO," "M1" or "M2".
Chart #1
SA-63-4
Blower Motor does not op,erate at all.
Chart #2
SA-63-5
Blower Motor will only operate in "HI."
Chart #3
SA-63-6
One Blower speed inoperative, other than "HI."
Chart #4
SA-63-6
Blower Motor operates in "HI" continuously with

Ignition Switch "OFF."
.
Disconnect High Blower Relay.

If Blower Motor stops, replace High Blower Relay.
If Blower Motor continues to run, repair short to
B+ inCKT101 .
8A -
63 -C:4

CHART #1
BLOWER MOTOR DOES NOT OPERATE tN "HI;"
BUT DOES OPERATE IN "LO'." "M1"
OR "M2" . :~'~',.'
.
DISCONNECT HIGH BLOWER RELAY FROM CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERM" A2" AND GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN TERM" A2" AND TERM "C2".

IS TEST LIGHT "ON"?
IGNITION SWITCH IN "RUN."

SELECTOR SWITCH IN "VENT."
BLOWER SWITCH IN "HI."
CONNECT TEST LIGHT BETWEEN TERM" A 1" AND GROUND.
IS TEST LIGHT "ON"?
REPLACE THE HIGH BLOWER RELAY.
. REPAIR OPEN IN CKT 202.
REPAIR OPEN IN CKT 650.
CHECKCKT52 FORAN OPEN OR FORA POOR

CONNECTION AT BLOWER SWITCH C:1 TERM "B".
IF O~. REPLAC~ THEBLOWER SW.ITCH.
ELECTRIGAL DIAGNOSIS SA - 63 - 5
CHART #2
BLOWER MOTOR DOES NOT OPERATE AT ALL

WITH A TEST LIGHT, BACKPROBE BLOWER SWITCH BETWEEN
CONN C1 TERM ''E'' AND GROUND.
IS TEST Ll~.HT "ON"?

BLOWER SWITCH IN "LO."
BACKPROBE WITH TEST LIGHT BtTWEEN CONN C1
TERM" A" AND GROUND.
IS TEST LIGHT "ON"?
DISCONNECT HIGH BLOWER

RELAY.
USING FUSED JUMPER, JUMPER
TERM "82" AND TERM "C1 ".
.IGNITION SWITCH IN "RUN."
BLOWER SWITCH IN "LOW."
DOES THE BLOWER MOTOR RUN?
CHECK FOR POOR

CONNECTION AT
CONN C1 TERM "E"
AND TERM "A".
IF OK, REPLACE THE
BLOWER SWITCH.
BACKPROBE SELECTOR SWITCH CONN C2 TERM "C".

IS TEST LIGHT "ON"?
CHECK CKT 66 FOR AN OPEN OR FOR A

POOR CONNECTION AT SELECTOR
SWITCH C2 TERM "B" AND TERM "C" .
IF OK, REPLACE THE SELECTOR SWITCH.
'
'
JUMPER CONNECTED FROM PREVIOUS STEP.

DISCONNECT BLOWER MOTOR CONNECTOR.
CONNECT TEST LIGHT BETWEEN CONN TERM "A"
ANDTERM"B".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT HIGH BLOWER

RELAY CONNECTOR.
IF OK, REPLACE THE HIGH BLOWER RELAY.
JUMPER CONNECTED FROM PREVIOUS STEP.

CONNECT TEST LIGHT BETWEEN CONN TERM "B" OF
THE BLOWER MOTOR CONNECTOF. AND GROUND.
IS TEST LIGH,T "ON"?
CHECK FOR POOR CONNECTIONS:.

AT BLOWER MOTOR CONNECTOR.
IF OK, REPLACE BLOWER MOTOR.
REPAIR POOR CONNECTION OR OPEN IN CKT 65.
Rl:PAIR POOR CONNECTION OR OPEN IN CKT 850.
SA -
63 - 6

CHART #3
CHART #4
BLOWER MOTOR WILL ONLY OPERATE IN "HI"
ONE BLOWER SPEED INOPERATIVE,

OTHER THAN "HI"

BLOWER SWITCH IN "LO."
BACKPROBE WITH TEST LIGHT BETWEEN BLOWER RESISTOR
CONN TERM "B" AND GROUND.
IS TEST LIGHT "ON"?

BLOWER SWITCH IN "LO".
BACKPROBE BETWEEN BLOWER
RESISTOR CONN TERM "C" AND
GROUND.
IS TEST LIGHT ,;ON"?
BACKPROBE WITH TEST UGI-IT

BETWEEN HIGH BLOW-.ER
RELAY CONN TERM "82" AND
GROUND.
IS TEST LIGHT "ON"?

AT HIGH BLOWER RELAY CONN
TE~M"B2".
IF OK, REPLACE HIGH BLOWER
RELAY.

BETWEEN BLOWER
RESISTOR AND HIGH
BLOWER RELAY.
CHECK FOR POOR

CONNECTION AT
BLOWER SWITCH
CONN C1 TERM "A".
IF OK, REPLACE THE
BLOWER SWITCH.
CHECK FOR POOR

CONNECTiON AT
BLOWER RESISTOR
CONNECTOR.
IF OK, REPLACE
BLOWER RESISTOR
ASSEMBLY.
CIRCUIT OPERATION
With the Ignition Switch in "RUN," battery
voltage is applied to the Selector Switch. The Selector
Switch applies power to the Blower Switch in all
modes but "OFF." With the Blower Switch set to "LO,"
battery voltage is applied to the Blower Motor through
the Blower Resistor and the normally closed contacts
of the High Blower Relay. The Blower Motor runs at
low speed. When the Blower Switch is in the "Ml" or
DISCONNECT BLOWER RESISTOR CONN.

BLOWER SWITCH IN SUSPECT POSITION.
CONNECT TEST LIGHT FROM SUSPECT TERMINAL (LO= 8,
M1 = A, M2 = D) TO GROUND (HARNESS SIDE OF
CONNECTOR).
IS TEST LIGHT "ON"?
BACKPROBE WITH A TEST

LIGHT BETWEEN CONN C1
OF THE SUSPECT TERMINAL
(LO= A, Ml= C, M2 = D) AND
GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
SUSPECT TERMINAL
OF BLOWER
RESISTOR CONN.
IF OK, REPLACE THE
BLOWER RESISTOR.
REPAIR OPEN IN SUSPECT CIRCUIT

(LO= 60, M1 = 63, M2 = 72).
CHECK FOR POOR

CONNECTION AT
SUSPECT
TERMINAL.
IF OK, REPLACE
BLOWER SWITCH.
"M2" positions, the operation is similar to the

operation in "LO" except the resistance through the
Blower Resistor is decreased, causing the Blower
Motor to run faster in "Ml" and even faster in "M2".
When "HI" blower speed is selected, the Blower Switch
applies voltage to the High Blower Relay coil. The
High Blower Relay is energized, applying voltage
from CKT 202 through the relay directly to the Blower
Motor. The Blower Motor then runs at high speed.
BLANK
63 - 7
SA 64 - 0 ELECTRICAL DIAGNOSIS
HVAC COMPRESSOR CONTROL

V6 VIN S
I
- - ill POWER
DISTRIBUTION
PAGE SA-10-3
I
I
I
AiC CRUISE
FUSE 12
20AMP
.BPNK 139 ,.. ....
5165 .........
.8 PNK
139
.8PNK f139
a1A
B2A
z-------2!__
84
.5DKGRN
BS
59
.35 DK GRNi
WHT
rn
459
------~
(100
S24S
3 BRN
~~~K
,--
3
- - - SBRN--11jbTO REAR DEFOGGER
.... PAGESSA-610, 1
241
241
TO 2nd SET OF CONTACTS
I
I
I
I
MAX
.. HEAT/DEF
SELECTOR
\
OFF~WITCH
..o_E_F___
(1 OF 2 SETS
OF CONTACTS)
I
I
I
I
L---- --------.J
AlC2
.35 DK GRN/WHT
762
F
C230

WITH COLORED TPAs.
A CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
P110
..
59
ASSEMBLY
VENT
- - .. ,HEATER
NORM _...

DIAGNOSING HVAC
SYSTEM. [HVAC CODES
WILL NOT ILLUMINATE
SERVICE ENGINE SOON
(MIL) LIGHT).
. ,
459
CONTROL
..........- -....."""""...._ _
PA_G_E_S_A_~~3-0--.........
ll~-f'
:1~~]""'"'~ hsv
.35 DK GRN/
WHT
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
-,1/P
r---- --------,~
I
DIAGNOSTICTROUBLE
CODES (DTCs) RELATED TO
HVAC WILL NOT ALLOW
THE PCM TO ENABLE THE
A/C COMPRESSOR RELAY.
.5 DKGRN
HVAC
FUSE3
25AMP
-1
IMPORTANT:
1
I
I
~
------...J
I' - 87*
L-
UNDERHOOD
ELECTRICAL
CENTER
I
I
I
I
I
I
I
I
I
I
SEE FUSE
BLOCK DETAILS
PAGE 8A11-15
--------+
:1
HOTINRUN
r-
- 32 WAY
32 WAY
32 WAY
~ (CLR)
r- -A/C -COMPRESSOR
- - - CLUTCH
- - RELAY
- - - - - - - - - A/C- REQUEST
- - - - - - - - - - -, POWERTRAIN
CONTROL
I CONTROL (BRIEFL y ENABLES
ALL SOLID
INPUT
I MODULE
5105---
I
I
.5DKGRN
59
I.. -
(BLK)
STATE
-=-
AiC
CLUTCH
STATUS
SV
!!_f - - ~ (BLK)
(BLU) 31
l~U!.. -
----------------~
AIC
CLUTCH
DIODE
(1 AMP)
rn
.35 RED/
BLK
Bf
.35
BLK
.35 BLK
59 .35 BLK
450
.8 BLK
lilii,
P
-1450
1 BLK
~~;UTCH
c
PRESS
TO IGNITION
CONTROL MODULE
PAGE 8A-20-1
450,..-
L.i04
SEE GROUND
DISTRIBUTION
PAGES SA-14-2, 3
2 STUDS WITH 2 TERMINALS

ON EACH (INTERCHANGEABLE)
~N~T ...I
3 r ~ (CLR)
4S2
....... ------
I
I
452
.35 DK BLU
732
.35 BLK
SEE SEQUENTIAL
FUEL INJECTION
PAGE SA-20-4
THE A/C CLUTCH DIODE, SEALED IN EPOXY,

APPROX 16mm UP FROM THE AiC COMPRESSOR
CLUTCH CONNECTOR, PREVENTS THE
PRODUCTION OF ELECTRICAL SPIKES WHEN THE
AiC CLUTCH IS TURNED OFF .
450
5108
.35 BLK
416
450
5115
.35 GRY
380
HARNESS
.5 DK GRN
5119
.5DK1;-GRN
A
A/C COMPRESSOR
CLUTCH
--
~:~~:R-1
ATURE
SENSOR
~
11----
.35 BLK
59
5114
--- - - - - -
.5 DK GRN
1 5 V ~~PO-:(P:.
A/C REFRIGERANT
PRESSURE
SENSOR
SENSOR
GROUND
tI
I
I
I
_______,.-----
._
A/C
REFRIGERANT
PRESSURE
S_!:NSOR
?!!J.
AiC EVAPORATOR
TEMPERATURE
SENSOR
.35 GRY
416
452
ELEC!TRICAL DIAGNOSIS SA-
64- 1

VS VIN P
I
-
e----t~
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
A/C - CRUISE
FUSE 12
20 AMP
, .8 PNK 139 ., ... - - - - - 5165 .,...
.8 PNK
139
.8 PNK 139
I
I
I
I
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-15
--+
:WRH~l
T: : .-
B
- - - - - - -
(100
-
r----
241
.35 DK GRN/
WHT
.5 DK GRN
459
59
5 1 0 5 - -. .
:I
.SDKGRN
:f
g
-
hsv
ALL SOLID
ST ATE
' -=-
SV
REF
- - -,,
,,
.35 RED/
BLK
--
.35 BLK
.S DKGRN
59
.3SBLK
450
450
5108- -
1 BLK t 5 0 , , , .
~
.35 GRY
1HVAC
CONTROL
IASSEMiii:v
A
B
C
D
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAY
32WAY
32WAY
32WAY
hsv ~~~~~-
:~~:i~:~GERA~:SOR
GROUND
~~~-~~--
380
.35 BLK
416
-~~~~~~~~THE AiC CLUTCH DIODE, SEALED IN EPOXY, '

APPROX 16mm UP FROM THE A/C COMPRESSOR
CLUTCH CONNECTOR, PREVENTS THE
PRODUCTION OF ELECTRICAL SPIKES WHEN THE
AiC CLUTCH IS TURNED OFF.
5115
...JL.G102
1 POWERTRAIN
0
A/C
" ::.14:2
24
I ~0~~~EL
(PCM)
~:::R- :
J.
~
SENSOR
-~~J
Q
.----------
I
I
--i.
~ ~~;T~~~~:N
732
.35 BLK
SEE SEQUENTIAL
FUEL INJECTION
PAGE 8A-21 4
tI
c
PRESS
I
I
I
PAGE8A-14-0
.35 DK BLU
452
HARNESS
450
5119
AIC COMPRESSOR
CLUTCH
Bl
tNPUT
SENSOR
----- -----"
A/CREQUEST -
.35
BLK
LT1
5114
rn
________ J
.SDK{;;GRN
A/C
CLUTCH
DIODE
(1AMP)
TO 2nd SET OF CONTACTS

PAGE8A-63-0
STATUS
::.. ...
TO REAR DEFOGGER
PAGES 8A-61-0, 1
241
241

DIAGNOSING HVAC
, SYSTEM. [HVAC CODES
WILL NOT ILLUMINATE
SERVICE ENGINE SOON
(MIL) LIGHn.
j"''.-,_.____ cw:~~
DIAGNOSTICTROUBLE
CODES (DTCs) RELATED TO
HVAC WILL NOT ALLOW
THE ECM TO ENABLE THE
Ai( COMPRESSOR RELAY.
CONTROL (BRIEFLY ENABLES

RELAY DURING CRANK)
L-
59
-A/~0-;P~S~ cTuT;; RTi.A7 -
h,
VENT
- - .. HEATER
,._ HEAT/DEF
SELECTOR
' DEF
SWITCH
(1 OF 2 SETS
OF CONTACTS)
IMPORTANT:
.35 BRN
-1------mt.,..
3 BRN
- , ~o , -
,-
_ _ ....
~,;:=f,, -,:,
SEE PAGE BA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
-,1/P
FU5E
BLOCK
5248.
~MPRESSOR
HVAC
FUSE 3
25AMP
3 BRN
~~
1
I
II-
I
I
111
t1
I
: r_-------\,1 ."'"
I
r-
UNOERHOOD
ELECTRICAL
CENTER
--
HOTINRUN
AIC
REFRIGERANT
PRESSURE
SENSOR
AiC EVAPORATOR
TEMPERATURE
I
.................................
. .4.1.6- " "
SENSOR .35 GRY
S]J1
416
452
SA ,64 .. 2 ELECTRICAL DIAGNOSIS

COMPONENT
.201-PG
LOCATION
NC Clutch Diode
(V6 VIN S) . . . . . . . . . . . . . Sealed in Harn, 10 cm from A/C Compressor
Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
NC Clutch Diode
(V8 VIN P) . . . . . . . . . . . . Sealed in Harn, approx 12 cm from Generator breakout 14
NC Compressor Clutch . . . RH side of Engine, below Generator , ....... , . . . . . . . . 14, 28
AJC Evaporator
Temperature Sensor . . . . Mounted in Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . 20 . . .
AJC Refrigerant Pressure
Sensor . . . . . . . . . . . . . . . . . Above RH Shock Tower, forward of A/C Compressor
Low Pressure Cut-off Switch ..................... . 19
(HV AC) Control Assembly Center of 1/P ...................................... . 21
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side ................... , 8 ....
(PCM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower 19
(PCM) (V8 VIN P) ..... . In Engine Compartment, rearward of RH Shock Tower 19
of wheelhouse ................ : .................. . 19
ClOO (10 cavities)
attached to PCM bracket .... : .................... . 15
0102 (LTl) ............. . Front of LH cylinder head
(3 rings, 3 wires and braided strap) ................ . 16
0104 (L32)
PllO ................... . Right side in dash panel, Engine to Passenger
Compartment ................................... . 19
8105 (L32)
breakout
8105 (LTl)
PCM breakout
8108 (L32) .............. Engine Harn, approx 4 cm from braided ground strap
11
8108 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 17 cm from Injector 3 breakout .. 24
8114 (L32) .............. Engine Harn, approx 10 cm from NC Compressor
Clutch Conn ..................................... 28
8114 (LTl) .............. Engine Harn, approx 12 cm from Generator breakout
14
8115 (L32) .............. Engine Harn, approx 10 cm from NC Compressor
Clutch Conn . ', ................................... 28
8115 (LTl) .............. Engine Harn, approx 12 cm from Generator breakout
14
Sll 7 (L32) .......... ' .. Engine Harn, approx 5 cm from main branch and
PCM breakout
8117 (LTl) .............. Engine Harn, approx 5 cm from clip near PCM and
main branch
FIG,
CONN
54
26
26, 54
37
35
40
15
202-22
202-23
35
202-25
35
202-26
36
202-28
28
37
202-0
202-7
29
56
35
20
44
54
26
54
26
LOCATION
COMPONENT
201-PG FIG.
Sl 19 (L32) . . . . . . . . . . . . . . Engine Harn, at RH Oxygen Sensor breakout . . . . . . . . 12 . . . 23
8119 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 18 cm from main branch and
PCM breakout
8165
Center breakout
8248
SYSTEM DIAGNOSIS
With Diagnostic Trouble Codes (DTCs) present,
refer to SECTION 6E3.
Without Diagnostic Trouble Codes (DTCs) present,
refer to SECTION lBl.
64 .. 3
CONN
8A -
76 - 0
r----
SEE POWER
I DISTRIBUTION
( PAGESA-10-1
COURTESY
FUSES
15AMP
I
1 ORN
3 ORN
.-
HOT AT ALL TIMES
1/PFUSE
BLOCK
HEADLIGHT
SWITCH
.SORN
CONVENIENCE
CENTER
r--c
I
I
I
I
I
I
, 1/P FUSE
GAGES
FUSE 9
IGN
10AMP (NOTUSED)
L---------
I BLOCK
I
I
I
-J
.SPNK
39
' 5206
~~~~~- --~~l~- ~r~:: _

--~~1~-_-_.._--,
SEE EXTERIOR
S210 - - - - - - -. .
-.
40
.8 BRN
I SEE POWER
. DISTRIBUTION
I PAGE SA-10-3
I
I
:---.:Cl~r--~.:
I
I
40
40 (CHEVY WITH U82)
SEE FUSE
BLOCK DETAILS
PAGESA-11-8
Ir- - - ~.- - - I
I HEAD
OFF
I
SEE FUSE
POWER
INPUT
...
'AUDIO
ALARM
MODULE
IGNITION SWITCH
. .
INPUT
LIGHTS ON
INPUT
sv
I
I
I
__ _J
SEAT BELT
INPUT
GROUND
.5 BLK
650
.35 YEL
237
SEAT BELT
SWITCH
(OPEN WITH LH
FRONT SEAT BELT
BUCKLED)
(CHEVY) C6
(PONn A12
r-
I
I
I
-i- ---
i<D
FASTEN
BELTS
iNoicATOR
IGNITION _....,_..
KEY
1NARN1NG
SWITCH
(CLOSED WITH
KEY IN IGNITION)
,INSTRUMENT
CLUSTER
I- I J~<lll
~
I
t__ r____ J
650
.35 BLK
.35TAN
ES
C200D
C200C
(PON
(CHEVY)
C4 n B 3 ~
1 BLK
650
3 BLK
------------S217
650
-----------,
l
5216
3 BLK
650
SEE GROUND
DISTRIBUTION
PAGES SA-14-7, 8, 9
3 BLK
750
SEE PAGE SA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
.STAN
II
-.-J
I
I
I
159
rzL:lJ,
A
DOOR JAMB
SWITCH, LH
(CLOSED WITH
DOOR OPEN)
76 - 1
BUZZER
GJII][I]G]
momm
Q.
GJ0
El
HORN
mEl
HZ/F
12015999
BLK
CONVENIENCE CENTER
**CAVITIES NOT LISTED ARE NOT OSED

CAVITY
WIRE COLOR
CKT
DESCRIPTION
LTGRN
80
KEY-IN-IGNITION SIGNAL
8A-76-0
ORN
40
POWER FEED FROM COURTESY FUSE #8
8A-11-8
BRN
PARK LIGHT ON FEED
8A-76-0
BLK/WHT
238
SEAT, Bl:L T SWITCH SIGNAL
8A-76-0
BLK
650
GROUND
8A-14-8
YEL
237
SEATBELT INDICATOR LAMP CONTROL
8A-76-0
PNK
39
8A-11-5
BRN
27
HAZARD FLASHER OUTPUT
8A-110-4
ORN
140
POWE,R FEED FROM STOP/HAZARD FUSE #6
8A-11-7
ORN
540
POWER FEED FROM CIGAR/HORN FUSE #7
8A-11-8
BLK
28
HORN RELAY CONTROL
8A-40-0
DKGRN
29
HORN FEED
8A-40-0
PAGE
SA -
76 - 2

COMPONENT
Convenience Center
201-PG FIG.
LOCATION
Left of Steering Column, mounted to bottom of
1/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ... . 15 ..
Door Jamb Switch, LH ... . Near base ofLH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 45 .. . 84
Headlight Switch ....... . LH side of 1/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66,67
15
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8
Ignition Key Warning
Switch ................ . Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 5
Instrument Cluster ...... . LH side ofl/P ................................................... .
Seat Belt Switch ........ . Part of Driver's Seat Buckle Assembly . . . . . . . . . . . . . . . 43
81
C200C (13 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
49
C200D (48 cavities) ..... . Part ofl/P Harn, between LH kick panel and
Steering Column ...... , ............ : . . . . . . . . . . . . . 25
49
C216 (11 cavities) ....... . Attached to base of Steering Column . . . . . . . . . . . . . . . . 34
63
0200 ................... . Near base ofLH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ................ 9 . . . . 16
S206
breakout
S210
S216
S217
S226
1/P Harn, approx 10 cm from Instrument Cluster
breakout
CONN
202-20
202-15
202-23
202-23
202-2
202-2
202-5

Diagnosis)
System
Check that 0200 is clean and tight.

If Ignition Key warning is inoperative check the
LH Door Jamb Switch or for open in CKT 159.
If all warning chimes are inoperative, check
Courtesy Fuse 8 for open.
Chee~ for a broken (or partially broken) wire

SYSTEM DIAGNOSIS
procedure(s).
SYSTEM CHECK
ACTION
NORMAL RESULTS
(1)
LIGHTS "ON" WARNING

Remove Ignition Key from Ignition Switch .
Headlamp Switch to "PARK" or "HEAD."
Headlamp Switch to "OFF."
Lights "ON" Warning sounds as long as the Headlight

$witch is in "HEAD" or in "PARK'."
IGNITION KEY WARNING

Ignition Key in Ignition Switch.
Open LH door .
Close LH door .
Ignition Key Warning Tone sounds as long as the LH

door is open .
(2)
ELECTRICAL DIAGNOSIS SA 76 '- 3
SYSTEM CHECK
;
ACTION
NORMAL RESULTS
(3]

Driver's seat belt latched .
Open LH door .
Close LH door .
No tone sounds.
SEAT BELT WARNING

Close LH door .
Driver's seat belt unlatched .
Seat Belt Warning Tone sounds for 5to 8 seconds.

Fasten Belts Indicator stays "ON."
SEAT BELT WARNING

Close LH door.
Latch driver's seat belt .
Ignition Switch to "OFF" and back to "RUN."
Seat Belt Warning Ton.e does not sound and does not
illuminate .
(4]
(5]
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
All warnings inoperative.
Chart #1
8A-76-4
Ignition Key Warning inoperative.
Chart #2
8A-76-4
Seat Belt Warning inoperative.
Chart #3
8A-76-5
Fasten Belts Indicator "ON" continuously.
Chart #4
8A-76-5
.. .
Fasten Belts Indicator inoperative.

Lights "ON" Warning inoperative.
Chart #5
8A-76-5
Check for poor connection at Convenience Center

terminal "D" or open in .CKT 9 to the Audio Alarm
Module. If OK, replace Audio Alarm Module.
Lights "ON" Warning sounds continuously with Check for poor connection at Convenience Center
terminal "H" or open in CKT 39 to the Audio Alarm
Module. If OK, replace Audio Alarm Module.
Ignition Key Warning sounds when LH front door is Check for short to ground in
Ignition Key Warning Switch.
open and key is not in Ignition Switch.
ci<"r
80. If OK, replace
Ignition Key Warning continues to sound when LH Check for poor connection at Convenience Center
front door is closed and Ignition Switch is in "RUN."
terminal ''H" or open in CKT 39 to the Audio Alarm
Module.
Seat Belt Warning sounds continuously.
Check for short to ground in CKT 238 or for Seat Belt

Switch stuck closed.
If OK, replace Audio Alarm Module.
SA.; 76 - 4 ELECTRICAL DIAGNOSIS

CHART #1
ALL WARNINGS INOPERATIVE
DISCONNECT AUDIO ALARM MODULE.

CONNECT A TEST LIGHT TO CONVENIENCE
CENTER FROM TERM "C" TO TERM "F".
TEST LIGHT "ON"?
CONNECT A TEST LIGHT TO CONVENIENCE

CENTER FROM TERM "C" TO GROUND.
TEST LIGHT "ON"?

TO AUDIO ALARM MODULE.

CONVENIENCE CENTER TERMINALS "C" AND "F"
OR OPEN IN CKT 650 FROM<:ONVENIENCE
CENTER TO G200.
CHART#2
IGNITION KEV WARNING INOPERATIVE
REMOVE KEY FROM IGNITION SWITCH.

USING A DVM, BACKl>ROBE C216 FROM TERM "F"
TO GROUND.
KEY IN IGNITION SWITCH.

IGNITION SWITCH IN "OFF."
CLOSE LH FRONT DOOR.
USING A DVM, BACKPROBE C216
FROM TERM "E" TO GROUND.

CONVENIENCE CENTER TERM "B" OR
OPEN IN CKT 80 FROM CONVENIENCE
CENTER TO C216.
IF OK, REPLACE AUDIO ALARM MODULE.
CHECK FOR POOR CONNECTIONS AT C216.

C216 AND LH DOOR JAMB SWITCH.
TERM "E5."
IF OK, REPLACE LH DOOR JAMB SWITCH.

AT C216 TERMINALS "E" AND "F".
IF OK, REPLACE IGNITION KEY
WARNING SWITCH.
ELECTRICAL DIAGNOSIS SA - 76 .~ 5
CHART #3
SEATBELT WARNING INOPERATIVE
SEAT BELT NOT BUCKLED.

DISCONNECT AUDIO ALARM MODULE.
WITH TEST LIGHT, BACKPROBE CONVENIENCE CENTER FROM TERM "C" TO TERM "E".
IS TEST LIGHT "ON"?
BACKPROBE FROM CONVENIENCE CENTER

TERM "G" TO SEAT BELT SWITCH CONN TERM" A".
IS TEST LIGHT "ON"?
BACKPROBE FROM CONVENIENCE CENTER

TERM "G" TO SEAT BELT SWITCH CONN TERM "B".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT TERM "E".

IF OK, REPLACE AUDIO ALARM MODULE.
CHECK SEAT BELT SWITCH CONNECTION.

IF OK, REPLACE SEAT BELT SWITCH.
CHART #4
CHART #5
FASTEN BELTS INDICATOR "ON" CONTINUOUSLY
FASTEN BELTS INDICATOR INOPERATIVE
REMOVE AUDIO ALARM MODULE.

FASTEN BEL TS INDICATOR "ON"?
PROBE WITH A TEST

LIGHT BETWEEN SEAT
BELT SWITCH CONN
TERM"A" ANDB+.
IS TEST LIGHT "ON"?
CHECK FOR SHORT TO

VOLTAGE TO CKT 237.
IF OK, REPLACE
INSTRUMENT CLUSTER
PRlNTED CIRCUIT.
REMOVE AUDIO ALARM MODULE.

CONNECT A FUSED JUMPER. FROM B + TO
THE CONVENIENCE CENTER TERM "G".
FASTEN IULTS INDICATOR "ON"?
FUSED JUMPER STILL

CONNECTED.
CONN FROM TERM "A12"
(PONT) OR "C6" (CHEVY).
TO GROUND.
TEST LIGHT "ON"?
CHE(K FOR POOR

CONNECTION AT
AUDIO ALARM
MODULE.
IF OK, REPLACE AUDIO
ALARM MODULE.
CHECK FOR POOR

CONNECTION AT
INSTRUMENT CLUSTER
CONNECTOR.
CHECK FASTEN BELTS
INDICATOR LAMP.
IF OK, REPLACE
INSTRUMENT CLUSTER
PRINTED CIRCUIT.
CHECK CKT 238 FOR A

SHORT TO GROUND.
IF OK, REPLACE SEAT
BELT SWITCH.
BETWEEN CONVENIENCE
CENTEff.AND
INSTRUMENT CLUSTER.

CIRCUIT OPERATION
The Audio Alarm Module generates a single tone
for: Lights "ON" Warning, Ignition Key Warning and
Fasten Belts Warning.
LIGHTS "ON" WARNING
When the Headlamp Switch i.s in "PARK" or

"HEAD," voltage is applied to the Lights "ON" Input
of the Audio Alarm Module. When the Ignition Switch
is turned out of the "RUN" position, voltage is removed
from the Ignition Switch Input of the Audio Alarm
Module. When voltage is present at the Lights "ON"
Input and no voltage applied to the Ignition Switch
Input, the Audio Alarm Module will sound the Lights
"ON" Warning.
The Audio Alarm Module applies voltage at all

times to the Ignition Key Warning Switch. When the
Ignition Key is placed into the Ignition Switch, the
Ignition Key Warning Switch .is closed. When the LH
front door is open, the LH Front Door Jamb Switch
closes the circuit to ground. The Audio Alarm Module
senses a voltage drop at the Ignition Key Input and
will sound the Ignition Key Warning.
FASTEN BELTS WARNING
The Audio Alarm Module applies voltage to the

Seat Belt Switch at all times. The Audio Alarm
Module senses a voltage drop at the Seat Belt Input
through the closed contacts of the Seat Belt Switch
when the driver's seat belt is unlatched. When the
driver's seat belt is latched, the Seat Belt Switch is
opened and the Audio Alarm Module senses voltage at ..
the Seat Belt Input. When the Ignition Switch is
turned to "RUN," voltage is applied to the Audio
Alarm Module Ignition Switch Input. When voltage is
present at the Ignition Switch Input and zero volt at
the Seat Belt Input, the Audio Alarm Module will
sound the Fasten Belts Warning for 5 to 8 seconds. If
voltage is present at the Ignition Switch Input and the
Seat Belt Input, the Audio Alarm Module will disable
the Fasten Belts Warning.
When the Ignition Switch is turned to "RUN," the

Audio Alarm Module senses voltage at the Ignition
Switch Input. When voltage is applied to the Ignition
Switch Input, the Audio Alarm Module applies voltage
to the Fasten Belts Indicator for 5 to 8 seconds
independent of the Seat Belt Switch and Fasten Belts
Warning.
BLANK
76 - 7
-----,~
rs;-P~ER -
FUSE
I DISTRIBUTION
GAGES
FUSE 9
PAGE 8A103
I
I
I BLOCK
I --
IGN
lO AMP (NOTUSED)
I
_J
L-------.8 PNK
39
-------------- - 5206
.35 PNK
(CHEVY)
071
(PONT) Al
INSTRUMENT
CLUSTER
::f
"
...............
.....,.......
SEE FUSI
BLOCK DETAILS
PAGE 8A-11-5
AS
r- - - - - - - - - - - - - - - - - - - - - - - - - I
,====:....-------------.~_.
- - - - - - - - - -.
ODOMETER
TO INDICATORS
~I
I
I
I
I
I
I
VOLTMETER
SPEEDOMETER
TACHOMETER
,.......- ...
I
I
___..
,,::::~.~Tr17 -
__.......
5242 .35 DK GRN/WH~J:17
-.~rr~l- ---
~5~K::Tr=1 -
SEE VEHICLE
SPEED SENSOR
PAGE 8A-33-0
C22~--------------
POWERTRAIN f""
CONTROL
MODULE
(PCM)
I
I
I
~ I._
817
-f
____
~
I
I
I
_.I
-,
:WHI121
13
r- -
"'I
I
I._
I
I
_..
POWERTRAIN
CONTROL
MODULE (PCM)
PAGE 8A21-1
.35WHI121
'
.8 BLK,WHT
451
(1
.... - -i
I.. -
-B[I
_.......
.......
31
(220
o,,o
SEE GROUND
DISTRIBUTION
PAGES 8A-14-1 (V8 VIN P)
8A-14-2, 3 (V6 VIN S)
B (BLK) V6 VIN S
B (BLK) V8 VIN P
4000
PULSES
PER MILE
451
5109 (V8 VIN P). 5110 (V6 VIN S)
-l ~---.
28
8
-------------l"::,o
.5 BLK/WHT
.35 DK GRN/WHT
.35 TAN
5
S.Zl
.5 BLK/WHTJ:51
C230
-I G103 (V8 VIN P)

IGNITION
G104 (V6 VIN S) a
CONTROL
__.__
11,!9DUI,! (ICM)
PAGE 8A-20-1
I
I
I
I
___ ....
.35 TAN
31
[B
OIL
PRESSURE
SENSOR
(APPROX 90 OHMS AT
HIGH PRESSURE
APPROX 10 OHMS AT
LOW PRESSURE)
ELECTRICAL DIAGNOSIS SA - 81
--,11p
'"seEPOWER -
FUSE
PCM BAT BLOCK
FUSE 4
'
10AMP
I DISTRIBUTION
I
I
('GHA-10-1
rn
L----
- -
.SORN
.I
340
IMPORTANT:
THE COOLANTTEMPERATUl'E
GAGE DOES NOT HAVE
EQUAL DIVISIONS FOR
TEMPERATURE. THE CENTER
OF THE GAGE IS EQUAL TO
BETWEEN 210F TO 220'F
(FOR Z49: 100'C TO 105'().
-1
5209
..............
__,........
.SORN
SEEFUSE
BLOCK DETAILS
PAGESA-11-7
340
(CHEVY) C14
(POND A13
~---------------------~-------------------,
I
COOLANT
TEMPERATURE
GAGE
BATIERY
COOLANT
TEMP,
MONITOR
SENSES
GENERATOR
OIL TURN ON
PRESSURE
MONITOR
SOLID STATE
IGNITION
470
!J
LOW
Oil
INPUT
GND
INDICATOR
CONTROL
ABS
OUTPUTS
FAIL~
-.....---,----.,.~
ABS
INOP"
INDICATOR
<D CD <D'
' "LOW
OIL"
INDICATOR
"CHECK
GAUGES"
INDICATOR
;~,'
~~~;~~ \ ~ }
I
I
I
I
I
I
I
";P;;l')~,TI- - - - - - - - - - - - -A17I- - 7,5I-;,1y- ----------------- .J

(CHEVY) 03
.35 DK GRN
C12
012
35 RED
135
.
06
225
.35 BRN
______________________ - __A
.35LTGRN
867
__ - _
1174
A3
*I
C220
.35 LT GRN
.35 DK GRN
135
.8RED
r------i.,
TURI'!! ON INPUT
(POWER UP FOR
REGULATORI
I
I
CLOSES WITH
1 qy OR LOWER
.. II OR
WITH 16.5V OR
HIGHER OR WITH
I STOPPED
GENERATOR GENERATOR
PAGE8A-30-1L -
'
f_._
--=-
867
225
ENGINE
COOLANT
TEMPERATURE
GAGE SENSOR
1365 OHMS AT 100'F.
[ ] 55 OHMS AT 260'F
.
C200D
C200A
I
I
I
I
I
.35 BRl',j
1174
B
~~teL
SENSOR
(NORMALLY
[ ] CLOSED,OPEN
WITH LOW OILI
.J
.35 BLK,WHT
.5 BLK,WHT
451 (V8 VIN Pl

451 (V6 VIN S)
82
C2
I"" -
-,
ELECTRONIC
ABS
I BRAKE
I FAIL
CONTROL
I
I MODULE (EBCM)
L.,
. PAGE SA-44-0
-
... , WITHNW9
ELECTRONIC
BRAKEfTRACTION
CONTROL
MODULE (EBTCMI
PAGE BA-44-2
Nea~
SEE PAGE IIA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
SEE INTERIOR LIGHTS

DIMMING PAGE SA-117-1
sEEPOWE;- DISTRIBUTION
PAGE 8A10-1
I
I
I
L---.8 ORN
SEE FUSE
BLOCK DETAILS
PAGE8A-11-7
........__ ..........
I
I
I
I
I
.5 GRY
39
.35 PNK
. .------11111115206
S224
39
340
.35 GRY
SEE INTERIOR
. . LIGHTS DIMMING
PAGESSA-117-1,3
SEE FUSE
BLOCK DETAILS
PAGESA-11-5
-1------ ------------- -------------,,

013
(CHEVY) C14
(PONn A13
INSTR.UMENTrCLUSTER
.8 PNK
S209
.8 ORN
..-,
340
C3
82
AS
I
I
ILLUMINATION
LAMPS
"SECURITY"
INDICATOR
G)
i1
\J;,I
l___ l_ ____ ~--- ---------~
G)
(PONn Al
(CHEVY) C13
.35 GRY
(4
TOS235
PAGE 8A-202 (V6 VIN S)
SA-21-2 (VS VIN P)
728
.35PPL
lO
A2
AS
THEFT,- DETERRENT
MODULE
PAGE SA-133;1
.SGRY
---------~
@\
G)
1 BLK
G)
'
G)
I
I
------------..J
650
120
SEE GROUND
DISTRIBUTION
PAGES SA-14-7,8
~~~!
-,
3 BLK
.650
I..-....:..
oil
FUEL GAGE SENDER

RESISTANCE
APPROXIMATE
FUEL LEVEL
3 BLK
FUEL
PUMP
750
88Q
FULL
60 !l
3/4
43Q
f/2
26Q
1/4
3 BLK
EMPTY
1450
1.on
Al""
C405B
1 BLK
1050
~05
WITH AC] OR AQ9
SEE GROUND
DISTRIBUTION
PAGESA-1411
ig~
SEE PAGE 8A30
FOR MEASURING
AND HANDLING
PROCEDURES
HOT IN ACCV OR RUN
TO HEADLIGHT
DIMMER SWITCH
PAGE SA-100-0, 2 (WITHOUTT61)
8A1021 (WITH T61)
TO FOG LIGHT
SWITCH
PAGE 8A100-1
1 LTGRN
(WITHOUT T61)
8A1021
(WITH T61)
3
C
11
.8LTGRN
SEE EXTERIOR
LIGHTS PAGE BA-1100
L-----.SLTBLU
.5 LT BLU/WHT
11
1g~~~
1
.8LTGRN
1!'.rs~P~;' - - - - ,
I DISTRIBUTION
I
PAGE8A-102 ~
I
CIRCUIT
I
BREAKER
I
I
30AMP
FUSE
BLOCK
TO AUDIO
ALARM MODULE
PAGE BA-76-0
.35 VEL
14
1414 (T61)
237
11
CHEVY ONLY
.8 LTGRN
(CHEVY) C11
'l
.35 PPL1WHT
C1
1572
_- - _-- ,!!!f ___ __ --,

1 ~~R~T 1 ~ ;~~~~ ~
1
T~E::~ ~
w 'Tr" w
w~
C6
r - - _JP~ri..!1,!_r _ - - - - _81!,f _ _!5
.,!12
C7
~8
r::::::l
VY
"FASTEN
f'r:\NDll.TOR
w~TOR
~~~~VICE
~ ENGINE
~~~
&-- -----c~~
(~~~~~)~I
.35 BRNIWHT
c23 o
.35 BRN1WHT
.8 BRN
\J;,I TRAC""
~::
358
.35 DK BLU
A9
r- -
C2000
1537
.35 DK BLU
81
BS
I - T. I
_.__
-=- J
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
PAGEBA-47-0
.I
ELECTRONIC
BR._A_K._E ~
\J;,I
D~~
33
.35 YEL/BLK
WITHNW9
ELECTRONIC
BRAKEtTRACTION
CONTROL MODULE
(EBTCM)
PAGE 8A44-2
68
cC2000
2 00A
A17
5228
33
EB
.35 YEL/BLK
.35 YEL/BLK
t ~S=.: 73 [ZJ ~fi::T

C200A
I '"BRAKE'' I
INDICATOR
I CONTROL I
L -
-I
(CLOSED
WITH LOW
COOLANT
WITH VB VIN
250
Yi
C
.SBLK
-=-
ELECTRONIC BRAKE
PAGESA-~
I
.
........
cC200D
2 00C
' ..::.:_p200
--1 --
68
SEE GROU ND
ION
~::::~.~ 4.7
r1Noi- -
I (ATOR
LATCH
SEE GROUND
DISTRIBUTION
PAGE SA-14-5
750
--
1~:jr
l.
l ~
l1NG
I
I
LC2J:!Ti!2L .I
RETAINED
.
- - - - - - ACCESSORY
ELECTRONIC BRAKEfTRACTION
POWER (RAP)
MODULE
PAGE 8A-44-2
PAGE 8A-1SO
WITH NW9
3 BLK
5220
~ - ....
3 BLK 250
....A_2105
341
68
_35 TANl33
WHT
84
C2
3 BRN
__ J
68
C2000
AS
r - _- ,
CONTROL
MODULE(EBCM)
~44-0
WHT
PAGE8A410
OUTPUT
L -
.35 TAN/
:!::~~E
~ i- ~ f1:~~;:;. ~1.
I/_ I
r~
35 YEL/BLK
1 3
~ : DK BLU11537
CONTROL
MODULE (PCM)
PAGES 8A200
8A210
~V~~LY)
1537
c200A
I
I
I
I
I
I
I
I
I
I
R"
SOFF'"
ICATOR
.35 TANtWHT
.5278
\(G))(G))l
~~
~~
.35 OK BLU
'.....
POWERTRAIN
iNDicATOR
LOW COOLANT
INDICATOR
FOR 249:
Pl lO
I
I
"BRAKE"~
INDICATORW
"AS
----1-------~:~l -------- 1---TO CRUISE

CONTROL
419
INDICAT.)R
419
wlNDICATOR
~ "LOW
~"AIRBAG"
w
INDICATOR
ry~::~T:;..,:
INOICATORw
=-0
\ r
SEATBELT"
~ ~!~~
.3SWHTi':75
015"'
--5208
H I C220
C15
3BRNJ;41
SEE ANTILOCK
BRAKES/
TRACTION
CONTROL
PAGE BA-44-2
..I
.35 ~:T'(:5
11
<llilq..- - - .5253
3BRN 1341
SEE FUSE
BLOCK DETAILS
PAGE 8A 11-9
15
1415 (T61)
L., -
341
C200D
.... -.,
.5DKBLU
.5 DK BLU/
WHT
-I
3 BRN
...
E11 yc2ooc
POWERTRAIN
CONTROL
MODULE (PCM)
PAGE BA-21-7
~!!!!!!!!!!!!!!!!!~. 5214
TO CONVERTIBLE
TOP SWITCH
PAGEBA-121-0
INDICATOR
LATCHING
CONTROL
A'
"
COOLANT
--iTvEL
LATCHING
MODULE
SA - 81
-4

(16
01
IO
12045515

BLK
INSTRUMENT CLUSTER
(CHEVY).
,..,
"
WIRE COLOR
CKT
C1
PPUWHT
1572
(2
TAN
31
OIL PRESSURE INDICATOR CONTROL
SA-810
C3
GRY
1/P ILLUMINATION LAMPS FEED
BA-812
(4
BLK
650
GROUND
SA-148
C6
YEL
237
BA-813
C7
C7
LTIILU
LTBLU,WHT
14
1414
(DOMESTIC) LEFT TURN SIGNAL SWITCH OUTPUT'

(WITH T61) LEFT TURN SIGNAL SWITCH OUTPUT
BA-813
SA-813
cs
BRN,WHT
419
SERVICE ENGINE SOON INDICATOR LAMP CONTROL
BA-81-3
C10
TAN,WHT
33
BRAKE WARNING INDICATOR LAMP CONTROL
'
DESCRIPTION
PAGE
CAVITY
..
,'
"ASR" INDICATOR LAMP CONTROL (WITH NW9)
BA-813
BA-813
,.
C11
LTGRN
11
C12
RED
C13
HIGH BEAM HEADLIGHTS ON
SA-813
225
GENERATOR OUTPUT- INDl<:ATOR CONTROL
SA-81-1
GRY
728
SECURITY INDICATOR LAMP CONTROL
SA-812
C14
ORN
34q
POWER FE ED FROM PCM BAT .FUSE 4
SA-117
C15
C15
DKBLU
DKBLU,WHT
15
1415
(DOMESTIC) RIGHT TURN SIGNAL SWITCH OUTPUT

(WITH T61) RIGHT TURN SIGNAL SWITCH OUTPUT
8A813
8A813
C16
BRN
358
AIR BAG INDICATOR CONTROL
8A813
01
DKGRN,WHT
817
VEHICLE SPEED SIGNAL -4000 PULSES PER MILE
BA-810
02
PPL
30
FUEL GAGE SIGNAL
8A812
03
DKGRN
135
COOLANT TEMPERATURE SENSOR SIGNAL
8A811
05
WHT
121
TACHOMETER SIGNAL
BA-810
06
LTGRN
867
ABS FAIL SIGNAL
SA-811
07
PNK
39
POWER FEED FROM GAGES FUSE 9
BA-11 5
08
BLK!WHT
451
GROUND
8A141,2,3
011
YELJBLK
68
LOW COOLANT LEVEL INDICATOR CONTROL
8A813
012
BRN
1174
OIL LEVEL SENSOR SIGNAL
BA-811
013
PNK
39
8A-115
015
WHT
375
"SKIP SHIFT" INDICATOR LAMP CONTROL
BA-813
016
DKBLU
1537
ABS ACTIVE OUTPUT
SA-813
,'(
-5
12065803
BLK
INSTRUMENT CLUSTER,
(PONTIAC)
CAVITY
WIRE COLOR
CKT
A1
PNK
39
SA-11-5
A2
PPL
30
FUEL GAGE SIGNAL
SA-81-2
Al
GRY
728
SECURITY INDICATOR LAMP CONTROL
SA-81-2
A4
SRN/WHT
419
SERVICE ENGINE SOON INDICATOR LAMP CONTROL
SA-81-3
AS
PNK
39
SA-11-5
A6
YEUBLK
68
LOW COOLANT LEVEL INDICATOR CONTROL
SA-81-3
A7
BRN
358
AIR BAG INDICATOR CONTROL
SA-81-3
AS
PPUWHT
1572
"TCS OFF" INDICATOR LAMP CONTROL (WITH NW9)
SA-81-3
A10
TAN/WHT
33
BRAKE W.'\RNING INDICATOR LAMP CONTROL
SA-81-3
A11
LTGRN
11
HIGH BEAM HEADLIGHTS ON
SA-81-3
A12
YEL
237
SA-81-3
A13
ORN
340
POWER FEED FROM PCM BAT FUSE 4
SA-11-7
A14
RED
225
GENERATOR OUTPUT.INDICATOR tONTROL
SA-81-1
A15
BRN
1174
OIL LEVEL SENSOR SIGNAL
SA-81-1
A16
DKBLU
1537
"L,OW TRAC" INDICATOR LAMP CONTROL"
SA-81-3
A17
DKGRN
135
COOLANT TEMPERATURE SENSOR S\~NAL
SA-81-1
82
GRY
1/P ILLUMINATION LAMPS FEED
SA-81-2
83
BLK
650
GROUND
SA-14-8
84
WHT
375
"SKIP SHIFT" INDICATOR LAMP CONTROL
8A81-3
85
BS
DK BLU
DKBLU/WHT
15
1415
(DOMESTIC) RIGHT TURN SIGNAL SWITCH OUTPUT

(WITH T61) RIGHT TURN SIGNAL SWITCH OUTPUT
SA-81-3
SA-81-3
812
DKGRN/WHT
817
VEHICLE SPEED SIGNAL - 4000 PULSES PER MILE
SA-81-0
813
WHT
121
TACHOMETER SIGNAL
SA-81-0
814
814
LTBLU
LT BLU/WHT
14
1414
(DOMESTIC) LEFT TURN SIGNAL SWITCH OUTPUT

(WITH T61) LEFT TURN SIGNAL SWITCH OUTPUT
SA-81-3
SA-81-3
815
BLK/WHT
45.1
GROUND
SA-14-1,2,3
816
TAN
31
OIL PRESSURE INDICATOR CONTROL
SA-81-0
817
LTGRN
867
ABS FAIL SIGNAL
SA-81-1
DESCRIPTION
PAGE
BA - 81
-6
ELECTRltAL DIAGNOSIS
FOR CONNECTOR CHART, SEE SECTION SA-202.
(2000
E13
06
"I
86
11P HARNESS TO FORWARD

DDDDDDDDDDDDDE
II
II
ILI,
11
11
In
11
11
t::=:::;11
Hi
1l=:::::=::J
~I
II
1-1-1
II 1"
II I
1
II
II
81
ADDDDDDDDDDDDDDDDDA
11
12077822
M CONNECTOR
F-TERMINAL
48-WAV M METRI-PACK MIXED SERIES

BLK
(200A

1/P HARNESS
J AH DODD DD DD DD DD DODD D AI
1
12047842
BLK

1/PHARNESS
(2008
81
c1
01
__1_1__I[
__11_--11
__1_1__11
_1__11 1_1-I 11___1_1__

I II 1_1--
1
I
I
86
C6
D6
12084183
18-WA V F METRI-PACK MIXED SERIES
BLK
1/P HARNESS
(200(
IADDDDDD DODD DDDml

1
12047840
GRY
..
I FOR CONNECTOR CHART, SEE SECTION SA-202.

(220
ENGINE HARNESS
TO 1/P HARNESS
It? 'ii1 ~Cf?~

~ c~:u:!J
c:'h ca
12064769
WHT
IFOR CONNECTOR CHART, SEE SECTION SA-202.

(230
lttl ~ Ci5J Cf?~

~ ell dJ &
ENGINE HARNESS TO
1/PHARNESS
ca
12064871
BLU
-7
SA~ 81 -8 ELECTRICAL DIAGNOSIS
IFOR CONNECTOR CHART. SEE SECTION 8A-202.

C405B
1/P HARNESS TO FUEL
TANK UNIT PIGTAIL/
REAR WHEEL SPEED
SENSOR JUMPER HARNESS
12092789
10-WAV M METRI-PACK 150, 280 SERIES
BLK
C405A
C405C
FUEL TANK UNIT
PIGTAIL TO
1/PHARNESS
REAR WHEEL
SPEED SENSOR
JUMPER HARNESS
TO 1/P HARNESS
12110481
12092800
5-WA V F METRI-PACK 150, 280 SERIES
4-WA VF METRI-PACK MIXED SERIES

BLK
RED
ELECTRICAL DIAGNOSIS SA- 81- 9
INSTRUMENT CLUSTER: WITH GAGES (CHEVY)

FORZ49:
(Ci)) (G))
\
HECK GAUGES ,
SECURITY LOW TRAC '3

SERVICE
KE
'
ENGINE SOON BRA
-- 2.' 1.J.
., ,,
11,
18'
8':'
//
1:3~~
+
\ ~ . , . . .,
'4
16--
I/
-1
- :a.
RPM
XlOOO
--~O eo, =
'30 so,
-20 40
.:. ,o
FORZ49:
:ii _...
.,.+
c!O '
MPH
......
.o-
a-
\ \ I
, SO
~/
. .
'
' ' 60
70 BO so' I
100 120 140 100 / /
'6' 7
16
~0 "'*"
120 ....
200
130c!20 140.:
~8
km/h
. ,111
, , 260
,'& ..
1so::
LOW OIL
UNLEADED FUEL ONLY
-e
~)oo
INSTRUMENT CLUSTER FRONT VIEW
(8)
15
8
13
016
01
INSTRUMENT CLUSTER REAR VIEW
INSTRUMENT CLUSTER
SIOEVIEW
LAMP LOCATION LEGEND

1
"AIRBAG'' Indicator Lamp
Low Coolant Indicator Lamp (VS only)
"ABS INOP" Indicator Lamp
10
"LOW OIL" Indicator Lamp
"BRAKE" Indicator lamp
11
"LOW TRAC" Indicator Lamp
"CHECK GAUGES" Indicator Lamp
12
Right Turn Indicator Lamp
Fasten Seat Belt Indicator Lamp
13
"SECURITY" Indicator Lamp
High Beam Indicator Lamp
14
"SERVICE EN~INE SOON" Indicator Lamp
Illumination Lamp
15
"ASR" Indicator Lamp
Left Turn Indicator Lamp
16
"SKIP SHIFT" Indicator Lamp
SA - 81
- 10
INSTRUMENT CLUSTER: WITH GAGES (PONTIAC)
___o
FORZ49:
LOW
TRAC
~ ~
260'
'0
BD'
..t~
\.
'IUD
ABS
INOP
220
210
'al
~~'jl
8
(.'\
\..:J
18
,E
F.
0
0
INSTRUMENT CLUSTER - FRONT VIEW
0 0
0
7
INSTRUMENT CLUSTER - REAR VIEW
LAMP LOCATION LEGEND
1
.. AIR BAG" Indicator Lamp
Low Coolant Indicator Lamp (VB only)
.. ABS INOP" Indicator Lamp
10
"LOW OIL" Indicator Lamp
"BRAKE" Indicator Lamp
11
"CHECK GAUGES" Indicator Lamp
12
Right Turn Indicator Lamp
Fasten Seat Belt Indicator Lamp
13
"SECURITY" Indicator Lamp
High Beam Indicator Lamp
14
"SERVICE ENGINE SOON" Indicator Lamp
Illumination Lamp
15
"SKIP SHIFT" Indicator Lamp
Left Turn Indicator Lamp
16
"TCS OFF" Indicator Lamp
COMPONENT
LOCATION
201-PG
FIG.

Module . . . . . . . . . . . . . . . . In molded pocket of dash mat, center above floor tunnel 45 . . . 84
Module (DERM) ....... . Snapped in bracket, behind RH side ofl/P Compartment 8 . . . . 15
Pass Thru Grommet .............................. 8 . . . . 14 ..
Pass Thru Grommet .............................. 8 . . . . 14
Engine Coolant Level Sensor
(VS VIN P) . . . . . . . . . . . . Mounted on upper right side ofradiator . . . . . . . . . . . . . . 19
35
Gage Sensor (V6 VtN S)
Left front of Engine, mounted in Head . . . . . . . . . . . . . . . 27
52
Engine Coolant Tem~erature
Gage Sensor (VS VIN P)
Mounted in LH Head, between 1 and 3 Cylinders . . . . . 16
29
Fuel Tank Unit . . . . . . . . . . Under rear of vehicle
Generator . . . . . . . . . . . . . . . RH front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 29 26, 56
I/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
(V6 VIN S) . . . . . . . . . . . . . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . 52
Instrument Cluster . . . . . . . LH side of I/P ................................................... .
Oil Level Sensor . . . . . . . . . Lower left side of Engine, in oil pan . . . . . . . . . . . . . . . . . . 11, 24 20, 44
Oil Pressure Sensor
(V6 VIN S) . . . . . . . . . . . . . Lower left side of Engine, above oil filter ............ . 11
20
Oil Pressure Sensor
(VS VINP) ........... . Mounted to top center of Engine block, rear of manifold 26
50
19
(PCM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower
35
19
(PCM) (VS VIN P) ..... . In Engine Compartment, rearward of RH Shock Tower
35
17
(RAP) Module ......... . In molded pocket of dash mat, center above floor tunnel 9
In
1/P,just
right
of
Radio,
attached
to
Air
Bag
Bracket
.
8
15
Part
of
Forward
Lamp
Harn,
between
LH
kick
panel
C200A (17 cavities)
and Steerirtg Column ............................ . 25
49
Part
of
Forward
Lamp
Harn,
between
LH
kick
panel
C200B (18 cavities)
an~ Steering Column ............................ . 25
49
C200C (13 cavities)
Steering Column ................................ . 25
49
Part
ofl/P
Harn,
between
LH
kick
panel
and
C200D (48 cavities)
49
Steering Column ................................ . 25
20
Under
RH
side
of
1/P,
behind
RH
kick
panel
.........
.
37
C210 (4 cavities) ........ .
37
C220 (10 cavities) ....... . Under RH side of 1/P, be hind kick panel ............. . 20
37
C230 (10 cavities) ....... . Under RH side of 1/P, behind kick panel ............. . 20
Part
of
Pass
Thru
Conn,
forward
of
rear
axle,
to
C405A (4 cavities) ... : .. .
Fuel Tank Unit ................................. . 5
9
Part
of Pass Thru Conn, forward of rear axle, to
C405B (10 cavities) ..... .
Pass Thru Panel ................................ . 5
9
of
Engine
Block,just
above
Starter
RH
side
G103 (LTl) ............. .
(1 ring, 1 wire) .................................. . 40 ... 72
- 11
CONN
202-20
202-12
202-13
202-13
202-21
202-23
202-22
202-23
202-23
202-25
202-26
202-27
202-18
202-2
202-2
202-2
202-2
202-19
202-6
202-7
202-8
202-8
BA - 81
- 12 ELECTRICAL DI.AGNOSI.S

COMPONENT
LOCATION
201.;PG
G104 (L32) . . . . . . . . . . . . . . 2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, 1 stud in Intake Manifold . . 29 . . .
G200 . . . . . . . . . . . . . . . . . . . . Near base ofLH"A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ......... : . . . . . . 9 . . . .
G305 . . . . . . . . . . . . . . . . . . . . Bolted to Floor Pan Bar #2, under Driver's Seat
without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
Pl 10 . . . . . . . . . . . . . . . . . . . . Right side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . 19 . . .
8109 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 4 cm from main branch and
PCM breakout
8110 (L32) . . . . . . . . . . . . . . Engine Harn, approx 7 cm from RH Oxygen Sensor
breakout
8206 . . . . . . . . . . . . . . . . . . . . I/P Harn, approx 18 cm from Convenience Center
breakout
8208 . . . . . . . . . . . . . . . . . . . . Cross Car Harn, approx 5 cm from Express Down
Module breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . .
8209 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 24 cm from Convenience Center
breakout
8214 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 7 cm from G200 breakout
8215 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 30 cm before DLC_breakout
8216 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 5 cm from Convenience Center (Pont)
8220 . . . . . . . . . . . . . . . . . . . . Cross Car Harn, approx 9 cm from C200 breakout . . . . . 45 . . .
8224 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 4 cm from Instrument Cluster (Pont)
8228 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 15 cm before DLC breakout
8242 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 26 cm from Instrument Cluster Conn
8253 . . . . . . . . . . . . . . . . . . . . I/P Harn, approx 35 cm from Convenience Center
breakout
8273 . . . . . . . . . . . . . . . . . . . . Forward Lamp Harn, approx 25 cm from breakout
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . .
8278 . . . . . . . . . . . . . . . . . . . . Forward Lamp Harn, approx 9 cm from EBCM breakout
FIG.
CONN
56
16
11
35
84
84
14

Diagnosis)
System
For Instrument Cluster removal and replacement,

refer to SECTION SC.
1. It is possible to have an open circuit to an indicator
within the Cluster, though unlikely. Check
circuits from suspect socket to connector terminals
before replacing Cluster for an indicator problem.
2. If more than one gage or indicator are inoperative,
check the appropriate fuse and ground before
continuing.
inside of tllejnsul_ation which could cause system
1
malfunction
but
prove
'GOOD"
in
a

integrity of other systems (see ''Troubleshooting
SYSTEM DIAGNOSIS

procedures.
81 - 13
SYSTEM CHECK (for Indicators)

ACTION
NORMAL RESULTS
[1]
Turn Ignition Switch from "OFF" to "RUN."
- "AIR BAG" Indicator will flash 7 to 9 times, then go

out.
- "ABS INOP" Indicator is "ON" for approximately
3 seconds.
- "TCS OFF" (Pont) or "ASR" (Chevy) Indicator "ON"
approximately 3 seconds.
- "BRAKE" Indicator "ON" approximately 3 seconds.
- "CHECK GAUGES" Indicator is "ON" continuously.
- "LOW OIL" Indicator is "ON" for approximately
1 second.
- "LOW COOLANT" Indicator "ON" approximately
1 second.
- "LOW TRAC" Indicator "ON" approximately
3 seconds.
- "SECURITY" Indicator is "ON" for approximately
5 seconds.
- Fasten Seat Belt Indicator "ON" if not buckled.
[2]
Turn Ignition Switch slowly through "BULB TEST" - (MIL) "SERVICE ENGINE SOON" Indicator "ON"
to "START."
momentarily at "START" then goes "OFF."
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Instrument Cluster Illumination Lamps are inoperative See "Interior Lights Dimming," SECTION BA-117.
or do not dim properly.
GAGES
Coolant Temperature Gage always indicates Cold.
Chart #1
BA-81-15
Coolant Temperature Gage always indicates Hot.
Chart #2
.BA-81-15
Coolant Temperature Gage appears inaccurate.
Chart #3
BA-81-15
Fuel Gage always indicates Empty.
Chart #4
BA-81-16
Fuel Gage always indicates.Full.
Chart #5
BA-81-16
Fuel Gage appears inaccurate.
Chart #6
BA-81-17
Oil Pressure Gage always indicates High Pressure.
Chart #7
SA-81-18
Oil Pressure Gage always indicates Low Pressure.
Chart #8
BA-81-18
Oil Pressure Gage appears inaccurate.
Chart #9
SA-81-18
Speedometer inoperative or inaccurate.
See "Vehicle Speed Sensor," SECTION 8A-33.
Tachometer inoperative or inaccurate.
Chart #10
SA-81-19
Voltmeter inoperative or inaccurate.
Chart #11
SA-81-19
INDICATORS
"ABS INOP" Indicator problem.
See SECTION SE 1.
SA - 81
- 14 ELECTRICAL DIAGNOSIS

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
"AIR BAG" Indicator problem.
See SECTION 9JA.
"BRAKE" Indicator problem.
See "Brake Warning," SECTION 8A-41.
"CHECK GAUGES" Indicator always "ON."
Chart #12
SA-81-20
"CHECK GAUGES" Indicator does not turn "ON."
Chart #13
SA-81-20
Fasten Seat Belt Indicator problem.
See "Audible Warnings," SECTION 8A-76.
High Beam Indicator problem.
See "Headlights and Fog Lights," SECTIONSA-100

(without DRL), SECTION 8A-102 (with DRL).
Low Coolant Indicator does not turn "ON."
Chart #14
SA-81-21
Low Coolant Indicator always "ON" (coolant level

OK).
Chart #15
BA-81-22
Low Coolant Indicator turns "ON" and "OFF" Check for an open or poor connection in CKT 68
intermittently while driving.
between C200C and Retained Accessory Power
Module (with AU3) or Coolant Level Latching Module
(without AU3). Also check power and ground to the
Coolant Level Latching Module. If circuits and
connections are good, replace the respective module.
NOTICE: The module should keep the indicator

"ON" (latched) for entire Ignition cycle after the
Engine Coolant Level .Sensor detects a low.
"LOW OIL" Indicator does not turn "ON" when oil
level is low.
Chart #16
SA-81-23
"LOW OIL" Indicator stays "ON" wfien oil level is OK:
Chart #17
SA-81-23
"LOW TRAC" Indicator problem.
See SECTION SE 1.
"SECURITY" Indicator problem.
See SECTION 90.
"TCS OFF" (Pont) or "ASR" (Chevy) Indicator problem.
See SECTION 5E2.
"SKIP SHIFT" Indicator problem.
See SECTION 6E3.
Low Coolant Indicator turns "ON" with bulb check but Replace Low Coolant Level Sensor.
does not turn "ON" when coolant level is low.
(MIL) "SE~VICE ENGINE SOON" Indicator problem.
See SECTION 6E3.
Turn Indicator problem, Left or Right.
See "Exterior Lights," SECTION BA-110.
POWER AND GROUNDS

More than 1 gage or indicator inoperative.
Disconnect Instrument Cluster and connect a Test

Light across the appropriate power and ground
terminals.
Test Light "ON"? - Check connector for poor
connection to Cluster. If OK, replace Instrument
Cluster.
Test Light "OFF"? - Repair open in power or ground
circuit to Cluster.
CHART #1
CHART #2
COOLANT TEMPERATURE GAGE ALWA VS

INDICATES COLD
COOLANT TEMPERATURE GAGE ALWAYS

INDICATES HOT
IGNITION "ON" - ENGINE "OFF."

DISCONNECT ENGINE COOLANT TEMPERATURE
GAGE SENSOR CONNECTOR.
CONNECT A JUMPER BETWEEN TERM" A" OF
CONNECTOR AND GROUND.
COOLANT TEMP GAGE SHOULD MOVE ALL THE
WAY TO THE RIGHT (HOT).
DOES IT?

DISCONNECT ENGINE COOLANT TEMPERATURE
GAGE SENSOR CONNECTOR.
DOES THE GAGE MOVE BACK TO THE LEFT (COLD)?
REPLACE THE ENGINE

COOLANT TEMPERATURE
GAGE SENSOR.
CHECK FOR POOR

CONNECTION.
IF OK, REPLACE THE
ENGINE COOLANT
TEMPERATURE GAGE
SENSOR.
CHECK FOR A SHORT TO

GROUND IN CKT 135.
IF OK.REPAIR/REPLACE THE
INSTRUMENT CLUSTER.
CHECK CKT 135 FOR A POOR

CONNECTION OR AN OPEN.
IF OK, REPAIR/REPLACE
INSTRUMENT CLUSTER.
CHART #3
COOLANT TEMPERATURE GAGE APPEARS INACCURATE

DISCONNECT ENGINE COOLANT TEMPERATURE GAGE SENSOR CONNECTOR.
USING 1/P TESTERJ 33431 OR EQUIVALENT, CONNECT ONE RED CLIP LEAD FROM THE
TESTER TO THE SENSOR CONNECTOR TERM" A". CONNECT THE OTHER RED CLIP
LEAD TO GROUND.
ADJUST THE RESISTANCE DIALS OF THE TESTER TO 1400 OHMS AND THEN 55 OHMS.
THE COOLANT TEMP GAGE SHOULD REGISTER COLD AND THEN HOT.
DOES IT?
REPLACE THE ENGINE

COOLANT TEMPERATURE
GAGE SENSOR.
- 15
CHECK FOR A POOR CONNECTION

OR HIGH RESISTANCE IN CKT 135.
INSTRUMENT CLUSTER.
SA - 81
- 16

CHART #4
FUEL GAGE ALWAYS INDICATES EMPTY
ASSUMES OTHER GAGES ARE OPERATING NORMALLY.

DISCONNECT FUEL TANK UNIT CONN C405A.
DOES FUEL GAGE INDICATE FULL?
IGNITION "OFF."
DISCONNECT INSTRUMENT CLUSTER CONN.
IGNITION "ON" -ENGINE "OFF."
CONNECT A TEST LIGHT FROM TERM "013" TO TERM "02" (CHEVY)
OR TERM "AS" TO TERM "A2" (PONT).
IS TEST LIGHT "ON"?
r-
-------------------,
:
:
REPLACE FUEL GAGE SENDER, :

PARTOFFUEL TANKUNIT.
:
REFER TO SECTION 6C.
1
REPAIR SHORT TO
GROUND IN CKT 30.
CHART #5
FUEL GAGE ALWAYS INDICATES FULL
(VERIFY THAT FUEL TANK IS NOT ACTUALLY FULL)
DISCONNECT FUEL TANK UNIT CONN C405A.

CONNECT A FUSED JUMPER TO C405B TERM" A2"
(10-WAY CONN MOUNTED TO PANEL) TO GROUND.
DOES FUEL GAGE INDICATOR MOVE TO EMPTY?
IGNITION "OFF."
CONNECT FUSED JUMPER FROM C405B TERM" A2" TO
TERM "A3" (10-WAY CONN MOUNTED TO PANEL).
DOES FUEL GAGE INDICATOR STAY ON EMPTY?
r-
--------------------------------------------,
IGNITION "OFF."
CHECK FOR OPEN IN CKT 1050 OR CKT 30 TO FUEL TANK UNIT, OR FOR
POOR CONNECTION AT C405.
IF OK, REPLACE FUEL GAGE SENDER, PART OF FUEL TANK UNIT.
REFER TO SECTION 6C (A SHORT TO B + ON CKT 30 COULD CAUSE AN
ALWAYS FULL INDICATOR CONDITION, THOUGH UNLIKELY).
:
:
:
I
:
'
:
:
:
1
~----------------------------------------------J
CHECK FOR OPEN IN CKT 30 BETWEEN C405B AND

INSTRUMENT CLUSTER, OR FOR BAD CONNECTION AT
CLUSTER CONN TERM "02" (CHEVY) OR TERM "A2"
(PONT).
IF OK, REPAIR/REPLACE INSTRUMENT CLUSTER (A
SHORT TO B + ON CKT 30 COULD CAUSE AN ALWAYS
FULL INDICATOR CONDITION, THOUGH UNLIKELY).
REPAIR OPEN IN CKT 1050 BETWEEN G305

AND (405, OR POOR GROUND AT G305.
CHA~T #6
FUEL GAGE APPEARS INACCURATE
DISCONNECTFUEL TANK UNIT CONN C40SA.

USING 1/P TESTER J 33431., CONNECT ONE RED CLIP LEAD FROM THE TESTER TO
C405B TERM" A2" (10-WA Y CONN MOUNTED TO PANEL). CONNECT THE
OTHER RED CLIP LEAD TO GROUND.
SET TESTER TO "O" OHMS.
IGNITION "ON" -ENGINE "OFF."
DOES FUEL GAGE JNDICATE EMPTY?
rn
IMPORTANT:
IF A J 33431 IS UNAVAILABLE, RESl~TORS OF EQUAL.VALUE MAY BE USED.
SET RESISTANCE TO "90" OHMS FOR 1

MINUTE OR UNTIL GAGE READS FULL, THEN
SLOWLY REDUCE RESISTANCE TO "O" OHMS
OVER 1 MINUTE'S TIME.
AS RESISTANCE VALUES CHANGE, DOES
GAGE INDICATOR CHANGE VALUES EQUAL
TO THE TABLE BELOW?
r- ------------------------------------~,
: CHECK FOR INTERMITTENT OPEN IN CKT 1050 OR FOR POOR :
I
GROUND CONNECTION.
'
1
: CHECK FUEL TANK UNIT WIRES FOR DAMAGE.
:
: CHECK FOR MECHANICAL CLEARANCE BETWEEN FLOAT
:
I
AND TANK INTERIOR.
1
: IF THE CONNECTIONS ARE LOOSE OR CORRODED, OR
:
:
WIRES SHORTED, REPAIR AS REQUIRED.
:
I
IF OK, REPLACE FUEL GAGE SENDER (REFER TO SECTION 6C). 1
CHECK CK.T 30 AND CONNECTORS TO CLUSTER

AND FUEL TANK UNIT FOR A RESISTIVE OPEN
OR POOR.CONNECTION. (A TOTALLY OPEN
C~T 30 WOULD CAUSE GAGE TO READ FULL, A
SHORT TO. GROUND WOULD READ EMPTY.)
IF OK, REPAIR/REPLACE INSTRUMENT CtUSTER.
!=HECl(CKT 30 AND CONNECTORS TO CLUSTER

.AND FUEL TANK l,JNIT FOR A RESISTIVE OPEN
OR POOR CONNECTION. (A TOTALLY OPEN
CKT 30 WOU!-D CAUSE GAGE TO READ FULL, A
SHORT TO GROUND WOULD RE.AD EMPTY.)
IF OK, REPAI.R/REPLACE INSTRUMENT CLUSTER.
L---------------------------------------~
FUEL GAGE SENDER

RESISTANCE
A_PPROXIMATE FUEL LEVEL
88n
FULL
60 n
3/4
43 n
1/2
26n
1/4
1.0 Q
EMPTY
SA- 81 -18 ELECTRICAL DIAGNOSIS
rn
CHART #7
CHART #8
OIL PRESSURE GAGE ALWAYS INDICATES

HIGH PRESSURE
OIL PRESSURE GAGE ALWA VS INDICATES

LOW PRES SU RE
rn
IMPORTANT:
CHECK FOR PROPER OIL LEVEL, THEN CHECK OIL

PRESSURE WITH A MECHANICAL GAGE BEFORE
PROCEEDING. IF NOT OK, REFER TO SECTION 6A.
IGNITION HON" - ENGINE "OFF.ff

DISCONNECT OIL PRESSURE SENSOR CONNECTOR.
CONNECT A JUMPER BETWEEN TERM uAn OF
DOES GAGE MOVE BACK TO THE LEFT (LO PRESSURE)?
CHECK FOR POOR

CONNECTION.
IF OK, REPLACE OIL
PRESSURE SENSOR.
IMPORTANT:
CHECK FOR PROPER OIL LEVEL, THEN CHECK OIL

IGNITION HON" - ENGINE "OFF."

DOES OIL PRE SS URE GAGE MOVE ALL THE WAY TO THE
RIGHT (HIGH PRESSURE)?
CHECK FOR A POOR

CONNECTION OR OPEN IN
CKT31.
INSTRUMENT CLUSTER.
CHART#9
rn
OIL PRESSURE GAGE APPEARS INACCURATE

IMPORTANT:
CHECK FO.R PROPER OIL LEVEL, THEN CHECK OIL

USING 1/P TESTER J 33431 OR EQUIVALENT, CONNECT ONE RED
CLIP LEAD TO THE SENSOR CONNECTOR TERM n A" AND CONNECT
THE OTHER RED CONNECTOR TO GROUND.
SET THE RESISTANCE DIALS ON THE TESTER TOO OHMS,40 OHMS
AND 100 OHMS.
THE OIL PRESSURE GAGE SHOULD GO FROM LO PRESSURE TO
APPROXIMATELY 30 psi, AND THEN TO HIGH PRESSURE.
DOES IT?
CHECK CKT 31 FOR POOR OR

CORRODED CONNECTIONS.
INSTRUMENT CLUSTER.
CHECK FOR SHORT TO GROUND

IN CKT 31.
.IF OK, REPAIR/REPLACE THE
INSTRUMENT CLUSTER.
81
CHART #10
TACHOMETER INOPERATIVE OR INACCURATE
(ASSUMES ENGINE RUNS NORMALLY)
(V6 VIN S) DISCONNECT IGNITION CONTROL MODULE CONN C1 (6-WAY).

(VS VIN P) DISCONNECT THE POWERTRAIN CONTROL MODULE CONN A.
USE 1/PTESTERJ 33431 WITHJ 33431-10 HARNESS OR EQUIVALENT.
(V6 VIN S) CONNECT THE TESTER TO CONN C1 TERM "C" AND GROUND.
(VS VIN P) CONNECT THE TESTER TO CONN A TERM "13" OF THE
SET THE TESTER TO 54 mph (60 Hz).
DOES THE TACHOMETER INDICATE APPROXIMATELY 1200 rpm FOR (V6 VIN S)
OR 900 rpm FOR (VS VIN P)?
(V6 VIN S) CHECK FOR POOR CONNECTION AT

IGNITION CONTROL MODULE CONN C1.
IF OK, REPLACE IGNITION CONTROL MODULE.
(VS VIN P) CHECK FOR POOR CONNECTION AT
POWERTRAIN CONTROL MODULE CONN A TERM "13".
IF OK, REPLACE POWERTRAIN CONTROL MODULE.
CHECK FOR AN OPEN, SHORT TO GROUND ORB+ IN CKT 121.

IF OK, REPAIR/REPLACE INSTRUMENT CLUSTER.
CHART #11
VOLTMETER INOPERATIVE OR INACCURATE

CONNECT A DVM SET TO DC SCALE TO THE POSITIVE AND NEGAT.IVE
TERMINALS OF THE BATTERY.
DOES THE VOLTMETER AT THE INSTRUMENT CLUSTER CLOSELY MATCH
THE VOLTAGE READING ON THE DVM?
START ENGINE AND AGAIN MEASURE THE VOLTAGE

ACROSS THE BATTERY TERMINALS.
DOES THE VOLTMETER IN THE INSTRUMENT
CLUSTER STILL CLOSELY MATCH THE DVM?
-19
SA - 81
- 20
ELECTRICAL DtAGNOSIS

CHART #12
"CHECK GAUGES"INDICATOR ALWAYS "ON"
ENGINE RUNNING AT IDLE.

MEASURE SYSTEM VOLTAGE ACROSS BATTERY.
IS VOLTAGE MORE THAN 16.5 VOLTS OR LESS THAN 11.2 VOLTS?
----------------------------------------------,
CHECK FOR PCM DIAGNOSTIC TROUBLE CODES RELATIVE TO CHARGING

SYSTEM, OIL PRESSURE OR TEMPERATURE.
REFER TO SECTION 6E.
VERIFY COOLANT TEMPERATURE IS BELOW APPROXIMATELY 252F FOR
V6 VIN SOR BELOW 244F FOR VB VIN P.
VERIFY OIL PRESSURE IS ABOVE 8.3 psi (MINIMUM FOR PUMP). ANYTHING
BELOW 3 TO 5 psi SHOULD CAUSE CHECK GAGES LIGHT TO TURN "ON."
ARE ALL OK?
---
r:
1
------------------,
REPAIR CHARGING SYSTEM, :
1
L--------------------J
-------------------- .~--.-------',
FOR THE SPECIFIC SYSTEM INDICATING

A PROBLEM CONDITION, REPAIR
MECHANICAL OR ELECTRICAL FAILURE.
SEE GAGES CHARTS IN THIS SECTION.
CHECK FOR OPEN OIOOOR CONNECTION IN

CKT 225. (IF CIRCUIT IS OPEN, GENERATOR WILL
NOT GENERATE VOLTAGE AND VEHICLE MAY BE
RUNNING ONLY ON BATTERY POWER.)
IF OK, REPLACE INSTRUMENT CLUSTER.
CHART #13
"CHECK GAUGES" INDICATOR DOES NOT TURN. "ON"
START ENGINE WHILE MONITORING "CHECK GAUGES" INDICATOR (SEE VIEW OF CLUSTER FOR LOCATION).
DID "CHECK GAUGES" INDICATOR TURN "ON" FOR APPROXIMA 'rELY 1 SECOND? ("CHECK GAUGES" INDICATOR
WILL STAY ON CONTINUOUSLY IF ENGINE IS NOT STARTED.)
IS THERE AN INDICATION OF A PROBLEM

WITH ONE OF THE FOLLOWING SYSTEMS?
- CHARGING SYSTEM
- COOLANT TEMPERATURE
- OIL PRESSURE
FOR GAGE FAILURE INDICATIONS, SEE SYMPTOM

TABLE TO REFERENCE SPECIFIC CHARTS.
FOR SYSTEM FAILURES:
- CHARGING SYSTEM, REFER TO SECTION 603
- COOLANT TEMPERATURE, REFER TO SECTION 68
- OIL PRESSURE, REFER TO SECTION 6A2A (V6 VIN S) 1
SECTION 6A3A (VB VIN P). :
----------------------------------~
-------------------------------------~
REPLACE "CHECK GAUGES" INDICATOR LAMP.

CYCLE IGNITION FROM "OFF" TO "ON" AGAIN.
IF INDICATOR DOES NOT TURN ON,
REPAIR/REPLACE INSTRUMENT CLUSTER.
SYSTEM OPERATING NORMALLY.

NO TROUBLE FOUND.
CHART #14
"LOW COOLANT" INDICATOR DOES NOT TURN "ON"
(ASSUMES OTHER INDICATORS OPERATE NORMALLY)
DISCONNECT ENGINE COOLANT LEVEL SENSOR.

CONNECT A FUSED JUMPER FROM CONN TERM "B" TO GROUND.
DOES INDICATOR TURN "ON"?
IGNITION "OFF."
DISCONNECT C200A ONLY (ONE OF THE
TWO FORWARD LAMPS TO 1/P HARNESS
CONNECTORS).
CONNECT THE FUSED JUMPER FROM C200D
TERM "A 17" TO GROUND.
DOES INDICATOR TURN "ON"?
CHECK FOR OPEN IN CKT 68 BETWEEN C200 AND

INSTRUMENT CLUSTER CONN TERM "011" (CHEVY)
OR TERM" A6" (PONT) OR FOR POOR CONNECTION
TO CLUSTER.
IF OK, REPLACE INDICATOR LAMP. (IT IS POSSIBLE TO
HAVE AN OPEN ORCUIT TO THE INDICATOR WITHIN
THE CLUSTER, THOUGH UNLIKELY. CHECK CIRCUITS
FROM SOCKET TO CONNECTOR TERMINALS BEFORE
REPLACING CLUSTER.)
CHECK FOR POOR CONNECTION AT CONN C200A

TERM "A17" OR OPEN IN CKT68 BETWEEN C200A
AND ENGINE COOLANT LEVEL SENSOR.
CHECK FOR AN OPEN IN GROUND CKT 250

TO TERM "C" OF CONNECTOR OR FOR A
POOR CONNECTION.
IF OK, REPLACE ENGINE COOLANT LEVEL
SENSOR.
- 21
SA - 81
- 22

CHART #15
"LOW COOLANT" INDICATOR ALWAYS "ON"
(COOLANT LEVEL OK)
DISCONNECT ENGINE COOLANT LEVEL SENSOR.

IS INDICATOR "ON"?
(WITH AU3) DISCONNECT RETAINED ACCESSORY

POWER MODULE CONNECTOR.
(WITHOUT AU3) DISCONNECT COOLANT LEVEL
LATCHING MODULE CONNECTOR.
IS INDICATOR "ON"?
DISCONNECT C200A FROM C200D

LEAVING C2008 AND C200C CONNECTED.
IS INDICATOR "ON"?
(WITH AU3) REPLACE RETAINED ACCESSORY

POWER MODULE.
(WITHOUT AU3) REPLACE COOLANT LEVEL
LATCHING MODULE.
DISCONNECT C200C FROM C200D LEAVING

C2008 CONNECTED.
IS INDICATOR "ON"?
REPAIR SHORT TO GROUND IN CKT 68 BETWEEN

C200A AND ENGINE COOLANT LEVEL SENSOR.
REPAIR SHORT TO GROUND IN CKT 68 FROM TERMINALS "A 17"

AND "EB" OF C200D AND INSTRUMENT CLUSTER CONNECTOR
TERM "011" (CHEVY) OR TERM" A6" (PONT).
IF NO SHORT FOUND, REPLACE OR REPAIR INSTRUMENT
CLUSTER AS NECESSARY.
REPAIR SHORT TO GROUND IN CKT 68 BETWEEN C200C AND

RETAINED ACCESSORY POWER MODULE CONNECTOR (WITH
AU3) OR COOLANT LEVEL LATCHING MODULE CONNECTOR
(WITHOUT AU3).
CHART #16
"LOW OIL" INDICATOR DOES NOT TURN "ON" WHEN OIL LEVEL IS LOW
IMPORTANT:
DUE TO THE PROGRAMMING OF THE CLUSTER, THE "LOW OIL" INDICATOR WILL NOT TURN "ON"
IF A LOW OIL CONDITION HAS OCCURRED WHILE ENGINE IS RUNNING. LET ENGINE COOL
APPROXIMATELY 45 MINUTES THEN KEY "ON" BEFORE PERFORMING DIAGNOSTICS.
TURN IGNITION FROM "OFF" TO "ON" WHILE MONITORING "LOW OIL"

INDICATOR (SEE VIEW OF CLUSTER FOR LOCATION).
DID "LOW OIL" INDICATOR TURN "ON" FOR APPROXIMATELY 1 SECOND?
IGNITION "OFF," WAIT A MINIMUM OF 35 MINUTES FOR

CLUSTER'S COLD OIL DRAIN BACK CALCULATION TO CLEAR.
DISCONNECT OIL LEVEL SENSOR CONNECTOR.
DOES "LOW OIL" INDICATOR COME "ON" AND STAY "ON"?
REPLACE "LOW OIL" INDICATOR LAMP.

CYCLING IGNITION FROM "OFF" TO "ON" AGAIN.
IF INDICATOR DOES NOT TURN ON,
REPAIR/REPLACE INSTRUMENT CLUSTER.
VERIFY THERE IS A LOW OIL CONDITION.

IF LOW OIL, REPLACE OIL LEVEL SENSOR.
CHECK FOR A SHORT TO GROUND IN CKT 1174.

CHART #17
"LOW OIL" INDICATOR STAYS "ON" WHEN OIL LEVEL IS OK
IGNITION "OFF," WAIT A MINIMUM OF 35 MINUTES FOR CLUSTER'S

COLD OIL DRAIN BACK CALCULATION TO CLEAR.
DISCONNECT OIL LEVEL SENSOR CONNECTOR.
JUMPER THE HARNESS CONNECTOR FROM TERM" A" TO TERM "B".
DOES INDICATOR TURN "ON" FOR APPROXIMATELY 1 SECOND
THEN GO "OFF"?
IGNITION "OFF."
JUMPER STILL CONNECTED AT SENSOR CONN.
DISCONNECT INSTRUMENT CLUSTER.
CONNECT A TEST LIGHT FROM TERM "012" (CHEVY) OR
TERM "A15" (PONT) TO B +.
IS TEST LIGHT "ON"?
VERIFY OIL LEVEL TO BE CORRECT.

IF OIL LEVEL IS OK, CHECK FOR POOR
CONNECTION AT OIL LEVEL SENSOR CONNECTOR.
IF OK, REPLACE OIL LEVEL SENSOR.
CHECK FOR POOR CONNECTION TO CLUSTER AT

TERM "012" (CHEVY) OR TERM" A15" (PONT).
- 23
BA -
81 - 24
ELECTRlCAL DIAGNOSIS

CIRCUIT OPERATION
The Instrument Cluster contains Analog Gages
and Indicators. Some Gages and Indicators are
controlled by solid state controls within the Cluster;
some are controlled by direct circuits into the Cluster
from other components. These operations are
described here briefly.
1
"ABS INOP" INDICATOR, FORZ49:
f~es~
\t:::}}
See SECTION 5El.
resistance (approximately 55 ohms at 260F (hot) and

approximately 1365 ohms at 100F). The varying
sensor resistance causes the current through the coils
to fluctuate. The magnetic fields of the coils move the
pointer.
"FASTEN SEATBELT" INDICATOR
See "Audible Warnings," page SA-76-0.

FUEL GAGE
"AIR BAG" INDICATOR
See SECTION 9J.

"ASR" INDICATOR {CHEVY)
See SECTION 5E2.

,, .
"BRAKE" INDICATOR, FOR 249: {G))
II
<G>
See "Brake Warning," page SA-41-5.

"CHECK GAUGES" INDICATOR
The Instrument Cluster's internal circuitry

monitors three inputs for determining when to
illuminate the "CHECK GAUGES" Indicator.
The "CHECK GAUGES" lndicator is provided a
ground for illumination when:
1. The Coolant Temperature Sensor indicates
above normal temperature (252F for
V6 VIN Sor 244F for V8 VIN Pl,
2. The Instrument Cluster senses the Generator
turn on input is at ground potential. The
Generator pulls CKT 225 low with system
voltage at or below l 1.2v or with 16.5v or
higher, also pulled low if Generator is stopped.
3. The Oil Pressure Sensor indicates below
normal pressure. The minimum rating for the
pump is 8.3 psi, though the sensor will be
approximately 3 to 5 psi at 10 ohms which will
cause the "CHECK GAUGES" Indicator to
illuminate (maximum pressure should be
about 90 ohms at the sensbr).
4. The Instrument Cluster performs a bulb check
function for approximately one second after
Ignition "ON."
COOLANT TEMPERATURE GAGE
The Coolant Temperature Gage contains internal

coils that create magnetic fields when current. flows
though them. The current through the coils varies
depending on the Coolant Temperature Sensor
The Fuel Gage contains internal coils that create

magnetic fields when current flows through them. The
curre'nt through the coils varies depending on the Fuel
Gage Sender resistance (see Fuel Level/Resistance
Chart). The varying sender resistance causes the
current through the coils to fluctuate.. The magnetic
fie Ids of the coils move the pointer.
HIGH BEAM INDICATOR
The High .Beam Indicator has system voltage

applied to it whenever the Headlights are "ON" and
the Headlight Dimmer Switch is on "HIGH." The
Indicator has a constant ground and will illuminate
whenever system voltage is applied.
"LOW COOLANT" INDICATOR (VS VIN P)
The "LOW COOLANT" Indicator has system

voltage applied in "RUN," "BULB TEST" or "START."
The Indicator requires a ground for illumination.
There are two ways the Indicator receives a ground:
1. During bulb check through the Engine
Coolant Level Sensor.
2. Whenever the Engine Coolant Level Sensor
detects a low coolant condition.
The Engine Coolant Level Sensor performs a bulb
check by grounding the circuit to the indicator for
approximately one second after Ignition "ON." When
a low coolant condition occurs, a ground path is
supplied through the Engine Coolant Level Sensor to
the Indicator. At the same time, ground is supplied
through the Engine Coolant Level Sensor to the
Retained Accessory Power Module (with AU3) or
Coolant Level Latching Module (without AU3). The
module is designed to provide a continuous ground
path to the Indicator for the remainder of the Ignition
cycle in which a momentary low coolant condition
occurred. (The module provides its own ground to the
Indicator until the Ignition is turned "OFF." This is
called latching.)
"LOW OIL" INDICATOR
The Instrument Cluster's internal circuitry will

only check the Oil Level Sensor at Ignition "ON" if
Drainback Times are met (35 minutes after Ignition
"OFF" if the Engine was still cold, or 4 minutes after
Ignition "OFF" if the Engine was hot. Hot is defined
as running for at least 17 minutes). Drainback Timer
sets at Ignition "OFF." The sensor has normally closed
contacts that are open under a low oil condition. After
determining a low oil condition exists, the "LOW OIL"
Indicator is provided a ground for illumination. The
Indicator also receives a ground for approximately one
second during the Cluster's bulb check function right
after Ignition "ON."
"LOW TRAC" INDICATOR
See SECTION 5El.

OIL PRESSURE GAGE
The Oil Pressure Gage contains internal coils that

create magnetic fields when current flows through
them. The current through the coils varies depending
on the Oil Pressure Sensor resistance. (Low pressure
resistaJ;).ce is approximately 10 ohms, high pressure
resistance is approximately 9.0 ohms.) The varying
sensor resistance causes the current through the coils
to fluctuate. The magnetic fields of the coils move the
pointer.
"SECURITY" INDICATOR
See SECTION 9D.

"SKIP SHIFT" INDICATOR
See SECTION 6E3.

(MIL) "SERVICE ENGINE SOON"
INDICATOR, FOR 249: ' : ~
See SECTION 6E3.ri._JJ

SPEEDOMETER
See "Vehicle Speed Sensor," page SA-33-0.

TACHOMETER
The Tachometer displays Engine speed in

Revolutions Per Minute (RPM). Voltage pulses from
the Ignition Control Module (V6 VIN S) or the
Powertrain Control Module ( VS VIN P) are
interpreted by solid state logic circuits within the
Cluster. The solid state circuits process the pulses and
put out a signal that drives the pointer of the meter.
81 - 25
The pointer is moved with magnetic fields created

from coils within the Tachometer.
"TCS OFF" INDICATOR (PONT)
See SECTION 5E2.

VOLTMETER
The Voltmeter measures the vehicle's electrical

system voltage during run or stopped conditions. The
Voltmeter has two coils internally that create
magnetic fields. These coils are made of a different
amount of windings and are in series with a calibrated
resistance. Any voltage between 8 to 18 volts will
create a magnetic field that will move the pointer to
the appropriate voltage indication.
SA -
WIPER/WASHER: PULSE
.I FUSE
BLOCK
._
_______ _ __ ...
ACCY
(NOTUSEDl
1
I
143
1 YEL
143
WIPER/WASHER
SWITCH ASSEMBLY
WASHER
SWITCH
MIST
HI
MIST,
OFF
e e
LO
PULSE
3600
.8 PNK
94
WIPER/
WASHER
REQUEST
INPUT
WIPERS
DELAY
INPUT
WIPER
INTERLOCK
1------------,
(PT()
_ ......_ ......--+.. LOW
INPUT
ISOLAf
TION
DIODE
(WIPERS)
(3AMP)
1------------'
WIPERS
ENABLE
SOLID
STATE
,.. .....
1--------,
END OF
SWEEP
SWITCH
(OPEN AT
END OF
"SWEEP"
AND
"PARK"
POSITION)
.....
PARK
POSITION I--'--"'-'--+-----.
INPUT
I
I
I
--~I
.8 RED
SPEED
RELAY
---1----1-..
T2
T1
PARK
RELAY
PARK
SWITCH
(CLOSED
UNTIL WIPERS
IN "PARK")
228
GROUND
PARK
WIPERS----CONTROL
WIPER MOTOR
ASSEMBLY
.8BLK
150
SEE GROUND
DISTRIBUTION
PAGE SA 146
(215
91 - 1

STEERING COLUMN HARNESS
06294569
11-WAV F PACK-CON I
12129126
5-WA V F METRI-PACK MIXED SERIES
BLK
BLK
WIPER MOTOR ASSEMBL V
COMPONENT
LOCATION
201-PG
I/P Fuse Block .......... . LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . .
Isolation Diode (Wipers) .. Approx 10 cm from C215 breakout, in Forward
Lamp Harn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Washer Pump Motor ..... Front of vehicle, below Engine Hood Latch . . . . . . . . . . . 25
Wiper Motor Assembly
LH Wiper Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiper/Washer Switch
Assembly . . . . . . . . . . . . . . In left side of Steering Column, actuated by
Multi-Function Lever ........................... . 3 ....
C200B (18 cavities)
C200D (48 cavities)
Partofl/P Harn, between LH kick panel and
Steering Column ................................ . 25
0106 ................... . Near top LH side ofradiator, in top ofT-Bar ......... . 19
PlOO
Compartment ................................... . 19
8113
Center breakout
For a SE)rvice Part Cross Reference List and Information, refer to SECTION 8A-200.
SYSTEM DIAGNOSIS
Refer to SECTION SE for Diagnosis.
FIG.
15 ..
CONN
202-23
64
46
18 ..
202-28
5
49 ..
202-2
49 ..
64 ..
35
202-2
202-4
36
SA-' 100 - 0 ELECTRICAL DIAGNOSIS
HEADLIGHTS AND FOG LIGHTS (CHEVY)

WITHOUT DRL (T61)
HOT AT ALL TIM ES
- - - .,,;p
FUSE
I BLOCK
I
I.-------.
FUSIBLE
LINK Z
1 RUST
3 RED
L----
702
SEE INTERIOR
LIGHTS DIMMING
_ GRV
5
-S
PAGES 8A-117 -0, 1
,,,. ....___ _t
~
r-""'ll--------"""--"""'l~------------.. . T'"----------"""f. . .
.8 ORN
240
.35G:Y
SWITCH
ILLUMINATION
LAMP
CD
HEAD
.8 BRN
.35GRV
_HEADLIGHT
SWITCH
SEE EXTERIOR
LIGHTS
PAGE 8A-110-4
+
-------~St :
I
BRN'
I
I
, , , . . ~ :1 r~ou,m
DIMMER
SWITCH
.35 BLK
650
,;
3 VEL
CV
10
'-----------------~......
11
3LTGRN
3 VEL
A
10
G)
B
150
LEFT
3 BLK
. ._ _ _ _ _ _ _
3 BLK
~'(~
.,
150
11
3 YEL
.8 LTGRN,
10
l~~~ENT .8LTGRN111
~----1---~
CLUSTER
C11
~01
3 BLK
~~;:!ss~1~~5. 6
.,_
250
3 BLK
250
I
IT\
I SEE INSTRUMENT ~ I I
CLUSTER: W I T H d BEAM
I
! GAGES
INDICATOR
SJ.!1
-
3 BLK
1!,AGESSA-81-2,3
- - - - - r--
- ------,
250
SEE GROUND
DISTRIBUTION
5216
PAGESSA-14-7,8
750
3 BLK
~::f650 -
....._
~ -
3 BLK
SEE PAGE SA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
""i.
1 LTGRN
HIGH BEAM
HEADLAMP,
RIGHT
HIGH BEAM
HEADLAMP,
LEFT
~ SEEGROUND
-
11
150
5113
.8 LTGRN
11
C200B C200D
5152
-,
3LTG:N
LOWBEAM
,HEADLAMP,
3BLK
c3
1 LTGRN
(NOT USED)
650
100 - 1
.35 GRY
8
.5 BRN
9
.8 LTGRN
11
<D
INDICATOR
LAMP
(FOG LIGHTS ON)
OFF
<D
ON
WITHT96
ONLY
SWITCH
ILLUMINATION
!,!,MP
DV
(NOT USED)
SEE GROUND
DISTRIBUTION
PAGES SA-14-7, 8
rsE;;O;;ER- DISTiilBUTION
(AGE SA-10-1
I
I
I
I
I
I
I
I
11
.SORN
1340
r-~"1111"~~-iir---.FoG
LIGHTS
RELAY
WITH T96
ONLY
1 PPL
34
5160. - - - - - - - - - - - - - - - - -
1 p:134
1 p:134
~ FOG LAMP,
FOG LAMP,~
LEFT FRONT~
\J;.I RIGHTFRONT
1 BL:r 50
5113. 3 BLK
150
----.J106
ll
1 BL: ~50
............... SEEGROUND
-
......____
- . . . . . DISTRIBUTION
....-- PAGES SA-14-S, 6
3 BLK
250
------2105
8A -
HEADLIGHTS AND FOG LIGHTS (PONTIAC)

WITHOUT DRL (T61)
HOT AT ALL TIMES
,.,.. -
1 RUST
3 RED
---,1/P
FUSE
BLOCK
I
I
.I .---------.
FUSIBLE
LINK Z
702
.8 ORN
240
l
H
SWITCH@
ILLUMINATION
LAMI'
HEAD
D
A V 3V:Lr0
.8 BRN.
TO HEADLIGHT ....
DOORMODULE .....
PAGE 8A-104-0
Bij5 C200D
C200B
1 VEL 10
1 VEL
CQ................
10
B
HEADLIGHT
DIMMER
S_W_IT_C_H
-c
.35 BLK
650
A
1 LTGRN
11
C3T
.8LTGRN
C200B
(2000
11
1 LTGRN
11
5152.,
. . . . . . . . . . . . . . . . . . . . .. .
~::1:
Bl __
1 TAN
r- - -
12
1t
~:T_G~N111
A
1 LTGRN
--- -
INSTRUMENT
CLUSTER
C160
11
I HEADLAMP~
r-----i----,
I
@BEAM
I
INDICATOR
I SEE INSTRUME.NT~ - - - I
CLUSTER: WITH
I
I GAGES
~-----~i---lL---'i------~
1 BLK
150
C160
y-
1 BLK
C
250
Cl6S
y-
~-,. r-lill
1 BLK
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
11
so
1 BLK 12so
"" 1... ~ji~~f. . "" 1,..

_.tl.2106
.J
-,
"""'"'": 1 3:
-:.v :
HEADLAMP
DOOR
-----2105
HEADLAMP
DOOR
ASSEMBLY.RH
HI
l!~ES.!A-!!.-2.2_ -
r--:
=-- J
~
1 B::iso
SEE GROUND
DISTRIBUTION
PAGES 8A-14-7, 8
..... 3 BLK
,..
750
'
16::16----
G 00
2
~-
100 - 3
.35 GRY
. . . . . . .1. . . .
8
5226
.5 BRN
9....~:::D:~:______-ir-------------B"T"------------.~
SEE EXTERIOR LIGHTS

PAGESA-110-4
OFF
ON
SWITCH
iLJ:uMiNATION
LAMP
G)
WITHT96
ONLY
INDICATOR
L~
(FOG LIGHTS ON)
1 PPL
34
358:fso
5216. -
.5 YEL
.SBRN
1 Lf GRN
317
~---,
l'sE;;O;;ER- -
I DISTRIBUTION
PAGE SA-10-1
I
I
I
I
I
I
I
I
I
I
n4o
.-~..,..~~-.,...-.FOG
LIGHTS
RELAY
WITH T96
ONLY
L-----------
11
1 PPL
650
~ SEEGROUND
- - . . . . DISTRIBUTION
PAGESSA-14-7,8
3 BLK
~~G.20.0. . . . .1 . . . . . . . .
50
I
I
I
I
I
I
I
.SORN
--~~--~as--~-
3 BLK
83
1
1
I
I UNDERHOOD
-
1 PPL
ELECTRICAL
..JcENTER
34
5160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
1 p:134
1 p:134
~ FOG LAMP,
FOG LAMP,~
LEFT FRONT
\.;;f;_I
\.;;f;_I RIGHT FRONT

8
1 BL:r 50
1 BL KT250
~
~. 3 BLK
150
__A,J106
ClOOD
C2008
SEE GROUND
........_
DISTRIBUTION
.....-- PAGES SA-14-5, 6
- ?.!.!.?.
3 BLK
250
__A,J105
34
SA -
100 - 4
HEADLIGHTS AND FOG LIGHTS

WITHOUT DRL(T61)
12129077
BLK
HEADLIGHT SWITCH
CAVITY
WIRE COLOR
CKT
BRN
BLK
650
YEL
PAGE
DESCRIPTION
\;
PARK LAMP FEED
SA-100-0,2
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-100-0, 2
GRY
POWER FEED FROM 1/P DIMMER FUSE #13
SA-100-0, 2
ORN
240
POWER FEED FROM TAIL LTS FUSE #10
SA-100-0,2
RED
702
POWER FEED FROM FUSIBLE LINK Z
SA-100-0, 2
I I Ic I I
A
lHIGIFlEI
12045688
8-WAY M METRI-PACK 150 SERIES
BLK
FOG LIGHT SWITCH
COMPONENT
LOCATION
Fog Lamp, Left Front

Fog Lamp, Right Front .. .
Fog Light Switch ........ .
Fusible Links ........... .
Headlamp, Left (Pont) ... .
Headlamp, Right (Pont) .. .
Headlight Dimmer Switch
Lower LH side of front Fascia

Lower RH side of front Fascia
Lower LH side of I/P ....................... .
Above RH Shock Tower .................... .
LH front of vehicle ......................... .
RH front of vehicle
Part of Steering Column, activated by
Multi-Function Lever .................... .
LH side of I/P ............................. .
Headlight Switch ....... .

High Beam Headlamp, Left
(Chevy) ............... .
High Beam Headlamp,
Right (Chevy) ......... .
Low Beam Headlamp, Left
(Chevy) ............... .
Low Beam Headlamp,
Right (Chevy) ......... .
Exterior, left front

Exterior, right front
201-PG
FIG.
37,38 . .. 66,67
10
19
23 . ..... 43
3,35 . ... 5,52
37,38 . .. 66,67
CONN
202-21
202-15
ELECTRICAL DIAGNOSIS SA.:
COMPONENT
Instrument Cluster ...... .
Cl60 (3 cavities)
Cl65 (3 cavities)
C200A (17 cavities)
C200B (18 cavities)
C200D (48 cavities)
Gl05
Gl06
0200
PlOO
8112
8113
8151
8152
8153
8160
S214
8216
8224
8226
100 - 5
LOCATION
201-PG FIG.
CONN
LH side of I/P ................................................... . 202-23
LH side of I/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
202-23 .
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
202-28
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 23
43
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 23
43
and Steering Column ................... : . . . . . . . . . 25
49
202-2
Part of Forward Lamp Harn, between LH kick pane 1
49
202-2
Steering Column ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
49
202-2
NeartopRHsideofradiator,intopofT-Bar .......... 19
36
NeartopLHside.ofradiator,intopofT-Bar .......... 19
35
Near base ofLH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . .. . 9 .. . . 16
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36
Forward Lamp Harn, approx 10 cm from G 105 breakout
Center breakout
Forward Lamp Harn, at E1ectrical Center breakout
Center breakout
Forward Lamp Harn, at Air Pump breakout
Forward Lamp Harn, approx 4 cm from Coolant Fan breakout
1/P Harn, approx 7 cm from G200 breakout
I/P Harn, approx 4 cm from Instrument Cluster (Pont)
1/P Harn, approx 10 cm from Instrument Cluster breakout
For a Service Part Cross Reference List and Information, refer to SECT I ON SA-200.
Diagnosis)
l. Always suspect an open lamp filament before
proceeding with diagnostics.
2. Make sure Lamp Connectors are free from
corrosion.
3. Check that grounds 0200, 0106 and 0105 are
clean and tight.
4. Check Fusible Link Z for open.
5. Check TAIL LTS Fuse 10 and I/P Dimmer Fuse 13
for open. If fuse(s) are open, refer to Chart #15 in
this section.
6. On Pontiac Models if Headlamp door(s) do not open
and Headlamps do not illuminate, repair
Headlamp door(s) failure first. See "Headlight
Doors," page SA-104-0.

SYSTEM DIAGNOSIS
SA -

WITHOUT DRL(T61)
SYMPTOM TABLE (CHEVY)
PROCEDURE
PAGE NUMBER
LO Beam and HI Beam Headlights are inoperative.
Chart #1
SA-100-8
LO Beam Headlights inoperative, HI Beam Headlights

operate normally.
Chart #3
SA-100-9
HI Beam Headlights inoperative, LO Beam Headlights

operate normally.
Chart #4
SA-100-9
HI Beam Indicator inoperative, HI Beam. Headlights

operate normally.
Chart #5
SA-100-9
One LO Beam or one HI Beam Headlamp inoperative.
Chart #8
SA-100-10
LO beams or HI beams do not turn "OFF."
Chart #9
SA-100-10
SYMPTOM
HI Beam Headlights and LO Beam Headlights "ON" at Check for short to B + in CKTs 11 and 12.
the same time.
If OK, replace Headlamp Dimmer Switch.
Fog Lights do not turn "ON" but Park Lights operate
normally.
Chart #12
8A-100-12
Fog Lights do not turn "OFF."
Chart #13
SA-100-13
One Fog Lamp inoperative.
Chart #14
SA-100-13
Fog Lights "ON" Indicator Lamp on; Fog Light Switch Check for:
inoperative but Fog Lights operate normally.
Poor connection at C200 terminal "83".
Open in CKT 34 between S160 and Fog Light Switch.
Open in CKT 650 to ground.
Poor connections at Fog Light Switch.
If OK, replace Fog Light Switch.
Fuse(s} blows when replaced or when attempting to
use lighting system.
Chart #15
SA-100-14
ELECTRICAL DIAGNOSIS 8A
100 7
SYMPTOM TABLE (PONTIAC)

PROCEDURE
PAGE NUMBER
LO Beam and HI Beam Headlights are inoperative.
Chart #2
SA-100-8
LO Beam Headlights inoperative, HI Beam Headlights

operate normally.
Chart #6
SA-100-10
HI Beam Headlights inoperative, LO Beam Headlights

operate normally.
Chart #7
SA-100-10
HI Beam Indicator inoperative, HI Beam Headlights

operate normally.
Chart #5
SA-100~9
One LO Beam or one HI Beam Headlamp inoperative.
Chart #10
SA-100-11
LO Beams or HI Beams do not turn "OFF."
Chart #11
SA-100-11
SYMPTOM
HI Beam Headlights and LO Beam Headlights "ON" at Check for short to B + in CK Ts 11 and 12.
replace Headlamp Dimmer Switch.
the same time.
Fog Lights do not turn "ON" but Park Lights operate
normally.
Chart #12
BA-100-12
Fog Lights do not turn "OFF."
Chart #13
BA-100-13
One Fog Lamp inoperative.
Chart #14
SA-100-13
If OK,
Fog Lights "ON" Indicator Lamp on; Fog Light Switch Check for:
Poor connection at C200 terminal "83" .
inoperative but Fog Lights operate normally.
Open in CKT 34 between 5160 and Fog Light Switch .
Open in CKT 650 to ground.
Poor connections at Fog Light Switch.
If OK, replace Fog Light Switch.
Fuse(s) blows when replaced or when attempting to

Chart #15
BA-100-14
SA -
100 - 8
HEADLIGHT AND FOG LIGHTS

WITHOUT DRL (T61)
CHART #1 (CHEVY ONLY)
LO BEAM AND HI BEAM HEADLIGHTS ARE INOPERATIVE
WITH A TEST LIGHT, BACKPROBE HEADLIGHT

SWITCH CONN TERIIII "J" TO GROUND.
IS TEST LIGHT "ON"?
HEADLIGHT SWITCH TO "HEAD."

CONNECT A TEST LIGHT FROM HEADLIGHT
SWITCH CONN TERM "E" TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT C200 TERM "86".

CHECK FUSIBLE LINK Z FOR OPEN .. ,
HEADLIGHT SWITCH AND FUSIBLE LINK Z.
CHECK FOR POOR CONNECTION AT HEADLIGHT SWITCH.

IF OK, REPLACE HEADLIGHT SWITCH. .
CHECK FOR POOR CO~NECTION AT C200 TERM "BS".

IF OK, REP~IR OPEN IN CKT 10 BETWEEN HEADLIGHT
SWITCH AND S1S1.
CHART #2 (PONTIAC ONLY)

LO BEAM AND HI BEAM HEADLIGHTS ARE INOPERATIVE

CONNECT A TEST LIGHT FROM HEADLIGHT DIMMER SWITCH CONN TERM "B" TO GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT FROM HEADLIGHT

SWITCH CONN TERM "E" TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR AN OPEN IN CKT 702', AN OPEN IN FUSIBLE

LINK ZORA POOR CONNECTION AT C200.
CHECK FOR POOR CONNECTION AT HEADLIGHT SWITCH.
IF OK, REPLACE HEADLIGHT SWITCH.
CHECK FOR POOR CONNECTION AT HEADLIGHT

DIMMER SWITCH.
IF OK, REPLACE HEADLIGHT DIMMER SWITCH.
CHECK FOR POOR CONNECTION AT C200 TERM "BS".

IF OK, REPAIR OPEN IN CKT 10 BETWEEN HEADLIGHT
SWITCH AND HEADLIGHT DIMMER SWITCH.
100 .. 9
CHART #3 {CHEVY ONLY)
CHART #4 {CHEVY ONLY)
LO BEAM HEADLIGHTS INOPERATIVE,

HI BEAM HEADLIGHTS OPERATE NORMALLY
HI BEAM HEADLIGHTS INOPERATIVE,

LO BEAM HEADLIGHTS OPERATE NORMALLY

DISCONNECT A LO BEAM HEADLAMP
CONNECTOR.
TERM" A" OF HEADLAMP CONN.
IS TEST LIGHT ON?
CHECK FOR POOR

CONNECTIONS AT
HEADLIGHT CONNECTORS.
IF OK, CHECK FOR MU.L TIPLE
HEADLAMP FAILURE.

HEADLIGHT DIMMER SWITCH TO "HI".
IS HI BEAM INDICATOR "ON"?

HEADLIGHT DIMMER SWITCH TO
"HI."
WITH A TEST LIGHT TO GROUND,
BACKPROBE HEADLIGHT DIMMER
SWITCH CONN TERM "B".
ISTESTLIGHT"ON"?
CHECK S151 FOR OPEN

IN CKT 10 TO LO BEAM
HEADLIGHTS.

BETWEEN HEADLAMP
DIMMER SWITCH AND S151.
CHECK FOR OPEN

IN CKT 11
BETWEEN
HEADLIGHT
DIMMER SWITCH
TERM "A"
ANDS152 ..
CHECK FOR POOR

CONNECTION AT
HEADLIGHT DIMMER
SWITCH.
IF OK, REPLACE
HEADLIGHT DIMMER
SWITCH.
CHART #5
HI BEAM INDICATOR INOPERATIVE,
INSTRUMENT CLUSTER .
REMOVE
SWITCH TO "HEAD."
HEADLIGHT
HEADLIGHT
DIMMER
SWITCH TO "HI."
PROBE INSTRUMENT CLUSTER
CONN TE.RM "A 11"
WITH
A DIGITAL MULTIMETER TO GROUND.
MEASURE VOLTAGE .
OVOLTS
CHECK FOR POOR CONNECTION AT C200 OR

OPEN IN CKT 11 BETWEEN HEADLIGHT
DIMMER SWITCH CONN AND INSTRUMENT
CLUSTER CONN.
CHECK FOR POOR CONNECTION AT INSTRUMENT

CLUSTER CONNECTOR TERM "A11 ".
CHE(K FOR MISSING OR DAMAGED HI BEAM
INDICATOR LAMP OR POOR CONNECTION AT THE
INSTRUMENT CLUSTER PRINTED CIRCUIT.
CHECK PRINTED CIRCUIT FOR DAMAGE OR
FLAWS.
REPLACE OR REPAIR AS NECESSARY.
8A -
100 - 10

WITHOUT DRL (T61)
CHART #6 (PONT ONLY)
LO BEAM HEADLIGHTS INOPERATIVE,

ONE LO BEAM OR ONE HI BEAM

HEADLAMP INOPERATIVE

HEADLIGHT DIMMER SWITCH "LO."
BACKPROBE HEADLIGHT DIMMER
SWITCH CONN TERM "C" WITH A TEST
LIGHT TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT HEADLIGHT
DIMMER SWITCH.
IF OK, REPLACE HEADLIGHT
DIMMER SWITCH.
CHECK FOR OPEN IN

CKT 12 BETWEEN THE
HEADLIGHT DIMMER
SWITCH TERM "C" AND
5153.
DISCONNECT INOPERATIVE
HEADLAMP CONN.
HEADLIGHT DIMMER SWITCH TO
"HI" If HI BEAM IS INOPERATIVE.
HEADLAMP CONN TERM "A"
(LO BEAM) OR TERM" A" (HI BEAM)
TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
HEADLAMP CONN.
(LH) CHECK FOR OPEN
IN GROUND CKT 150.
(RH) CH ECK FOR OPEN
IN GROUND CKT 250.
IF OK, REPLACE
HEADLAMP.
(HI BEAM) REPAIR

OPEN IN CKT 11
BETWEEN 5152 AND
INOPERATIVE
HEADLAMP CONN.
(LO BEAM) REPAIR

OPEN IN CKT 10
BETWEEN 5151 AND
INOPERATIVE
HEADLAMP CONN.
CHART #7 {PONT ONLY)
HI BEAM HEADLIGHTS INOPERATIVE,

LO BEAM HEADLIGHTS OPERATE NORMALLY
LO BEAMS OR HI BEAMS DO NOT

TURN "OFF"

HEADLIGHT DIMMER SWITCH TO "HI".
IS HI BEAM INDICATOR "ON"?
(LO BEAMS) DISCONNECT HEADLIGHT

SWITCH CONN FROM HEADLIGHT SWITCH.
(HI BEAMS) DISCONNECT CONNECTOR

FROM HEADLIGHT DIMMER SWITCH.
DO HEADLIGHTS TURN "OFF"?
CHECK FOR POOR

CONNECTION AT HEADLIGHT
DIMMER SWITCH.
IF OK, REPLACE HEADLIGHT
DIMMER SWITCH.
CHECK FOR OPEN IN

CKT 11 BETWEEN
HEADLIGHT DIMMER
SWITCH TERM" A"
ANDS152.
(LO BEAMS) REPLACE

HEADLIGHT SWITCH.
(HI BEAMS) REPLACE

HEADLIGHT SWITCH.
(LO BEAMS) REPAIR

SHORT TO B + IN
CKT 10.
(HI BEAMS) REPAIR

SHORT TO B + IN
CKT 11.

ONE LO BEAM OR ONE HI BEAM HEADLAMP INOPERATIVE
DISCONNECT INOPERATIVE HEADLAMP CONN.

HEADLIGHT DIMMER SWITCH TO "LO" IF LO BEAM IS INOPERATIVE OR TO
"HI" IF HI BEAM IS INOPERATIVE.
CONNECT A TEST LIGHT FROM HEADLAMP CONN TERM "B" (LO BEAM) OR
TERM" A" (HI BEAM) TO GROUND.
IS TEST LIGHT "ON"?

HEADLAMP CONN.
(LH)CHECK FOR OPEN IN GROUNDCKT 150.
(RH) CHECK FOR OPEN IN GROUND CKT 250.
IF OK, REPLACE HEADLAMP.
(HI BEAM) REPAIR OPEN IN CKT 11 BETWEEN

5152 AND INOPERATIVE HEADLAMP CONN.
(LO BEAM) REPAIR OPEN IN CKT 12 BETWEEN

5153 AND INOPERATIVE HEADLAMP CONN.

LO BEAMS OR HI BEAMS DO NOT TURN "OFF"
DI.SCONNECT HEADLIGHT SWITCH CONNECTOR FROM

HEADLIGHT SWITCH.
DIS(:ONNECT CONNECTOR FROM

HEADLIGHT DIMME~ SWITCH.
(LO BEAMS) REPAIR SHORT TO B + IN CKT 12.
(HI BEAMS) REPAIR SHORT TO B + IN CKT 11.
REPAIR SHORT TO B + IN
CKT 10 TO HEADLIGHT
DIMMER SWITCH.
100 - 11
BA-100-12 ELECTRICAL DIAGNOSIS

WITHOUT DRL {T61)
CHART #12
FOG LIGHTS DO NOT TURN "ON" BUT PARK LIGHTS OPERATE NORMALLY
HEADLIGHT SWITCH TO "PARK."

WITH A TEST LIGHT TO GROUND, BACKPROBE FOG LIGHT SWITCH CONN TERM ''E'' (CHEVY) OR TERM "D" (PONT).
IS TEST LIGHT "ON"?

FOG LIGHT SWITCH TO "ON."
WITH A TEST LIGHT TO GROUND, BACKPROBE FOG LIGHT
SWITCH CONN TERM "F" (CHEVY) OR TERM "A" (PONT).
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT FOG LIGHT SWITCH

CONN TERM "E" (CHEVY) OR TERM "D" (PONT).
IF OK, REPAIR OPEN IN CKT 9 BETWEEN FOG LIGHT
SWITCH AND 5226.

FOG LIGHT SWITCH TO "ON."
REMOVE FOG LIGHTS RELAY FROM UNDERHOOD ELECTRICAL
CENTER.
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS RELAY
CAVITY "H2" IN THE UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT FOG LIGHT SWITCH

CONN TERM "F" AND TERM "E" (CHEVY) OR TERM "A"
AND TERM "D" (PONT).
If OK, REPLACE FOG LIGHT SWITCH.
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS RELAY

CAVITY "H4" IN THE UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT C200 TERM" A 16."

IF OK, REPAIR OPEN IN CKT 317 BETWEEN FOG LIGHT
SWITCH AND FOG LIGHTS RELAY LOCATED IN
UNDERHOOD ELECTRICAL CENTER.
CONNECT A FUSED JUMPER FROM FOG LIGHTS RELAY

CAVITIES "H4" TO "H1" IN UNDERHOOD ELECTRICAL CENTER.
DO FOG LIGHTS TURN "ON"?
WITH A TEST LIGHT TO B +, PROBE FOG LIGHTS RELAY

CAVITY "HS" IN UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT FOG LIGHTS RELAY.

IF OK, REPLACE FOG LIGHTS RELAY.
CHECK FOG LIGHTS FUSE 2 LOCATED IN UNDERHOOD

ELECTRICAL CENTER FOR OPEN.
IF OPEN, CHECK FOR OPEN OR SHORT TO GROUND
THROUGH CKTS 1340 AND34 INCLUDING FAULTY RELAY.
IF FUSE.CONTINUES TO BLOW, REFER TO CHART #15 IN
THIS SECTION.
IF FOG LIGHT SWITCH "ON" INDICATOR LIGHT

ILLUIIIIINATES WITH FUS.ED JUMPER INSTALLED, CHECK
FOR POOR CONNECTIONS AT F9G LAMP BULBS.
IF OK, CHECK FOR MULTIPLE BULB FAILURE.
IF FOG LIGHT SWITCH "ON" INDICATOR LIGHT DOES NOT
ILLUMINATE WITH FUSED JUMPER INSTALLED, CHECK FOR
OPEN IN CKT 34 BETWEEN FOG LIGHTS RELAY AND 5160.
REPAIR OPEN IN CKT 11 BETWEEN FOG

LIGHTS RELAY AND 5152.
CHART #13
FOG LIGHTS DO NOT TURN "OFF"
FOG LIGHT SWITCH "OFF."

DISCONNECT FOG LIGHTS RELAY LOCATED IN UNDERHOOD
ELECTRICAL CENTER.
DO FOG LIGHTS REMAIN "ON" WITH RELAY REMOVED?
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS

. RELAY CAVITY "H2" IN UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
DISCONNECT CONNECTOR FROM FOG LIGHT SWITCH .

WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS
RELAY CAVITY "H2" IN UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
REPAIR SHORT TO B + IN CKT 34

BETWEEN FOG LIGHTS AND FOG
LIGHTS RELAY.
REPAIR SHORT TO B + IN CKT 317 BETWEEN

FOG LIGHT SWITCH AND FOG LIGHTS RELAY.
CHART #14
ONE FOG LAMP INOPERATIVE
DISCONNECT CONNECTOR FROM FOG LAMP THAT DOES

NOT ILLUMINATE AND CONNECT A TEST LIGHT BETWEEN
TERMINALS" A" AND "B" OF THAT FOG LAMP CONNECTOR.
TURN PARK LIGHTS AND FOG LIGHTS "ON."
IS TEST LIGHT "ON"?

GROUND, PROBE THE SAME
FOG LAMP CONN TERM "A".
IS TEST LIGHT "ON"?
REPAIR OPEN IN GROUND CIRCUIT TO FOG LAMP

CONNECTOR {LH)CKT 150 OR{RH)CKT 250.
CHECK FOR POOR CONNECTIONS

AT FOG LAMP CONN
TERMINALS "A" AND "B".
IF OK, REPLACE FOG LAMP.

BETWEEN 5160 AND
INOPERATIVE FOG LAMP.
SA-100- 14 ELECTRICAL DIAGNOSIS

WITHOUT DRL (T61)
CHART #15
FUSE{S) BLOWS WHEN REPLACED OR WHEN AITEMPTING TO USE LIGHTING SYSTEM
REPLACE BLOWN FUSE(S).

DOES FUSE BLOW BEFORE
ATTEMPTING TO OPERATE SYSTEM'?
TEST SYSTEM ONE FUNCTION AT A

TIME, UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMATIC
TO DETERMINE WHAT CIRCUITS OR
COMPONENTS COULD BE FAILING.
USE A TEST LIGHT OR DVM TO
NARROW IN ON SHORT TO GROUND
POTENTIAL (DISCONNECTING
COMPONENTS IS HELPFUL WHEN
TRYING TO CHECK CIRCUITS THAT
SHOULD NOT BE AT A GROUND
POTENTIAL).
CIRCUIT OPERATION (CHEVY)

HEADLIGHTS
Voltage is applied to the Headlight Switch at all

times from Fusible Link Z. When the Headlight
Switch is in "HEAD," voltage is applied directly from
the Headlight Switch through CKT 10 to the LO Beam
Headlamps. Voltage is also applied through CKT 10 to
the Headlight Dimmer Switch. When the Headlight
Dimmer Switch is placed in "HI," voltage is applied
through the closed contacts of the Dimmer Switch to
the HI Beam Headlamps and the HI Beam Indicator.
When HI Beams are selected both the LO Beam
Headlamps and HI Beam Headlamps will be
illuminated. The LO Beam Headlamps, HI Beam
Headlamps, and HI Beam Indicator are permanently
grounded so that when battery voltage is applied, the
lamps operate.
USE SCHEMATICS AND DVMTO CHECK SUSPECT

POWJ:R CIRCUITS FOR A SHORT TO GROUND
POTENTIAL, EITHER THROUGH A FAUL TY
COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS
FUSE TERMINALS. START BY DISCONNECTING
ONE COMPONENT AT A TIME.
IF ALL RELATED COMPONENTS ARE
DISCONNECTED AND SHORT IS STILL PRESENT,
LOCATE AND REPAIR SHORT IN WIRING.
CIRCUIT OPERATION (PONTIAC)

HEADLIGHTS
Voltage is applied to the Headlight Switch at all

times from Fusible Link Z. When the Headlight
Switch is in "HEAD," voltage is applied to the HI and
LO Beam Circuits through the Headlight Dimmer
Switch.
At the same time, this voltage is applied to the
Headlamp Door Motor Assemblies, which allows the
doors to open.
When the Headlight Switch is moved to "HEAD"
and the Headlight Dimmer Switch is placed in "LO,"
voltage is applied through the closed contacts of the
Headlight Dimmer Switch to the LO Beam Circuit of
the Headlights. When the Headlight Dimmer Switch
is placed in "HI," battery voltage is applied to the HI
Beam circuit of the Headlights, and the HI Beam
Indicator. The LH Headlamp, RH Headlamp, and the
HI Beam Indicator are permanently grounded so that
when battery voltage is applied, the lamps operate.
FOG L~GHTS
With the Headlight Switch in "HEAD" or "PARK,"

voltage is applied to one side of the Fog Light Switch.
When the Fog Light Switch is closed, voltage is applied
to one side of the Fog Lights Relay Coil, energizing the
relay (the other side of the coil is grounded through the
HI Beam Filament of the Headlamps).
When energized, the normally open contacts of the
Fog Lights Relay close, allowing voltage to be applied
to the Fog Lights.
When the HI Beams are activated, ground is
removed to one side of the Fog Lights Relay Coil, deenergizing the relay and turning off the Fog Lights.
100 - 15
SA -
102 - 0
ELECTRICAL DIAGNOSIS.

(CHEVY)
AMBIENT
LIGHTSENSOR
I
I
I
B
.5
.5 LTGRN/ BLK
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
TURN B-U
FUSE 2
20AMP
GAGES
FUSE 9
ioA-MP
IGN
(NOT USED)
.8 BRN
SEE FUSE
BLOCK DETAILS
1137
___ ..J
1138
YELi
BLK
.JS TANt33
WHT
0)
SEE BRAKE
WARNING SYSTEM
PAGE 8A-41-0
HOTINRUN
141
.8 PNK
SEE FUSE
BLOCK DETAILS
5207
8
__ ::~E::~1: _____ . BR;Jl
41
.......__
.......-- -
39
5206
3
- - - - - - - - - - PAGESA-11-5 - - - - - - - - - - J S P : 1 :
----------- G
LEFT
TURN
RELAY
~IGNITION
LIGHT SENSOR
INPUT
PARK
LEFT
BRAKE
TURN
CONTROL INPUT GROUND INPUT
DRLCONTROL
LOGIC
SOLID STATE
IGNITION
PARK
RIGHT
HEADLIGHT LIGHT
HEAD TURN
RELAY
RELAY
ON
RELAY
CONTROL
CONTROL INPUT CONTROL
RIGHT
TURN
INPUT
EfA
.35L T B~U
1134
.S LT BLU,'WHT
BRAKE
PARKrn
SWITCH
1415
.SLTBLU
.35 BLK
1414
.5 DK BLU
14
TO INSTRUMENT
CLUSTER
LEFT TURN
INDICATOR
PAGE 8A-81-3
650
Li----iJ
18
TO INSTRUMENT
CLUSTER
RIGHT TURN
INDICATOR
PAGE 8A-81-3
TURN/HAZARD
SWITCH ASSEMBLY
YEL
DK GRN
--------N
.8 YEL
18
.8 DK GRN
15
19
C216
19-
-5217
3 BLK
650
SEE GROUND
DISTRIBUTION
L _.
SEE EXTERIOR LIGHTS

PAGE SA-110-1
'----,iiiiiiiiiiiiiiiiii.-------------~
PAGE58A-14-8, 9
g~~~
S2160
Df.- - - - - - - - - - - - - - - - - - - - - - Di4
_________________________ D t 6
---------------------.8 LT BLU
3 BLK
.8 BRN
650
14
B
5 BRN
s15-:,.,
PARK/TURN
LAMP,
LEFT FRONT
@
Gy
------------------------
8 BRN
IL
.8BLK
150
.8 BLK (WITHOUT PWR ACCESSORIES)

3 BLK (WITH PWR ACCESSORIES)
. - SEE GROUND
DISTRIBUTION
750
PAGE SA-14-7
.8 BRN
9
........
TO FRONT
.....,.......MARKER
LAMPS
PAGE8A-110-3
P100
8 DK BLU
B
15
@PARK/TURN
LAMP,
RIGHTFRONT
GY---------"'
I[
.8BLK
250
I
\
DRL MODULE
C1 = BLUE CONNECTOR
C2 = BLACK CONNECTOR
.35 GRV
JRED1WHT
--
HEAD
OFF
PARK
HEADLIGHT
SWITCH
Er
3 VEL
3 VEL
.8BRN
10
9
PAGES 8A-117-0, 1
.8 LT GRN
SEE EXTERIOR
LIGHTS
PAGE 8A-110-4
.5 BRN
5214 .8 LTGRN
11
.8LTG
1RN1,:-i
P100
10
B
CJ
~~HEADLIGHT
DIMMER
TO FOG LIGHT
SWITCH
PAGE 8A-102-4
LO - - - " HI
cV
WITH T96 ONLV
C200D
2
C 00B
Cl I
INSTRUMENT
CLUSTER TO HIGH
PAGE 8A-81-3 BEAM
INDI
,CA TOR
r- - -,
SWITCH
...
A
1 LTGRN
(NOT USED)
A,~
I
I
I
I
TO FOG LIGHT
SWITCH
PAGE 8A-102-4
WITH T96 ONL V
L..--1
11
3 VEL
.8BRN
10
LOW B E A M ~
HEADLAMP, L
LEFT
3 BLK
150
3 BLK
150
,1----8 K-------------~,- ~
11111
BL
"'
:,~'
,::1...
----2106
3 BLK
250
3 BLK
250
SEE GROUND
DISTRIBUTION
PAGES 8A-14-5, 6
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES

(PONTIAC)
AMBIENT
LIGHTSENSOR
(2f)
SEE BRAKE
WARNING SYSTEM
PAGE 8A-41-0
I
I
.5
.SLTGRN/BLK
1-------
GAGES
FUSE 9
10AMP
IGN
(NOTUSEO)
.8 BRN
141
.8 PNK
SEE FUSE
BLOCK DETAILS
- . 5207
BLOCK DETAILS
41
8
__ ::~E::~1:_ - - - - . BR
35
- - - - - - - - - - - PAGE8A-11-5 - - - - - - - - -
----------- G
LEFT
TURN
RELAY
~
LIGHT SENSOR
INPUT
PARK
BRAKE
CONTROL INPUT GROUND
Er
.35 LT B:U
SEE FUSE
1137
------~- ..
S;;P~;: DISTRIBUTION
PAGE 8A10-3
TURN B-U
FUSE 2
20AMP
~r--------------- --~
1138
YEL/
BLK
.35TANr33
WHT
rl
HOTIN RUN
es206
P:K1
3
~
IGNITION
DRL CONTROL
LOGIC
SOLID STATE
LEFT
TURN
INPUT
39
RIGHT
TURN
INPUT
IGNITION
PARK
HEADLIGHT LIGHT
HEAD
RELAY
RELAY
ON
CONTROL
CONTROL INPUT
RIGHT
TURN
RELAY
CONTROL
1134
.SLTBLU/WHT
1414
BRAKE
PARKrn
SWITCH
1415
.5 LT BLU
.35 BLK
.5 DK BLU
14
TO INSTRUMENT
CLUSTER
LEFT TURN
INDICATOR
PAGE 8A-81-3
650
15
TO INSTRUMENT
CLUSTER
RIGHT TURN
INDICATOR
PAGE 8A-81-3
TURN/HAZARD
SWITCH ASSEMBLY
r-5217
~~;T;~~~~gN
PAGES 8A-14-8, 9
yL.. 3 BLK
.
SEE EXTERIOR LIGHTS
5216 O f . > - - - - - - - - - - - - - - - - - - - - -
.8LTBLU
650
06
,
14 - - - - - - - - - - - - ~ ; N - - - - - - - - ~ -------~;R-N-----------~~;BLU
8
I
3BLK
-1:----------- -------- --
PAGE8A-110-1
650
\J'
B ,"\
@
L
I
L
PA_!!!,TUR_tj_
LAMP, LEFT
FRONT
"'
G
5150.
.8BLK
150
.8 BLK (WITHOUT PWR ACCESSORIES)

3 BLK (WITH PWR ACCESSORIES)
~ SEE GROUND
DISTRIBUTION
PAGE SA-14-7
750
-lllli......
MODULE
PAGE8A-110-3
-g~~-~- - t l
9
15 PlOO
@i
T
---------111(
...____...,l
B,"\
TOFRONT
MARKER LAMPS
AND
HEADLIGHT
........... DOORS
.8 BRN
P~!l.~TURN
LAMP, RIGHT
FRONT
.8 BLK
250
102 - 3
HOT AT ALL TIMES
FUSIBLE
LINK Z
1 RUST
ORL MODULE
3 RED
C1 = BLUE CONNECTOR
C2 = BLACK CONNECTOR
702
.SORN
240
___________ J:
J REOWHT
.35 GRY
1372
,----'"'lll:""""________,,.:""""----------.oAYTIME
PARK--+----+LIGHT
RELAY
RUNNING
LIGHTS (ORL}
MODULE
SOLID STATE
DO NOT
MEASURE
RESISTANCE
-----+-HEADLIGHT
RELAY
--
HEAD
OFF
SWITCH
ILLUMINATION
LAMP
PARK
.8 BRN
G;s;J
1 YEL
.5 BRN
HEADLIGHT
DIMMER
SWITCH
--
LO
.....
__
,,,,.

PAGES SA-117-2, 3
TO HEADLIGHT
DOOR MODULE
PAGE SA-104-0
10
SEE EXTERIOR
LIGHTS
PAGESA-110-5
TO 1/P CLUSTER
PAGE SA-81-3
HI
1 LTGRN
11
TO FOG LIGHT
SWITCH
PAGE 8A 102-5
1 LT GRN
1T
11,j l l l l l - - - - - - - - - - - 1 L T G R N - ~ TO FOG LIGHTS

J
RELAY
11
PAGE SA-102-5
~ii
WITH T96 ONLY

5153.
1 TANJ'.2
1 LTGR"A11
1 TANl.2
165
160
1 TA=i,;--~~T-G~NT1~
.8BRN
cE: -
-1-,-,I r - ,!:" - - -
PAGE SA-14-6
I BLK
i;.so
:::,~:~:,:g, ..,_ _"""
.:,J:~60
-..._
ll-------~8.BLmKllll____.iiiiiiiiiiiiiiiiiii~--------~.;:
1 T:N,12---,~;~i,~
----
'"L.,~..Cf c~*:- -V:- :a c:1r:- -~- -,..-,,....:"
HEAOLAMPr DOOR ASSEMBLY,
, ._ _ _ _ _150------~85:LK_ _ _ _ _ _ _ _ _ _ _3BLJ.
_L..1~
WITH T96 ONLY
1 LTGR~11
J L- - -
,HEADLAMP
DOOR ASSEMBLY
R!HTJ
1 BLK,50
1 B:Kr:~65
~~:T~~~u;gN
PAGE SA-14-5
:::i:-- J
___Jlj105

(CHEVY)
- - -,,,p
FROM 5214
PAGE 8A-1021
FROM 5226
PAGE SA-102-1
l1P
DIMMER
FUSE 13
SAMP
,~
ruse
I BLOCK
__ .....
.5 GRY
.8 LT GRN
11
.S BRN
SEE INTERIOR
5 2 2 4 - - ~ LIGHTS DIMMING
PAGE 8A-117-1
'"J
- - - - - - - - - - - - - - - - - - - - - - . - - - - - - - F O G LIGHT
INDICATOR
LAMP (FOG LIGHTS ON)
OFF
ON
SWITCH
SWITCH
ILWMINA TION
~MP
WITH T96
ONLY
oV
(NOT USED)
3SB~KJSO
5216. -
.5 YEL
3BLK
317
-
~ SEEGROUND
-...... DISTRIBUTION
PAGES 8A-14-7, 8
65~0. . . . . . . .
l.B.LK. . . . . .::::J"'.
'-_
G200
750
UNDERHOOD
ELECTRICAL
CENTER
r--"T"----'"'IFOG
LIGHTS
RELAY
WITH T96
ONLY
A
'-I
1
. . . . . . . . . . . . . . . . . ..LTG-RN
......
11
FROMS152
PAGESA-102-1
5160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1 p:134
1 p:134
~ FOG LAMP,
FOG LAMP,~
LEFT FRONT~
\it,) RIGHT FRONT
1 BL:J 50
1 BL:r250
~
SEE GROUND
........_
5 1 1 3 - - - - . . . . . DISTRIBUTION
,,..- PAGES 8A-14-5, 6
3 BLK
150
-A.J.106
-~
3 BLK
250
___ejil_l!?_
ELECTRICAL DIAGNOSIS BA-102- 5

(PONTIAC)
-
-Sl,P
I ruse
,---
FROM 5226
PAGE BA-102-3
BLOCK
__ ....
.5 GRY
.5 BRN
SEE INTERIOR
5 2 2 4 - - ~ LIGHTS DIMMING
PAGE SA-117-3
""J
OFF
B
FOG LIGHT
~-
<I>
SWITCH
illuMINATION
I,_~
ON
WITHT96
INDICATOR
ONLY
lAMP
. '------'
(FOG LIGHTS ON)
1 PPL
83
.3SBL: ~50
lo
-----""".
5216. -
.5 YEL
r ----
I
I
I
I
I
I
I
I
I
3 BLK
317
-
SEEPOWER
DISTRIBUTION
PAGE SA-10-1
UNDERHOOD
ELECTRICAL
I CE.NTER
34
(2000
(2008
SEEGROUND
~ DISTRIBUTION
PAGESSA-14-7,8
650
3 BLK
~~G200---,so. . . . . . . .
1340
1 PPL
. - ~ . - ~ - - . . , . . ~.. FOG
LIGHTS
WITH T96
ONLY
H=tH5t. .
1LTGRN
1PPl
34
8~-~~2-3
11
~:134
5160 - - - - - - - - - - - - - - - - - - ..
1
p:134
~ FOG LAMP,
FOG LAMP,~
LEFT FRONT
\J;)
\J;) RIGHT FRONT

8
1 BL:Jso
1 BL KT2so
__.olllllll
5113. 3 BLK
....
--.-.--------.J
_______<8 ~~~~
,_
________________________________
L- - - - - - - - - -
150
....AJ106
SEE GROUND
.....__
~ DISTRIBUTION
,,- PAGES BA-14-5, 6
SJ.!1
3 BLK
250
....AJ105
34
SA -
102 - 6
HEADLIGHTS AND FOG LIGHTS: DAYTIME RUNNING LIGHTS (T61}
12129077
BLK
HEADLIGHT SWITCH

CAVITY
WIRE COLOR
CKT
BRN
BLK
650
YEL
DESCRIPTION
PAGE
PARK LAMP FEED
SA-102-1,3
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-102-1, 3
GRY
SA-102-1,3
RED!WHT
1372
POWER FEED TO DRL MODULE - HEADLIGHT RELAY
SA-102-1,3
ORN
240
SA-102-1, 3
RED
702
SA-102-1, 3
~[&',:?ct?
[f][2][f] r2:J
12064766
8-WA V F METRI-PACK 150 SERIES
12064998
BLU
BLK
DAYTIME RUNNING LIGHTS (DRL) MODULE C1
DAYTIME RUNNING LIGHTS (DRL) MODULE C2
102 - 7
IA I B Ic ID I
IHfGIFIEI
12045688
12064762
8-WA Y M METRlPACK 150 SERIES

BLK
FOG LIGHT SWITCH (PONT)
FOG LIGHT SWITCH (CHEVY)
COMPONENT
LOCATION
GRY
201-PG FIG.
Ambient Light Sensor

Mounted in top ofl/P, near Defrost Grill .............
(DRL) Module ......... . Mounted behind Radio and HV AC Controls, left of
1/P Compartment ............................... .
Fog Lamp, Left Front . . . . . Lower LH side of front Fascia
Fog Lamp, Right Front . . . Lower RH side of front Fascia
Fog Light Switch . . . . . . . . . Lower LH side ofl/P .............................. .
Fusible Links . . . . . . . . . . . . Above RH Shock Tower ........................... .
Headlamp, Left (Pont) . . . . LH front of vehicle ................................ .
Headlamp, Right (Pont) . . . RH front of vehicle
Multi-Function Lever ........................... .
Headlight Switch . . . . . . . . LH side ofl/P .................................... .
~~~~~~~-~'
H/B~e~~)~
-~~~t.
High Beam Headlamp, Right
(Chevy) . . . . . . . . . . . . . . . .
I/P Fuse Block .. . .. .. .. ..
Instrument Cluster . . . . . . .
Low BeamHeadlamp, Left
(Chevy) ............ , .. .
Low Beam Headlamp, Right
(Chevy) ............... .
Park Brake Switch ...... .
Park/Turn Lamp, Left Front
Park/Turn Lamp,
Right Front ........... .
Turn/Hazard Switch
Assembly ............. .
Cl60 (3 cavities)
C165 (3 cavities)
C200A (17 cavities)
C200B (18 cavities)
C200D (48 cavities)
22
41
7 " ..
12
37,38
66,67
19
23 ... 43
10
CONN
202-20
202-21
3,35. 5,64
37,38 66,67
202-15

LH side of 1/P Carrier, on the side .. .. .. .. . .. . .. . .. .. 8 .. .. 15 ..
LH side ofl/P ................................................... .
202-23
202-23

In console, at base of Park Brake Lever ............. . 43
Exterior, left front ................................ . 17
81
32
Exterior, right front .............................. . 17
32
Part of Steering Column .......................... .

of wheelhouse ................................... .
Headlight Door Bracket ......................... .
Headlight Door Bracket ......................... .
Part of l/P Harn, between LH kick panel and
Steering Column ................................ .
3 " .. 5
19
36
23
43
23
43
25
49
202-2
25
49
202-2
25
49
202-2
202-28
8A

COMPONENT
C216 (11 cavities) ....... :
G105 ................... .
G106 ................... .
G200 .............. ..... .
PlOO
8112
8113
8150
8151
8152
8153
8160
8206
8207
8214
8216
8217
8224
8226
8227
201-PG
LOCATION
At.tached to base of Steering Column . . . . . . . . . . . . . . . . 34
Near top RH side ofradiator, in topofT-Bar . . . . . . . . . . 19
Near top LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
Near bii.se of LH "A" pillar, bolted to I/P Mounting Stud
' behtnd kick panel (2 rings, 2 wires) ... , . . . . . . . . . . . . 9, . : ..
' Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ...
Forward Lamp Harn, approx 10 cm from G105 breakout
Center breakout
Forward Lamp Harn, approx 22 cm forward of Electrical
Center breakout, on lighting branch
Forward Lamp Harn, at Electrical Center breakout
Forward Lamp Harn, approx 8.cm from Electrical
Center breakout
Forward Lamp Harn, at Air Pump breakout
Forward Lamp Harn, approx 4 cm from Coolant Fan
breakout
breakout
'
'
1/P Harn, approx 7 cm from G200 breakout
breakout
I/P Harn, approx 10 cm from Convenience Center breakout
FIG.
63
36
35
CONN
202-5
16
36

Diagnosis)
System
Make sure Headlights and Park Lights operate

normally when using the Light Switch before
proceeding with Daytime Running Lamp (DRL)
diagnosis.
2. Make sure the Brake Warning System is
functioning properly. DRL will not turn "ON" if
Park Brake is "ON."
3. Check Fusible Link Z for open.
4. Check Turn B-U Fuse 2, Gages Fuse 9 and TAIL
LTS Fuse 10 for open. If fuse(s) are blown, replace
fuse(s). If fuse(s) re-blows, check for short to
ground through the suspected circuit(s).
malfunction
but
prove
"GOOD"
m a
1.
continuity/voltage
check
.with
a
systemdisconnected. These circuits may be
intermittent or resistive when loaded, and if
possible, should be checked by monitoring for a
voltage drop with the system operational (under
load).
Procedures," page 8A-4-0)
SYSTEM DIAGNOSIS
102 - 9
SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
DRLwill not turn "ON."
Chart #1
SA-102-9
DRL operates normally in daytime, but Park Lights and

Headlights will not turn "ON" automatically at dark.
Chart #2
8A-102-11
Park Lights will not turn "ON" automatically at dark

(Headlights turn "ON" OK).
Chart #3
SA-102-11
Headlights will not turn "ON" automatically at dark

(Park Lights turn "ON" OK).
Chart #4
SA-102-11
Park Lights always stay "ON" during daylight hours

(Headlights remain "OFF").
Chart #5
SA-102-12
Headlights always stay "ON" during daylight hours

(Park Lights remain "OFF").
Chart #6
8A-102-12
Park Lights and Headlights remain "ON" during

daylight hours.
Chart #5
Chart #6
SA-102-12
SA-102-12
LH Front Turn Signal inoperative.
Chart #7
8A-102-12
RH Front Turn Signal inoperative.
Chart #8
SA-102-13
SYMPTOM
Fog Lights entire system inoperative or individual For diagnosis, refer to "Headlights," SECTION SA-100.
lamp inoperative.
CHART #1
DRL WILL NOT TURN "ON"
DISCONNECT DRL MODULE CONN C1 (BLUE).

CONNECT A TEST LIGHT BETWEEN TERM "C" OF CONNECTOR AND GROUND.
IS TEST LIGHT "ON"?
AT SAME CONNECTOR, CONNECT THE TEST

LIGHT BETWEEN TERM "F" AND GROUND.
IS TEST LIGHT "ON"?
CHECK GAGES FUSE FOR OPEN.

IF OPEN, CHECK FOR SHORT TO GROUND THROUGH CKT 39.
CHECK FOR OPEN IN CKT 39 TO DRL MODULE.

LIGHT BETWEEN TERMINALS" A" AND "F".
IS TEST LIGHT "ON"?
CHECK TURN B-U FUSE FOR OPEN.

IF OPEN, CHECK FOR SHORT TO GROUND THROUGH CKT 141.
CHECK FOR OPEN IN CKT 141 TO DRL MODULE.
SA -
102 - 10

DRL WILL NOT TURN "ON"

LIGHT BETWEEN TERMINALS "E" & "F".
PARK BRAKE "OFF."
DOES TEST LIGHT STAY "OFF"?
REPAIR AN OPEN OR SHORT TO B + IN GROUND

CKT 650 BETWEEN DRL MODULE AND G200.
USING A DVM SET TO OHMS SCALE, CONNECT THE RED &

BLACK METER LEADS ACROSS TERMINALS "G" & "H" OF
CONN C1.
WHILE OBSERVING THE DVM, SHINE A BRIGHT LIGHT AT THE
DRL AMBIENT LIGHT SENSOR AT THE TOP OF THE
INSTRUMENT PANEL AND THEN COVER THE LIGHT SENSOR
WITH HEAVY MATERIAL.
DID THE RESISTANCE CHANGE SIGNIFICANTLY?
CHECK FOR PROPER ADJUSTMENT OF PARK BRAKE SWITCH.

CHECK FOR SHORT TO GROUND IN CKT 1134 BETWEEN
PARK BRAKE SWITCH AND DRL MODULE.
IF OK, REPLACE PARK BRAKE SWITCH.
BACKPROBE DRL MODULE CONN C2 (BLACK) WITH THE TEST

LIGHT BETWEEN TERM "F" AND GROUND.
HEADLIGHTS TURNED "OFF" AT LIGHT SWITCH.
DOES TEST LIGHT STAY "OFF"?
CHECK FOR AN OPEN OR SHORT TO GROUND

(ORB+) IN CKT 1137 OR CKT 1138.
IF OK, REPLACE AMBIENT LIGHT SENSOR.
CHECK FOR SHORT TO B + IN CKT 10.

IF NOT SHORTED, REPLACE HEADLIGHT SWITCH.
DO THE FRONT TURN SIGNAL BULBS ILLUMINATE NORMALLY

WHEN USING TURN SIGNAL LEVER?
r-
--------------------------------------,
: PERFORM CHART #7, "LH FRONT TURN SIGNAL INOPERATIVE," :

I
I PAGE SA-102-12 AND/OR CHART #8, "RH FRONT TURN SIGNAL
I
I
I INOPERATIVE,'' PAGE 8A-102-13.
1
L----------------------------------------J
rn
CHART #2
CHART #3
DRL OPERATES NORMALLY IN DAYTIME,

BUT PARK LIGHTS AND HEADLIGHTS DO NOT
TURN "ON" AUTOMATICALLY AT DARK
PARK LIGHTS WILL NOT TURN "ON"

AU TOMA Tl CALLY AT DARK
(HEADLIGHTS TURN "ON" OK)
IMPORTANT:
MAKE SURE PARK LIGHTS AND HEADLIGHTS OPERATE

PROPERLY FROM HEADLIGHT SWITCH BEFORE
PROCEEDING. IF NOT, REFER TO "EXTERIOR LIGHTS,"
SECTION SA-110 FOR PARK LIGHT DIAGNOSIS AND/OR
"HEADLIGHTS," SECTION SA-100 FOR HEADLIGHT
DIAGNOSIS.
DISCONNECT DRL MODULE CONN C1 (BLUE).
USIN<i A DVM SET TO THE OHMS SCALE, CONNECT THE RED
& BLACK METER LEADS ACROSS TERMINALS "G" & "H" OF C1.
WHILE OBSERVING THE RESISTANCE ON THE DVM, SHINE A
BRIGHT LIGHT INTO THE DRL AMBIENT LIGHT SENSOR (AT THE
TOP OF THE INSTRUMENT PANEL), THEN COVER THE LIGHT
SENSOR WITH A PIECE OF HEAVY MATERIAL.
DID THE RESISTANCE MEASUREMENTS CHANGE
SIGNIFICANTLY?
rn
CHECK FOR POOR

CONNECTION AT
THE DRL MODULE.
IF OK, REPLACE THE
DRLMODULE.
IMPORTANT:
MAKE SURE PARK LIGHTS OPERA TE NORMA LL y
FROM HEADLIGHT SWITCH BEFORE PROCEEDING. IF
NOT OPERA TING NORMALLY, REFER TO "EXTERIOR
LIGHTS," SECTION SA-110 FOR DIAGNOSIS.
DISCONNECT DRL MODULE CONN C2 (BLACK).

CONNECT A TEST LIGHT BETWEEN TERM "A" OF
IS TEST LIGHT "ON"?
RECONNECT CONN C2..

COVER DRL AMBIENT LIGHT
SENSOR WITH HEAVY
MATERIAL.
BACKPROBE CONN C2 WITH
THE TEST LIGHT BETWEEN
TERM "H" AND GROUND.
IS TEST LIGHT "ON"?
102 - 11
CHECK FOR AN OPEN, SHORT TO

GROU,ND, OR SHORT TO B + IN
CKT 1137 OR CKT 1138.
IF OK, REPLACE DRL AMBIENT
LIGHT SENSOR.

BETWEEN DRL MODULE.
ANDS226.
CHECK FOR OPEN

TAILLTS FUSE.
IF OPEN, CHECK FOR
SHORT TO GROUND
THROUGH CKT 240.
CHECK FOR OPEN IN
CKT 240 BETWEEN
1/P FUSE BLOCK AND
DRLMODULE.
CHECK FOR POOR

CONNECTION ATDRL
MODULE CONN C2
TERM"H".
IF OK, REPLACE DRL
MODULE.
CHART #4
HEADLIGHTS WILL NOT TURN "ON" AUTOMATICALLY AT DARK (PARK LIGHTS TURN "ON" OK)
rn
IMPORTANT:
MAKE SURE HEADLIGHTS OPERATE NORMALLY FROM HEADLIGHT SWITCH BEFORE
PROCEEDING. IF NOT, REFER TO "HEADLIGHTS," SECTION SA-100 FOR DIAGNOSIS.

CONNECT A TEST LIGHT BETWEEN TERM "D" OF CONNECTOR AND GROUND.
IS TEST LIGHT "ON"?
CONNECT A FUSED JUMPER BETWEEN TERM "F"

AND TERM "D" OF DRL MODULE CONN C2.
DO HEADLIGHTS TURN "ON"?
CHECK FOR POOR CONNECTIONS AT [)RL MODULE CONN C2.

REPAIR OPEN IN CKT 10 BETWEEN DRL MODULE AND 5227.
CHECK FOR AN OPEN IN CKT 1372 BETWEEN HEADLIGHT

SWITCH AND DRL MODULE.
IF OK, REPLACE LIGHT SWITCH.
CHART #5
CHART #6
PARK LIGHTS ALWAYS STAY "ON"

DURING DAYLIGHT HOURS
{HEADLIGHTS REMAIN "OFF")
HEADLIGHTS ALWAYS STAY "ON"

DURING DAYLIGHT HOURS
{PARK LIGHTS REMAIN "OFF")

DO PARK LIGHTS TURN "OFF""?
DISCONNECT DRL CONN C2 (BLACK).

DO HEADLIGHTS TURN "OFF""?
r-
----------------,
r-
REPAIR SHORT TO B + IN
:
:
:
I
:
:
~~!~COMPLETE CIRCUIT :
SCHEMATIC REFER TO
"EXTERIOR LIGHTS,"
SECTIONSA-110.
----------------,
CHECK FOR SHORT TO

B+ INCKT10.
REFER TO "HEADLIGHTS,"
SECTION SA-100 FOR
FURTHER DIAGNOSIS.
CHART #7
:
:
1
L------------------~
L------------------~
rn
LH FRONT TU RN SIGNAL I NOPERA TIVE

IMPORTANT:
MAKE SURE THE DRL SYSTEM OPERATES NORMALLY (FRONT
TURN SIGNAL BULBS ILLUMINATE DURING DAYLIGHT HOURS)
BEFORE PROCEEDING. IF NOT OPERATING CORRECTLY, PERFORM
CHART #1, "DRL WILL NOT TURN 'ON."'

WITH A TEST LIGHT TO GROUND, BACKPROBE DRL
MODULE CONN C2 TERM "E".
DOES TEST LIGHT ILLUMINATE (OR FLASH ON & OFF)
WHEN TURN SIGNAL LEVER IS MOVED TO THE "LEFT
TURN" POSITION"?
BACKPROBE SAME CONNECTOR

WITH THE TEST LIGHT BETWEEN
TERM "B" AND GROUND.
DOES TEST LIGHT ILLUMINATE WHEN
THE TURN SIGNAL LEVER IS MOVED
TO THE "LEFT TURN" POSITION"?
----------------------------------,
CHECK FOR POOR CONNECTION AT DRL MODULE.

CHECK FOR AN OPEN IN CKT 1414 BETWEEN
TURN/HAZARD SWITCH ASSEMBLY AND DRL MODULE.
IF OK, REFER TO "EXTERIOR LIGHTS," SECTION SA-110
FOR FURTHER DIAGNOSIS.
:
I
:
:
1
L------------------------------------~
CHECK FOR POOR CONNECTIONS AT DRL

MODULE CONN C2 TERMINALS "E" AND "B".
ELECTRICAL DIAG.NOSIS SA-
102 - 13
CHART #8
rn
RH FRONT TURN SIGNAL INOPERATIVE

IMPORTANT:
MAKE SURE THE DRL SYSTEM OPERA TES NORMALLY (FRONT TURN SIGNAL BULBS ILLUMINATE DURING
DAYLIGHT HOURS) BEFORE PROCEEDING.
IF NOT OPERATING CORRECTLY, PERFORM CHART #1, "DRL WILL NOT TURN 'ON."'

WITH A TEST LIGHT TO GROUND, BACKPROBE DRL MODULE CONN C2 TERM "G".
DOES TEST LIGHT ILLUMINATE (OR FLASH ON & OFF)WHEN TURN SIGNAL LEVER IS
MOVED TO THE "RIGHT TURN" POSITION?
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT

BETWEEN TERM"(" AND GROUND.
DOES TEST LIGHT ILLUMINATE WHEN THE TURN SIGNAL
LEVER IS MOVED TO THE "RIGHT TURN" POSITION?
----
--------------------------------,
CHECK FOR POOR CONNECTION AT DRL MODULE.

CHECK FOR AN OPEN IN (KT 1415 BETWEEN TURN/HAZARD
SWITCH ASSEMBLY AND DRL MODULE.
.
IF OK, REFER TO "EXTERIOR LIGHTS," SECTION SA-110 FOR
FURTHER DIAGNOSIS.
L-------------------------------------
CIRCUIT OPERATION
The Daytime Running Lamp (DRL) system
consists of a Control Module and an Ambient Light
Sensor.
During daylight hours; the DRL Module turns
"ON" the Front Turn Signal Lights if l.) Ignition is
"ON," 2.) The Headlights are "OFF" and 3.) If the Park
Brake is "OFF." As darkness approaches, the DRL
Module will turn "OFF" the Front Turn Signal Lights
and turn "ON" the Park Lights and Headlights.
The DRL Module determines daylight or
nighttime hours by receiving voltage from the
Ambient Light Sensor. As darkness approaches the
Ambie.nt Light Sensor will change resistance and thus
change the voltage received by the DRL Module.
The Control Logic within the DRL Module receives
its voltage from the Turn 8-U Fuse 2 and the Gages
Fuse 9. The Gages Fuse also supplies voltage to the
:
:
CHECK FOR POOR CONNECTION AT DRL MODULE

CONN (2 TERMINALS "C" AND "G".
IF.QK, R~PLACE D~L MODU~E.
relays within the DRL Module and supplies voltage to

the Front Turn Signal bulbs during DRL operation
through the Left and Right DRL Relays within the
DRL Module. The Headlight Switch supplies voltage
for the Headlights, through the Headlight Relay
contacts within the DRL Module, during nighttime
hours. The Tail Fuse supplies voltage to the Park
Lights during nighttime hours.
During DRL operation, the Turn Signals and
Hazard Flasher will operate normally. The Park
Lights and/or the Headlights may be operated
manually at any time by using the Light Switch.
The DRL Module will not operate if the system
voltage is less than 9 volts or greater than 18 volts.
When the Park Lights/Headlights are turned
"OFF," and the Ambient Light Sensor indicates a
night condition, the Park Lights will illuminate when
Ignition Switch is moved to "CRANK" position.
HEADLIGHT DOORS
HOT AT ALL TIMES
HOT AT ALL TIMES
r - - - - - - - - - - - - - - - -
f - - ,.
HEADllGHT
: ~ --;;~ ---------------:;i_~
-r
L---~~---------- ~-~
HEAD :,,SWITCH
L----
'
---..J
OFFf
..
/I
.5 BRN
I'" -
I
,..:;;====:....
....:===:...-., II
~ITHOUTT61
3YEL
1 ORN
840
1 ORN
10
3YEL,10
3YEL
522~
10
3YE~O
""I
ON
ON
~T!:!!_T .... MODULE
Fr----Hyg
.5B~N
r---,,,,
.
""'""~'
HEADLIGHT I"'
DIMMER
SWITCH
I
-,
""I
t.
la
I
... _....
-------------------------
BATIERY
~'15226
f""
.5BRN
LIGHTS
PAGES SA-110-2, 3, 5
1 YEL
DAYTIME
I RUNNING
LIGHTS
I (DRL)
PARK
LIGHTS
HEADLIGHTS
a.!N~T- -
i.
'"'------v,-------/
740
9
C200D
Pl OO
.5BRN
----5150
,o :~-- - - - - - - - - - - - - - - - - - - - - - '
Mj~
HEADLIGHT
DOORS
MODULE
PARK LIGHTS
ON INPUT
HEADLIGHTS
ON INPUT
SOLID STATE
OUTPUT
------I LEFT
BAT
REFERENCE
OUTPUT
..r'U"1.l"1...
SENSE
I INPUT
OPEN/CLOSE
RELAY
CONTROL
OUTPUTS RAPIDLY SWITCH

BETWEEN DRIVE AND COAST
- MOTORS ARE POWERED IN DRIVE
VOLTAGE FROM TURNING MOTOR
IS SENSED IN COAST
LOW COAST VOLTAGE INDICATES
ACTUATOR IS AT END OF TRAVEL,
STUCK OR DISCONNECTED. OUTPUT
STAYS IN COAST WHEN LOW COAST
VOLTAGE IS SENSED, OR AFTER 6
SECONDS. MOTOR STOPS.
....l'"'Ll"1.r
DRIVE fr-OAST
__..._
SENSE
INPUT
-=-
GROUND
OPEN
,,.- - ',-C-L_O_S_E--0-PE-N--,/ - '
RELAY
COIL
c
1 LTGRN
~
~
SEE PAGE 8A30
FOR PROPER
HANDLING
PROCEDURES
. ,.:,
1 DK GRN
t--
'-~!'_! ________ _
CLOSE
D
576
"'"'----------""
577
DK GRN/WHT
1 LT BLU
B
GRY!BLK
DJC1
578
1 DK BLU
579
150
3BL~
150
r-~
l
SEE GROUND
DISTRIBUTION
PAGE SA-146
HEADLAMP ..._...,__ _ _ _ _ _ _ __..._,.

DOOR MOTOR, LH
3 BLK
HEADLAMP ............- - - - - - - ~ , - . - .
DOOR MOTOR, RH
15300030
15300029
BLK
BLK
HEADLIGHT DOORS MODULE {C1)
HEADLIGHT DOORS MODULE{C2)
COMPONENT
LOCATION
201-PG

I/P Compartment ............................... .
LH front of vehicle
Ileadlamp Door Motor, LH
Headlamp Door Motor, RH
RH front of vehicle ................................ .
Multi-Function Lever ........................... .
Headlight Doors Module . . Forward of LH front wheelhouse, mounted to Air Intake
Headlight Switch . . . . . . . . LH side of I/P .................................... .
of wheelhouse ................................... .
C200B (18 cavities)
C200D (48 cavities)
Steering Column ................................ .
G106
Near top LH side of radiator, in top ofT-Bar ......... .
PlOO
Compartment ................................... .
8113
Center breakout
8150
8226
I/P Harn, approx 10 cm from Instrument Cluster
breakout
8227
breakout
For a Service Part Cross Reference List and Information, refer to SECTION BA-200.
7 ....
104 "I 1
FIG.
CONN
12
202-20
23 ... 43
3, 35 . 5,64
19 ... 36 ..
37,38 66,67
202-21
202-15
19
36
202-28
25
49
202-2
25
19
49
35
202-2
19
36
SA -
HEADLIGHT DOORS

Diagnosis)
System
Before doi:q.g Blectr.ical Diagnosis, check the

mechanical linkages attached to the Headlamp
Doors for binding, breakage, etc. ,
2. Check for corrosion at the Headlamp Door Motor
connector terminals.
3. If Headlamp Doors opeh slowly, check that G106 is
clean and tight and also that the battery is good
and fully charged.
4. If Headlamp Doors open only partially and no
problems were found with mechanical linkages on
Headlamp Doors, perform Chart #1.
5. If Headlamp Doors pop up without requesting
Headlights, check for bulletins to determine if a
correction is necessary.
1.

system operational(under load).
Check for proper instaHation of aftermarket
SYSTEM DIAGNOSIS
SYMPTOM TABLE
SYMPTOM
PROCEDURE
Pt\GE NUMBER
Both Headlamp Doors remain open or closed.
Chart #1
8A-104-3
LH Headlamp Door stays open or closed.
Chart #2
8A-104-3
RH Headlamp Door stays open or closed.
Chart #3
8A-104-4
104 - 3
CHART #1
BOTH HEADLAMP DOORS REMAIN OPEN OR CLOSED
rn
IMPORTANT:
IF HEADLIGHTS STAY ON. ALL THE TIME OR DO NOT TURN ON AT ALL,
REFER TO "HEADLIGHTS," PAGE 8A-1000.
DISCONNECT CONN C1 AT HEADLIGHT DOORS MODULE.

CONNECT A TEST LIGHT BETWEEN TERMI.NALS "O" & "E" OF
CONNECTOR ANO THEN BETWEEN TERMINALS "O" & "B".
TEST LIGHT SHOULD ILLUMINATE BOTH TIMES. DOES IT?
CONNECT THE TEST LIGHT BETWEEN

TERMINAI.S "A" & "P'' OF C1.
DOES THE TEST LIGHT ILLUMINATE
WHEN HEADLIGHTS ARE TURNED "ON"?
CHECK FOR OPEN IN GROUND CKT 150 FROM

HEADLIGHTS DOOR MODULE TO G106.
. CHECK l.H AND RH HEADLAMP DOOR FUSES FOR OPEN
ALSO CHECK FOR OPEN IN CKT 740 AND CKT 840.
IF FUSE(S) ARE BLOWN CHECK FOR SHORT TO GROUND
THROUGH CKT 740 AND/OR CKT 840.
----------------------,
:
I
:
:
I
I
I
REPAIR OPEN IN CKT\10 BETWEEN

HEADLIGHT DIMMER SWITCH AND
HEADLIGHT DOORS MODULE.

HEADLIGHT DOORS MODULE.
IF OK, REFER TO CHARTS 2 & 3 FOR
INDIVIDUAL HEADLAMP DOOR
DIAGNOSIS.
IF OK, REPLACE HEADLIGHT DOORS
MODULE.
~~----------------------
CHART #2
LH HEADLAMP DOOR STAYS OPEN OR CLOSED
DISCONNECT LH HEADLAMP DOOR MOTOR 2-WA Y CONNECTOR.

CONNECT A FUSED JUMPER FROM THE BATTERY POSITIVE
TERMINAL TO TERM "A" OF DOOR MOTOR 2-WAY CONNECTOR.
CONNECT A JUMPER FROM TERM "B" OF CONNECTOR TO GROUND.
IF DOOR WAS OPEN, IT SHOULD NOW CLOSE. DOES IT?
REVERSE THE WIRES TO TERMINALS" A" & "B"

(GROUND TO TERM "A").
IF DOOR WAS CLOSED, IT SHOULD NOW OPEN. DOES IT?
CHECK FOR A SHORT TO GROUND, SHORT TO

B + OR AN OPEN IN THE TWO WIRES FROM THE
HEADLIGHT DOORS MODULE TO THE HEADLAMP
DOOR MOTOR CONNECTOR (CKTS 576 & 577).
IF WIRES ARE OK, REPLACE THE HEADLIGHT
DOORS MODULE.
REPLACE THE LH HEADLAMP

DOOR MOTOR ASSEMBLY.
SA -
HEADLIGHT DOORS
CHART #3
RH HEADLAMP DOOR STAYS OPEN OR CLOSED
DISCONNECT RH HEADLAMP DOOR MOTOR i-WAY CONNECTOR.

CONNECT A FUSED JUMPER FROM THE BATTERY POSITIVE TERMINAL TO
TERM "A" OF DOOR MOTOR 2-WA Y CONNECTOR.
CONNECT A JUMPER FROM TERM "B" OF CONNE<;TOR TO GROUND.
IF DOOR WAS OPEN, IT SHOULD NOW CLOSE. DOES IT?
REVERSE THE WIRES TO TERMINALS "A" & "B" (GROUND

TO TERM" A").
IF DOOR WAS CLOSED, IT SHOULD NOW OPEN. DOES IT?
CHECK FOR A SHORT TO GROUND, SHORT

TO B + OR AN OPEN IN THE TWO WIRES
FROM THE HEADLIGHT DOORS MODULE TO
THE HEADLAMP DOOR MOTOR
CONNECTOR (CKTS 578 & 579).
IF WIRES ARE OK, REPLACE THE HEADLIGHT
DOORS MODULE.
REPLACE THE RH HEADLAMP

DOOR MOTOR ASSEMBLY.
CIRCUIT OPERATION
Voltage to open the Headlamp Doors and to power
the solid state circuitry is applied to the Headlight
Doors Module at all times at terminals "B" and "E" of
Cl. When the Headlights are turned "ON", voltage is
applied to terminal "A" of Cl as a request for the
Headlamp Doors to open.
When the Headlights are turned "ON", ground is
applied to the relay coil within the Headlight Doors
Module. The relay contacts close and voltage is
applied to the Headlamp Door Motor Assemblies.
Ground is provided for the motors through the solid
state circuitry until the Headlamp Doors are open.
The ground circuit for each Headlamp Door Motor is
rapidly switched within the Headlight Doors Module
between a ground potential and a high impedance
sense input. This input monitors for a fully open
Headlamp Door and will allow ground to be provided
until open or up to 6 seconds. A difficult to open or
obstructed door will be sensed as fully open and ground
will be removed by the m.odule.
When the Headlights are turned "OFF", the
ground to the relay coil within the module is removed.
The contacts then return to the normally closed
position which switches power and ground to the
Headlamp Door Motors. The Headlamp Door Motors
run in the opposite direction to close the Headlamp
Doors. The ground circuit operation within the
module is the same during the closing sequence as
during the opening sequence.
104 - 5
8A -
EXTERIOR LIGHTS
TURN/HAZARD/STOP
HOTINRUN
r-
1
I
I
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
.8 BRN
TURN/BU
FUSE 2
20AMP
141
.---5207
.8B:N~141
;~::HER
[l]l
.SORN
140
~~:HRE~ : CENTER
I":' "_-----~~-1~~ ~~
PPL
r-------
I
I
BRN
16
I
I
27
8
Y A - C 2 1 6 - - - - - - - - ~oLTBLU-------rtl
WHT
I
I
I
I
I
l-----
1TURN/HAZARD
SWITCH
I ASSEMBL y
_.1
I
I
I
1.---~~~~~-+~~~~-'
TURN
LEFT
20
HAZARD SWITCH
DKBLU
------------
---
DK GRN
.SYEL
18
18
C216
------------------------------------------------------------- J
.S LT BLU
.S LT BLU,WHT
14 (WITHOUTT61)
1414 (WITH T61)

(CHEVY) C7
(PONT) 814
r -f -
.5 LT BLU
.5 LT BLUIWHT
19
Ml
YEL
.8 DK GRN
19
LTBLU
14 (WITHOUTT61)
1414 (WITH T61)
I
I
II
15 (WITHOUTT61)
1415 (WITH T61)
- - - - - - -f - - - - - ,
RIGHT
t ...
~i1~ATOR
L-
.5 DKBLU,WHT
~ +
Y
IN_!C~O'.'.:_ -
...
-
SEE 1/P
CLUSTER
--,
3BLK,650
3 BLK
" '1(!0
750
I~
II
.5 DK BLU
~~ 5!B~ J
650
5216- -
INSTRUMENT
CLUSTER
'
1ND1c!~~~@
(PONT) B 3 l
(CHEVY) C4
1 BLK
C216
(CHEVY) C15
(PONT) BS
LEFT
.5 DK BLU
SEE GROUND
~~ci~~B8~l~N7,8
SEE PAGE SA-1102 FOR VEHICLE Vl/1.I!:!.OUT DAYTIME RUNNING LIGHTS (T61)
SEE PAGE SA-1103 FOR VEHICLE WITH DAYTIME RUNNING LIGHTS (T61)
.5 DK BLU/WHT
15 (WITHOUTT61)
1415 (WITH T61)
I,
COUPE
110 - 1
CONVERTIBLE
,~------------~A~__:;;;;;;;;;;;;;;;;;;;;;;;:_,
.8 YEL
.SORN,
820
P300
140
'\
.8 LT BLU
20
YEL
g ~
820
TO AUTO TRANS
PAGE SA-206 (V6 VIN Sj
SA-21-6 (VS VIN Pl
P410
(NOT USED WITH MANUAL TRANSi
--------~
.8YEL
5460
5243
VEL 820
YEL 820
_ _..___________..,___ CENTER HIGH
820
MOUNTED
"'t'
STOPLIGHT
(CHM SL)
TO 5271
PAGESA-34-1
BLK
BLK
5450
tM,O
l J
couPE
B1C420
l.--co_N_V_E-RT-IB_L_E..,
------------~"'~.:::========::...
'j
WITHC49
,m
DEFOGGER
PAGE SA-61-0
3BLK'.mJ,,..
..
....
, ..._ _ _ _ _
5420
.ml,.. '
5470. -
1150
.S BLK
3 BLK
SEE GROUND
DISTRIBUTION
PAGES SA-14-12,13
11 SO (WITHOUT C49l
1150 (WITH C49)
P300
,8 BLK
1550
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
EXTERIOR LIGHTS
WITHOUT DAYTIME RUNNING LIGHTS (T61)
FROM PAGE BA-110-0
HOT AT ALL TIMES
r - - ~ - ,
:1-
I
II
.5 LT BLU
14
HEAD
PARK
L-.-
,._, ,_, . ,. ,
SEE EXTERIOR LIGHTS

PAGE8A-110-4(CHEVV)
OFF
HEA.OLIGHT
1sw1~1:1
I
II
.SOK BLU
--Ji
.. l
.ltBR:f
~ -
.5226
-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-~~~~~~~~~~~~"
.8BRN
.~
.8BRN
9
.8 LT BLU
15
14
.5 BRN
.5 BRN
.5 BRN
I"" -
(2000
(2008
PONTONLV
.8 OK
BLU
15
(1
-i HEADLIGHT
,-
. I DOORS
MODULE
PARKfTURNQ
LAMP,
LEFT FRONT
MARKER L A M P , ~
LEFT FRONTW
150
5113. -
3 BLK
150
.SBLK
__....... SEE GROUND

-....... DISTRIBUTION
PAGE BA-14-6
A
PARK,TURN
LAMP,
('!;\MARKER LAMP,
RIGHT FRONT
.5 BLK
.8 BLK
\.l_)
RIGHT FRONT
Q
L.-J
250
.8 BLK
.150
lill. -
3 BLK
250
__....... SEE GROUND

DISTRIBUTION
PAGE 8A-14-S
-.......
250
110 - 3
EXTERIOR LIGHTS
WITH DAYTIME RUNNING LIGHTS (T61)
FROM PAGE 8A-110-0
-I-,
HOT AT ALL TIMES

HEADLIGHTr SWITCH
I
I
:1-
HEAD
PARK
L-c
.8 BRN
.3LTBLU
OFF
I
I
--J
14
I
.5 BRN
.5 BRN
.5 BRN
PARKITURNQ
LAMP,
LEFTFRONT
MARKER LAMP,n\
LEFT FRONT\V
("!!;\
MARKER LAMP,
WRIGHT FRONT
150
.5 BLK
150
C1
-, HEADLIGHT
,--
L. -
.J
PARKITURNQ
LAMP,
RIGHT FRONT
G
250
.8 BLK
150
siQ. - 3 BLK
.5 BLK
.8 BLK
15
BLU
I DOORS
MODULE
.8 DK
I"" -
PONTONLV
3 BLK
__....t/1.
250
SEE GROUND
~ DISTRIBUTION
PAGE 8A14-5
250
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
EXTERIOR LIGHTS (CHEVY)

REAR MARKER/LICENSE!TAIUSTOP!TURN
- - ,!!
r:---I
I
CONVENIENCE
CENTER
RADIO
-~
FUSE
I BLOCK
I
I
__ .J
L---.SORN
240
.S BRN
WITH T96
- - , AUDIO r- - ., I
I ALARM I
I I
MODULE
.
I --,
I I
I
1..--'I
L---o _J
r- - ..,
.5 BRN
r - - - - - ,
SEE POWER
DISTRIBUTIOIII
PAGE 8AU1
r- -
I
I
l<DRL)
I
A
_,MODULE
.5 BRN
LIGHTS
L. -
L.--1
.5 BRN
r- - -, DAYTIME
I
I RUNNING
-,IIP
IOIMMER
SWITCH
,.. _...
WITHT61
r-.;..
-,FOG
'LIGHT
SWITCH
.8 BRN
....
.8 BRN
TO C200D
CAVITVD4 ~"~. . . .11111111111111111. . . .,
WITHT61
9
PAGESA-110-3
WITHOUTT61
PAGE SA-110-2
.5 BRN
.5 BRN
9
FROM C216
PAGE SA-110-0
.8 BRN
.8 BRN
(NOT USED)
A"
!AILLAMP.~
RH I N B O A R D ~
.8 DK
19
GRN
G)
MARKER
.
LAMP,
LEFT REAR .
G)
t.:s
.5 BLK
B
.5 BLK
.5 BLK
1250
.5 BLK
1250
SEEPAGE 8A-.3-0
FOR PROPER
HANDLING
PROCEDURES
_..ollllllll
~ ~---
-......
A
TAIL!
STOP/
TURN
LAMP,
MARKER
LAMP, .
RIGHT REAR
.5 BLK
S430
SEE GROUND
DISTRIBUTION
PAGE SA-14-13
1 gB5 0
,5 BLK 1250
---,
.5 BLK
~
~
BLK
1250
1250
1250
1250
8
..
-5BLK. . . .)
'--~~_____,
1250
.5BLK
1250
.5 BLK
1250
ELECTRICAL DIAGNOSIS SA - 110 .. 5
EXTERIOR LIGHTS (PONTIAC)

REAR MARKER/LICENSE/TAIL/STOP/TURN
--,~
i-:--- ....
FUSE
. SEE POWER
DISTRIBUTION
PAGE 8A-10-1
I
I
CONVENIENCE
CENTER
R~DIO ... -
.5 BRN
.BORN
--.
L.-.J
<;_!
- _ ..J
r - - - - - 1 L----
240
AUDIO ... ALARM

MODULE
I
I
._
.5 BRN
WITHT61
-,FOG
LIGHT
SWITCH
I
I
.J
I"" -
-,1/P
DIMMER
SWITCH
L. -
.J
I"" -
.5 BRN
.J MODULE
.5 BRN
I RUNNING
LIGHTS
I (DRL)
L. -
.8 BRN
-, DAYTIME
_J
L---
I"" -
-,
WITHT96
I
I
I
I I-==
I--.
I I
I
L.-.J I
-,
--
I BLOCK
I
I
r_
TO
C200D
.8 _
BRN_ _
WITH
T61 CAVITY 04..
.,.._
. ._ _
PAGE SA-110-3
WITHOUTT61
PAGE BA-110-2
.5 BRN
.5 BRN
FROM C216
PAGE 8A-110-0
9
9
FROM C216
PAGE 8A-110-0
.8 BRN
.8~K
19
GRN
.8 BRN
.8 BRN
.8 BRN
9 . 8 *1:400
:
GRN
P400
.5 BRN
--1
5401-
.8 YAEL
18
~18
8
,. Y!'A
G):~~
MARKERG)
LAMP,
Bh:5
BLK
.5 BLK
1250
G
1250
.5 BLK
1250
))
TAIU
Q~~~~
LAMP,
~REAR
OUTBOARD
1250
.5 BLK
.5 BLK
1250
.5 BLK
5430
.8 BLK
1250
.8 BLK
1250
:...---------...------~--------
C4_3Q
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
1250
_5 BLK
MARKER
.8 BLK
t.t,
19
GRN
LEFT REAR
QUTBOARD
.8 BLK
.8 DK
TAIL/STOPIQ
QTAILISTOPI
TURN LAMP,
TAIL1STOPI
TURN
LAMP, LH
.8DKF9
GRN
A
LH INBOARD A
-5402
1250
.5 BLK
1250 ........._ _ _ _ _/ , . 5415

8 BLK
'-8BLK_ _,.~
.
TO BACKUP LAMP
r
PAGE8A1120
'1111111
1250
1250
~d
~ -
#':____
~
-""""'
~
SEE GROUND
DISTRIBUTION
PAGE 8A-14-12
1250
SA -
EXTERIOR LIGHTS
12004147
11-WA Y F PACK-CON I
BLK
1/P HARNESS TO STEERING COLUMN HARNESS
COMPONENT
LOCATION

201-PG
FIG.
Center High Mounted Stop

Light (CHMSL) . . . . . . . . . Rear center of Spoiler
Convenience Center . . . . . . Left of Steering Column, mounted to bottom of
1/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
15 . .
(DRL) Module ......... . Mounted behind Radio and HVAC Controls, left of
1/P Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12
Fog Light Switch ........ . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66, 67
Headlight Doors Module .. Forward of LH front wheelhouse, mounted to Air Intake 19 . . . 36 ..
Headlight Switch ....... . LH side ofl/P ............ ; . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66, 67
1/P Dimmer Switch ...... . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66, 67
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 ..
Instrument Cluster ...... . LH side of 1/P ................................................... .
License Lamp ........... . Center ofrear Fascia, above license plate . . . . . . . . . . . . 31
59
Marker Lamp, Left Front . Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Marker Lamp, Left Rear .. Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
59
Marker Lamp, Right Front Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Marker Lamp, Right Rear . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
59
Park/Turn Lamp, Left Front Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Park/Turn Lamp,
32
Right Front ........... . Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Radio .................. . Center ofl/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
65
Taillamp, LH (Pont) .... . Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
62
Taillamp, LH Inboard
(Chevy) ............... . Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
61
Taillamp, LH Outboard
61
Taillamp, RH Inboard
(Chevy) ............... . Exterior, right rear ................................ 32
61
Taillamp, RH Outboard
(Chevy) ............... . Exterior, right rear . ............................... 32
61
33
Taillamp, RH (Pont) .... . Exterior, right rear
62
Tail/Stop/Turn Lamp, LH
61
LH Inboard (Pont)
62
LH Outboard (Pont)
62
Tail/Stop/Turn Lamp, RH
(Chevy) ............... . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
61
62
RH Inboard (Pont) ..... . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RH Outboard (Pont) ..... Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
62
CONN
202-20
202-20
202-21
202-21
202-15
202-23
202-23
202-23
202-16
COMPONENT
LOCATION
201-PG
FIG.
Turn Flasher . . . . . . . . . . . . Mounted to bracket, right of Steering Column,

15
above Data Link Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Turn/Hazard Switch
Assembly ............. . Part of Steering Column . . . ... . . . . . . . . . . . . . . . . . . . . . . 3
5
C200B (18 cavities)
49
C200D (48 cavities) ..... . Part of 1/P Harn, between LH kick panel and
Steering Column ................................ . 25
49
C216 (11 cavities) ....... . Attached to base of Steering Column ............... . 34
63
C330 (3 cavities) ........ . Hatch to I/P Harn, center of roof near Don1e Lamp ... . 4 .... 6
C400 (6 cavities) ........ . LH Rear Cargo Compartment, between rear end
panel and carpet ................................ . 30 ... 57
C420 (2 cavities)
LH side of Hatch, between Hatch Frame and plastic
panel .......................................... . 4 .... 7
C430 (2 cavities) ........ . Between Rear Fascia and rear end panel, on LH side
32,33 61,62
G105 ................... . Near top RH side of radiator, in top of T-Bar ......... . 19
36
G106 ................... . Near top LH side ofradiator, in top ofT-Bar ......... . 19 ... 35
G200 ................... . Near base of LH "A" pillar, bolted to I/P Mounting Stud
behind kickpanel (2 rings, 2 wires) ............... . 9
16
G310
Bolted to roof, left of Dome Lamp (1 ring, 1 wire) ..... . 4 .... 6
G400
Convertible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
57
PlOO
Compartment ..... : ............................. . 19
36
P300
In rear center of roof, near Dome Lamp ............. . 4 .... 7
P400
Left rear in end gate panel ......................... . 30 ... 57
P410
In left side spoiler
S112
Forward Lamp Harn, approx 10 cm from G 105 breakout
S113
Center breakout
S150
S207
5216
5226
breakout
S243
I/P Harn, approx 14 cm from Fuel Pump Relay breakout 7
13
5400
Rear Body Harn, approx 13 cm from Left Backup Lamp
(Pont) or 20 cm from P400 branch (Chevy) breakouts . 32
61
S401
Rear Body Harn, approx 19 cm forward of P400 . . . . . . . 30
57
S402
Rear Body Harn, approx 16 cm forward of P400 . . . . . . . 30
57
5410
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
62
5415
Lamp breakout .................. , .............. . 33
62
S420
Hatch Harn, approx 7 cm from P300 ................ . 4 .... 7
S430
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
59
5440
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
59
S450
5460
S470
I/P Harn, approx 24 cm from Hatch Release Actuator
For a Service Part Cross Reference List and Information, refer to S_ECTION SA-200.
CONN
202-2
202-2
202-5
202-19
SA -
110 - 8
EXTERIOR LIGHTS

Diagnosis)
Make sure all lamps are operational before

replacing flashers:
System

SYSTEM DIAGNOSIS

For Daytime Running Lights (DRL) related
failures, refer to "Headlights and Fog Lights:
Daytime Running Lights (T61)," page SA-102-0.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
fuse(s) blows whl;!n replaced or when attempting to

Chart #1
BA-110-8
Entire lighting system inoperative.
Use schematics and DVM or test light to check suspect

power circuits and ground circuits for opens or poor
connections.
Individual lamp inoperative.
Determine if lamp is defective.

Check for corrosion or poor connection at socket .
If OK, use schematic and DVM or test light to
check suspect circuits.
CHART #1
FUSE(S) BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM
REPLACE BLOWN FUSE(S}.

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE SYSTEM?
TEST SYSTEM ONE FUNCTION AT A TIME,

UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMATIC TO
DETERMINE WHAT CIRCUITS OR
COMPONENTS COULD BE FAILING. USE A
TEST LIGHT OR DVM TO NARROW IN ON
SHORT TO GROUND POTENTIAL
(DISCONNECTING COMPONENTS IS
HELPFUL WHEN TRYING TO CHECK
CIRCUITS THAT SHOULD NOT BE AT A
GROUND POTENTIAL).
USE SCHEMATICS AND DVM TO CHECK

SUSPECT POWER CIRCUITS FOR A SHORT TO
GROUND POTENTIAL, EITHER THROUGH A
FAULTY COMPONENT OR IN WIRING.
If ALL RELATED COMPONENTS ARE
BLANK
110 - 9
SA -
BACKUP LIGHTS
I
--,l!J'
HOTINRUN
I FUSE
BLOCK
-I
TURN/B-U
FUSE2
20AMP
__ ...J
.8 BRN
141
5207. _ BRN
141
8
,.L
MANUAL TRANSMISSION
........... SEEFUSE
........ 'BLOCK DETAILS
PAGE 8A116
AUTOMATIC TRANSMISSION
.SBRN
.8 BRN
-1- - -.
c
141
r- -
A
, . . , - BACKUPLIGHT ... MANUAL
SWITCH (CLOSED TRANSMISSION
I
I
IN REVERSE)
I
I
141
I(
TRANSMISSION
jPOSITION
SWITCH
I 'SR 3 }/ , , 1
-+- ~..
I
I
... .:l. ____ _.
~rn,1~-_.
(MANUAL) 1 LTGRN
(AUTOMATIC) .8LTGRN
24
24
C400
.8 LT GRN
l
m~
..
24-_-____-____-____~~- - - - - - - -
-~~':*,.:"'#----------
BACKUP
LAMP,
.8 B~
24
l
-=-__-____-__~~T:+N
24 P 00
4
G)BACKUPG)BACKUP
LAMP,
LAMP,
~
lli
lli
250
y,
541 o
8 B~K
..
~
'
4,,.
.S BLK
1250 . . . .
--4
250
r,
8 B~
'
250
r,
.S BLK
.8 B~K
s41oe
SEE GROUND
DISTRIBUTION
PAGE 8A-14-13
'
4,,.
.S BLK
L---.J
250
es41s
1250 . . . .
T
_._G400
G)BACKUP
LAMP,
~
--4
1HO
SEE GROUND
DISTRIBUTION
PAGE 8A-1412
T
L---.J
_._G400
_.._
-
.JI
~I
g,. . ____,
A j '
,l l I
c
I tJ I b
12015307
BLK
COMPONENT
Backup Lamp, LH ....... .
Backup Lamp, RH ....... .
Backup Light Switch (M49)
(V6 VIN S) ............ .
Backup Light Switch (MM6)
(VS VIN P) . . . . . . . . . . . .
1/P Fuse Block . . . . . . . . . . .
Switch ................ .
C230 (10 cavities) ....... .
C400 (6 cavities) ........ .
LOCATION
Mounted in Taillamp Assembly
Mounted in Taillamp Assembly
201-PG
32, 33
32, 33
Middle of Transmission, left side . . . . . . . . . . . . . . . . . . . . 16
FIG.
30
Middle of Transmission, right side . . . . . . . . . . . . . . . . . . 26

51
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 . .
Under console, on base of shift control lever . . . . . . . . . .

LH Rear Cargo Compartment, between rear end
panel and carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G400
Convertible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PllO
Compartment ....................................
P400
Left rear in end gate panel . . . . . . . . . . . . . . . . . . . . . . . . . .
8207
8405
Rear Body Harn, approx 12 cm forward of P400 . . . . . . .
8410
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8410 (Chevy) ........... . Rear Body Harn, approx 27 cm from P400 branch
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear
Body Harn, approx 20 cm from Left Backup
8415 ................... .
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN
61, 62
61, 62
202-23
22
20
42 ..
37 ..
202-28
202-7
30
57 ..
202-19
30
57
19
30
35
57
30
57
33
62
32
61
33
62
8A -
112 - 2
BACKUP LIGHTS
(Perform before
Diagnosis)
beginning

System

inside of the insulation which could ,cause system
SYSTEM DIAGNOSIS

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER

Chart #1
SA-112-2
Both lights inoperative.

connections. Repair or replace as necessary.

Check for corrosion or poor connection at socket .
CHART #1
FUSE(S) BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM

DOES FUSE BLOW BEFORE A TT EMPTING TO OPERA TE SYSTEM?
TEST SYSTEM ONE FUNCTION AT A TIME,

UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMA TIC TO
ORCUITSTHATSHOULDNOTBEATA
GROUND POTENTIAL).

IF ALL RELATED COMPONENTS ARE
112 - 3
BLANK
SA -
INTERIOR LIGHTS
COUPE
HOT AT ALL TIMES
,---------------------------I
SEE POWER
DISTRIBUTION
PAGE SA-10-2
----,11P
FUSE
BLOCK
SEE POWER
DISTRIBUTION
PAGE SA-10-1
CIGAR/HORN
FUSE 11
25AMP
I
I
BATT
(NOT USED)
I
I
____ .J
L------------
1 ORN
3 ORN
40
40 (CHEVY WITH U82)
--lllli.....
5210
.5 ORN
.-------,
SEE FUSE
BLOCK DETAILS
PAGESA-11-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111!1~
................
40
B
DOME
LAMP
.8 ORN
540
.8 ORN
CIGAR_..,._ __
.SORN
40
,----,"""'--'I 11P
LIGHTER
CONSOLE
COMPARTMENT
LAMP
COMPARTMENT
LAMP
I
1-
OPEN
CLOSED
CLOSED
E3
@
B
C200C
C200D
.8 ORN
.A
.8 BLK
40
650
.8 BLK
A
650
.8 BLK
.SORN
5265-:--1
40
,.
650
-,
s211ei"'."---------------
'--~
40
.5 ORN
40
SEE GROUND
DISTRIBUTION
PAGE SA-14-9
c
~,;;;;:::;;;:::;;;:::;;!..._ _ _ _ _ _ _ _ _ _ _ __:;.!;~
REARVIEW
FROM EXTERIOR
LIGHTS 5226
PAGE8M10-4
MIRROR
. :f
I,og~;-li' 1 ~~~
.5 WHT
156
.SWHT
El
156
C200D
C200C
ON
ON
.5 BLK
.8 BLK
TO IIP DIMMER FUSE

PAGES BA-117-0, 2
SEE GROUND
DISTRIBUTION
PAGE SA-14-7
........_
5216
3BLK
, , . . - . . . . _ _ _ _ _ _ _. .
PAGE SA-14-8
650
3 BLK
COURTESY/
READING
LAMPS
WITHAUO
Al
.5 WHT 156
.5 WHT
5262 ,
- - - - - 1 - 5 6_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
'"":l . :. ~
SEEGROUND
DISTRIBUTION
TO KEVLESS
ENTRY RECEIVER
PAGE SA-132-1
650
~
3 BLK (WITH POWER ACCESSORIES)

.8 BLK (WITHOUT POWER ACCESSORIES}
T
I
............................ .
750
750
750 (WITHOUT
POWER
ISOLATION DIODE
(RAP} (3 AMP}
ACCESSORIES}
156
llli,
TO KEYLESS
ENTRY RECEIVER
PAGE SA-132-1
WITH AU3
52661
.5 GRY!BLK
74
111111"
745
745
TO RETAINED
ACCESSORY POWER
(RAP} MODULE
PAGE SA-15-0
r,TOIGNITION
KEV WARNING
159
SWITCH
PAGE SA-76-0
.5 TAN
A
~f~[]~?ii:
SWITCH.RH
CLOSED
WITH DOOR
OPEN
- - - - -
..Ir
't
.SGRY1
BLK
.5 GRViBLK
A
_35 WHT
SWITCH, LH
CLOSED
WITH DOOR
OPEN
114 - 1
INTERIOR LIGHTS
CONVERTIBLE
---,1,P
r ~P";;"w'; I DISTRIBUTION
I PAGE BA-10-2
,FUSE
BLOCK
'
BAIT
I
I
(NOT USED)
,. ____
___
L------------
1 ORN
40
1
IJ
SEE FUSE
BLOCK DETAILS
.BORN
..--------- --------------------------~-------...
.5 ORN
40
COURTESY
LAMP,
LEFT
REAR
.__PAGESA-11-8 __,
ls311
.SORN
.SORN
40
40
5210
.SO:N140
CIGAR
LIGHTER
.SORN
REAR
COMPARTMENT
LAMP
.BORN
40
40
.8 ORN
B
1/Pf""-""~--'I
COMPARTMENT
LAMP
_ _..B_ _ _ _,. CONSOLE
1-
COM PART-
OPEN
COURTESY
LAMP,
RIGHT
REAR
CLOSED
650
SEE GROUND
DISTRIBUTION
PAGE BA-14-9
-c1:-:~
f
.. .J
SEE GROUND
DISTRIBUTION
PAGES
SA-14-12,13
.SWHT
156
~~:.::F~
~
CLOSED
40
A
.S BLK
TO KEYLESS
ENTRY RECEIVER
650
PAGE SA-132-3
-.1---
REARVIEW
MIRROR
5316
FROM EXTERIOR
LIGHTS
5226
PAGE BA-110-4
":t
'w:; "', w"'
I,.q~;;lr
I"
~:
:
~
-
Dl
~MMER
44
.5 BLK
3 BLK
----------.....
'
650
SEE GROUND
DISTRIBUTION
PAGE SA-14-7
SEE GROUND
......_
DISTRIBUTION
PAGE
BA-148
, . , . - . . - - - - - - - - - - -. .
5216
650

.8 BLK (WITHOUT POWER ACCESSORIES)
T
I
....................... .
750
.....A.J200
WITHAUO
.5WH:I56
.5 BLK
.8 BLK
..--------,
650
. ._ _ _156_ _ __
TO 1/P DIMMER FUSE

PAGESSA-117-0, 2
3 BLK
ON
ON
SWITCH
.5 DK GRN
COURTESY/
READING
LAMPS
W-HTb~
ENTRY RECEIVER
.... PAGE SA-132-3
.......
l.S
156
1F
ISOLATION
DIODE (RAP)
,I,
750
750 (WITHOUT
POWER
ACCESSORIES)
TO KEVLESS
52 2
6
't _GRY!BLK
..-- 5
b
....
--(3 AMP)
5266
.5 GRY/BLK
745
.
5 GRV/BLK
745
745
159
.STAN
SWITC~;(l]
CLOSED WITH
DOOR OPEN
_
I.
WITH AU3
I.
TO RETAINED
ACCESSORY POWER
{RAP) MODULE
PAGE SA-15-0
TO IGNITION
KEY WARNING
SWITCH
PAGE BA-76-0
~r;11rr~t
DOOR OPEN
SA -
INTERIOR LIGHTS
COMPONENT
201-PG
LOCATION
Cigar Lighter ........... .

Console Compartment Lamp
Courtesy Lamp, Left Rear .
Courtesy Lamp, Right Rear
Dome Lamp ............ .
Door Jamb Switch, LH ... .
Door Jamb Switch, RH ... .
1/P Compartment Lamp .. .
1/P Dimmer Switch ...... .
1/P Fuse Block .......... .
Isolation Diode (RAP) ... .
FIG.
81
Mounted on front of console ................. . 43
81
Under Console Compartment Door .......... . 43
Mounted in left sail panel
Mounted in right sail panel
On roof, near hatch ........................ . 4 ...... . 6
Near base of LH "A" pillar .................. . 45 ..... . 84
Near base of RH "A" pillar .................. . 32 ..... . 49
Inside top center of compartment ............ . 22 ..... . 41
Lower LH side ofl/P ....................... . 37, 38 .. . 66,67
LH side of 1/P Carrier, on the side ........... . 8 ...... . 15
Sealed in Harn, approx 9 cm right of Rearview
84
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rear Compartment Lamp . Center of rear compartment below Hatch
Release Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 30
58
Rear Dome Light Switch .. Center of end panel, in Cargo Compartment . . . 30
57
Rearview Mirror ........ . Top center of windshield ......................................... .
C200C (13 cavities)
Part of Cross Car Harn, between LH kick panel
49
and Steering Column . . . . . . . . . . . . . . . . . . . . . . 25
C200D (48 cavities) ..... . Part ofI/P Harn, between LH kick panel and
49
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . 25
G200
Near base of LH "A" pillar, ho lted to 1/P
Mounting Stud behind kick panel (2 rings,
2wires) .................................. 9 ....... 16
G400
Bolted to Hatch Release Bracket in Rear
Compartment (2 rings, 3 wires Coupe) or (2
rings, 2 wires Convertible) . . . . . . . . . . . . . . . . . 30 . . . . . . 57
S'210
1/P Harn, approx 44 cm from Convenience
Center Pont or 12 cm from RR Defog Switch
(Chevy) breakouts
S216
breakout
S217
1/P Harn; approx 23 cm before DLC breakout
S220
Cross Car Harn, approx 9 cm from C200
84
breakout .................... . . . . . . . . . . . . . 45
S262
84
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . 45
S265
84
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . 45
S266
84
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . 45
S316
1/P Harn, approx at rear edge of door below left
sail panel
S317
1/P Harn, approx at rear edge of door below left
sail panel
S470
I/P Harn, approx 24 cm from Hatch Release Actuator
CONN
202-23
202-23
202-27
202-2
202-2
{Perform before
Diagnosis)
beginning
Sy~tem


SYSTEM DIAGNOSIS

SYMPTOM TABLE
SYMPTOM
.)>ROCEDURE
PAGE NUMBER

Chart #1
8A-114-3

Deterrr :ne if lamp is defective .

Ch~ck for corrosion or poor connection at socket .
CHART #1
FUSE{S) BLOWS WHEN REPLACED OR WHEN ATIEMPTING TO USE LIGHTING SYSTEM

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERA TE SYSTEM?
TEST SYSTEM ONE-FUNCTION AT A TIME,

UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMA TIC TO
GROUND POTENTIAi.).

If ALL RELATED COMPONENTS ARE
SA -
INTERIOR LIGHTS DIMMING (CHEVY)

HOT AT ALL TIMES
-----,1,P
SEE POWER
I DISTRIBUTION
I PAGE 8A-10-3
L. -
FUSE
SEE POWER
DISTRIBUTION
PAGE 8A-10-1
,._, . -
1/POIMMER
FUSE 13
5AMP
I BLOCK
I
I
____ ....
.5 GRV
.8 PNK
39
OIIILV ONECKT240
FROM FUSE 10
WffHOUTDRL
SEE FUSE
_.;,._
BLOCK DETAILS
PAGE 8A-11-5
...........-- -
S206
.8 ORN
.35 PNK
.8 ORN
240
39
SEE INTERIOR LIGHTS

PAGE SA-114-0 (COUPE)
8A-114-1 (CONVERTIBLE)
.5 WHT
240
.35G8Y
.5 BRN
156
COUPE
ONLY
.5 BLK
650
.35 BLK
6SO
ELECTRICAL DIAGNOSIS SA_
l
l
ciooc
C200D
.35 GRY
.35 GRY
r
,
. 'CID
8
A
TRACTION , CONTROL
SWITCH
.35 GRY
.5 GRY
.35 GRY
I
I
'-
BT
~1
35 GRV
I-,
r. .
~
521
.5 BLK/
I~
I
I""'
I
I
.35 GRY
750
.35 GRY
.35 GRY
.5 BLK/
WHT
HVAC
C3 CONTROL
ASSEMBLY
RADIO~
---.,
5220
SEE GROUND
DISTRIBUTION
PAGE SA-14-7
C1
650
L-;1~I
r------,
DELCO-BOSE
'l'
451
I
'
1 BLK 11051
.35 BLK
650
.35 BLK
G103
__tt_!_V8 VIN Pl
650
.5 BLK
.5 BLK
650
5221 - - ,
1 BLK
650
650
3BLK
1051
SEE GROUND
DISTRIBUTION
PAGE SA-14-10
.35 BLK
650
451
1 BLK
,...
1
l~I
l~I
II
II
. . . _.5109
(VS VIN Pl
.8 BLK/
WHT
WITH T96
T
I
I
I
DOOR
1!,b!JMINATION
LAMP. LH
----
.35 BLK
I
I
........
SEE GROUND
DISTRIBUTION
PAGE SA-14,1
...T
.5 BLK
650
SEE GROUND
DISTRIBUTION
PAGE SA-14-8
CID
CID
ASHTRAY@ PRNDL
ILLUMINATION
-LAMP
B
(USES A LIGHT
TUBE TO
ILLUMINATE
ASHTRAY}
6 LAMPS
,
IN PARALLEL
:,t
Ir I
WHT
5260
DOOR
ILLUMINATION
LAM_!),J!!:!
AUTOMATIC
TRANSMISSION
FOG
LIGHT
sw_lT_C_H
I ~ 11I,
451
MANl.lAL
TRANSMISSION
L:::_J
451
....1
.35BLK,WHT
J - -,
INSTRUMENrr
CLUSTER
8 (AUTOMATIC)
8 (MANUAL)
C3
,r ,
~.
.35 GRY
E7
, .. . . . . .S
. . . . . . . .,,~----~35-GRY
.
. . . . . . . . . . . . . ..
.SGRY
.35 GRY
117 _1
~
-
SEE GROUND
DISTRIBUTION
PAGE SA-14-9
.J
3 BLK
650

750
SA -
INTERIOR LIGHTS DIMMING (PONTIAC)
SEE POWER
I DISTRIBUTION
I PAGE SA-10-3
-,11p
l!P DIMMER
FU~
5 AMP
___ .J
L-------.8 PNK
I FUSE
BLOCK
I
I
.5 GRV
39
8
ONLY ONE CKT 240
FROM FUSE 10
WITHOUTDRL
SEE FUSE
BLOCK DETAILS
PAGE SA-11-5
.SORN
.SORN
240
.35 GRV
8
.35 GRV
240
8
.35 PNK
39
I " " ~- - - , PERFORMANCEi
I
I
I TRACTION
CONTROL
I~
I~~.
I~~.
I 'C__Y I
WITHM30
ANDNW9
PERFORMANCE
... _i_ .... ~

F
.35 BLK/
WHT
5215.
WITHM30
WITHOUT
9
_NW-- ~
451
9111!1 -
.5!':;f 51
B
.5 BLKI
WHT
C210
.-----'=:..._.;..--,
SEE GROUND
DISTRIBUTION
PAGESSA.-14-1, 2, 3
451
T
SEE INTERIOR LIGHTS
PAGE SA-114-0 (COUPE)
SA-114-1 (CONVERTIBLE)
.5 WHT
S109
.5 BRN
(VS VIN P). 5110

(V6 VIN 5)
.J
156
.8 BLKI
451
WHT
COUPE
ONLY
1/P
OIMMER
SWITCH
G103 (VS VIN P)
(V6 VIN S)
LO
~104
.5 DK GlfN
44
.35 BLK
.S BLK
650
650
l
l
.SGRY
.JS GRY
E7
.JS GRY
))
-.I
C200C
C2000
.35 GRY
117 - 3
5260
.35 GRY
.35 GRY
P.SOO
P6004
35G:Y18
.35 GRV
.35 GRV
.5 GRY
INSTRUMENT
CLUSTfl!
82
~l
6LAMPS
IN PARALLEL
I
I
t _J
..i~-~:~(~" : .:.~~"
f1 -~
I~
I ~
.35 GRY
.5 GRY
MISSION
8 (AUTOMATIC)
8 (MANUAL)
DOOR(!)
ILLUMJNAT!QJII
LAMP,_RH
AUTOMATIC
TRANSMISSION
A
.35 GRY
ASHTRAY~ PRNDL
~MP
ll.LUMINATION_
8
B
83
STEERING
WHEEL
CONTROLs.
~
-
I WITH UK] 1: ( ! )
~
L..
I
I
.35 GRY
(!) :
II
.5 BLK
...
Cl
f:;2.
r-
1 BLK
650
1 BLK
650
650
.5 BLK
PAGE 8A147
- -
-,HVAC
CONTROL
ASSEMBLY
: ( ! ) ( ! ) : ____ _
650
l~I
!.. --~
B
.35 BLK
8
SEE GROUND
DISTRIBUTION
Lov-.J
~RADIO
~:s~:
A LIGHT
TUBE TO
ILLUMINATE
ASHTRAY)
: f.~:
C1
1~1
1~1
II
- ,
I
.---RA_D--,ld I
\V
C3
650
.5 BLK
650
.35 BLK
650
.5 BLK
3 BLK
650
650
SEE GROUND
DISTRIBUTION
PAGE 8A148
SEE GROUND
DISTRIBUTION
PAGE 8A149
IJliii- - ...,
3 BLK
650

750
12034060
4-WAV F METRI-PACK 480 SERIES
NAT(WHT)
1/P DIMMER SWITCH
COMPONENT
LOCATION
201-PG
FIG.
CONN
Ashtray Lamp (Auto Trans) Lighting Tube from PRNDL Lamp

Ashtray Lamp
(Manual Trans) . . . . . . . . . Rearward of shifter, in ashtray . . . . . . . . . . . . . . . . . . . . . . 43 . . . 82
(DRL) Module ......... . Mounted behind Radio and HVAC Controls, left of
1/P Compartment ............................... . 7 .... 12 . . 202-20
Door Illumination Lamp, LH Behind door trim panel ............................ . 17 ... 31
Door Illumination Lamp, RH Behind door trim panel ............................ . 17 ... 31
Fog Light Switch ........ . Lower LH side of 1/P .............................. . 37,38 66,67 202-21
Headlight Switch ....... . LH side ofl/P .................................... . 37,38 66,67 202-15
(HV AC) Control Assembly Center ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . 40 .. 202-22
1/P Dimmer Switch . . . . . . . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38 66, 67 202-23
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 . . 202-23
Instrument Cluster . . . . . . . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-23
202-24
Performance Switch ..... . Mounted in center console behind shifter
202-24
79
Control Switch . . . . . . . . . Mounted in center console behind shifter . . . . . . . . . . . . . 42
PRNDL Illumination Lamp
(Auto Trans) . . . . . . . . . . . Under console, left of Shifter ....................... . 43
81
202-16
Radio . . . . . . . . . . . . . . . . . . . Center ofl/P Carrier .............................. . 36
65
202-27
66
37
SIR Coil Assembly ...... . Top of Steering Column ........................... . 3, 34 . 5,51
Radio (UK3) .......... . On Steering Wheel ............................... . 2 .... 3 . .. 202-27
Traction Control Switch .. Left side of upper console .......................... . 42
78
C200C (13 cavities)
202-2
49
Steering Column ................................ . 25
C200D (48 cavities)
202-2
49
Steering Column ................................ . 25
37 .. 202-19
202-19
63
C217 (4 cavities) ........ . Near base of Steering Column ..................... . 34
G103 (LTl) ............. . RH side of Engine Block,just above Starter
72
(1 ring, 1 wire) .................................. . 40
G104 (L32)
56
G200 ................... . Near base of LH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... . 9 .... 16
ELECTRICAL DIAGNOSIS SA-117 - 5
COMPONENT
LOCATION
201-PG
Near base of RH "A" pillar, bolted toI/P Mounting Stud

behind kick panel (1 ring, l wire) ............ ., . . . .
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P500
Between LH door arid "A" pillar . . . . . . . . . . . . . . . . . . . . .
P600 ................... . Between RH door and "A" pillar . . . . . . . . . . . . . . . . . .
8109 (LTl) ............. . Engine Harn, approx 4 cm from main branch and
PCM breakout
Sl 10 (L32)
Engine Harn, approx 7 cmJrom RH Oxygen Sensor
breakout
8206
breakout
8215
8216
8217
Cross Car Harn, approx 9 cm from C200 breakout
8220
I/P Harn, approx 7 cm from DERM breakout
8221
8224
8226
breakout
8260
Cross Car Harn, approx 13 cm from Rearvtew
Mirror breakout ............................... , .
FIG.
CONN
G201
9 . . . . 16
19
17
45
35
31
84
45 ... 84
45 . . . 84
For a Service Part Cross Reference List and Information, refer to SECTION. 8A-200.
Diagnosis)
System


With DRL suspect failures, for a better
understanding of the DRL System, refer to the
Circuit Operation and Circuit Mechanization in
SECTION 8A-102.
SYSTEM DIAGNOSIS

SA -
117 - 6
ELECTRICAL DIAGNOSIS,

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Fuse blows when replaced or when attempting to use

lighting system.
Chart #1
SA-117-6
LJse schematics and DVM or test light to check suspect


Check for corrosion or poor connection at socket.
CHART #1
FUSE BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE SYSTEM?
TEST SYSTEM ONE FUNCTiON AT A TIME,

UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE,SCHEMATIC TO
GROUND POTENTIAL).

CONNECT ADVM SET TO VOLTAGE ACROSS
IF All RELATED COMPONENTS ARE
LOCA TE,AND REPAIR SHORT IN WIRING.
ELECTRICAL DIAGNOSIS SA,.
BLANK
117 - 7
SA - 120- 0 ELECTRICAL DlAGNOSIS
POWER WINDOWS (A31)

HOT IN ACCY, RUN OR
I
I
:eP;W;DISTRIBUTION
PAGE8A102
WINDOWS
CIRCUIT
BREAKER 15
30AMP
11/PFUSE
BLOCK
,--
I
I
____ J
I
3 BRN
341
3 BRN
TO CONVERTIBLE
S253. - - - - - - -.... TOP SWITCH

3 BRN 1341
341
PAGE SA-1210
. , . C200D
E l l y C200C
-------..--.
3 B R N ~ - ~ 4 - 1 - - - - - - - - - - - - - - - - -. . .
3 BRN
341
3 BRN
3 BLK
341
750
3TAN
P600
167
3LTBLU
,-s220
166
I
I
3 DK BLU
164
.o50
3BLK
750
--w-1N"'Dow--1G_N..ITI_O_N_W_1N"'Do-w""'
SEE GROUND
DISTRIBUTION
PAGESA-14-7
DOWN REQ ON INPUT
SOLID STATE
UPREQ
MONITOR
3 BLK
r+--+---+-- EXPRESS
UP
DOWN
RELAY
STOPPED
INPUT
EXPRESS
650
3 DK BLU
EXPRESS
DOWN
MODULE
164
3 BRN
3 BRN
667
165
3 DK BLU
rn
DOWN
CONTROL
666
IMPORTANT:
EACH MOTOR CONTAINS

AN ELECTRONIC CIRCUIT
BREAKER (ECB).
ECB RESISTANCE INCREASES

IF MOTOR IS OVERLOADED.
RESISTANCE RETURNS TO
NORMAL AFTER VOLTAGE
IS REMOVED FROM MOTOR
TERMINALS.
P""""-----,11""''"1 WINDOW
MOTOR,LH
WITH
ECB
WINDOW
MOTOR.RH
WIT_H_ _
ECB
COMPONENT
Express Down Module
Power Window Switch, RH
Window Motor, LH ...... .
Window Motor, RH ...... .
C200C (13 cavities)
LOCATION
201-PG
Mounted to center of dash mat, above floor tunnel
9 ....
LH side ofl/P Carrier, on the side .................. . 8 . . . .
Inside LH door ................................... . 17
Inside RH door ................................... . 17
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
G200
behind kick panel (2 rings, 2 wires) ............... . 9 ....
P500
Between LH door and "A" pillar .................... . 17
P600
Between RH door and "A" pillar .................... . 45
8208
Cross Car Harn, approx 5 cm from Express Down
Module breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8220
Cross Car Harn, approx 9 cm from C200 breakout . . . . . 45
8253
breakout
8263 ' .................. . Cross Car Harn, approx 16 cm from C200 breakout
45 ...
120 - 1
FIG.
17
15
33
33
31
31
CONN
202-21
202-23
202-27
202-27
49
202-2
49
202-2
16
31
84
84
84
84

Diagnosis)
System
1. If both windows are inoperative, check windows

Circuit Breaker 15 for open. If open, check for
short to ground through CKT 341.
Check for poor connection at C200 terminal "El 1".
2. If windows move slowly, check that:
Windows free of mechanical binding and pivot
joints and tracks are properly lubed.
Battery is fully charged.
Ground G200 is clean and tight.
3. If the Express Down Feature does not work, but
window moves down with each switch depression,
check for poor connection at Express Down Module
terminal "A" or open in CKT 164 from Express
Down Module to 8263.

SYSTEM DIAGNOSIS
procedure(s).
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Operate each window "UP" and "DOWN" from Each window operates quietly and smoothly, with no
sticking. LH Front Window rolls down all the way
the Master Power Window Switch Assembly.
without the switch being held (Express Down
Feature).
(2)
Operate each window from its individual Window Each window operates quietly and smoothly, with no
Switch.
sticking.
SA -
120 - 2
POWER WINDOWS (A31)
[I] IMPORTANT:
FOR A BETTER UNDERSTANDING OF THE RETAINED ACCESSORY POWER (RAP)

OPERATION, REFER TO CIRCUIT OPERATION AT THE END OF THIS S_ECTION.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Both Power Windows inoperative from both switches.
Chart #1
8A-120-2
Power WindQws inoperative from the LH Switch, RH

Switch operates RH Window normally.
Chart #2
8A-120-3
RH Window inoperative from both switches, LH

Window operates normally
Chart #3
8A-120-4
RH Power Window inoperative from LH Power Check for poor connection at LH Power Window
Window Switch with normal operation from RH Switch. If OK, replace LH Power Window Switch.
Power Window Switch.
Express Down Feature inoperative. Window does Check for poor connections at Express Down Module
operate up and down while switch is held in the terminal "A" and terminal "(". Check for open in
CKT 164 from 5263 to terminal "A" of Express Down
desired position.
Module and in CKT 341 from 5208 to terminal "(" of
Express Down Module. If OK, replace Express Down
Important:
I
Module.
Express Down reature is for the. LH Window
[I]
only.
RH Power Window Switch inoperative, LH Power Check for poor connection or open in CKT 341 from
Window Switch operates normally.
RH Power Window Switch terminal "A" to 5208.
CHART #1
[I] IMPORTANT:
BOTH POWER WINDOWS INOPERATIVE FROM BOTH SWITCHES
IF BOTH WINDOWS ARE INOPERATIVE, CHECK WINOOWS CIRCUIT BREAKER 1 S FOR OPEN. IF OPEN, CHECK FOR SHORT TO.
GROUND THROUGH CKT 341.
IGNITION SWITCH IN THE "RUN" POSITION.

WITH A TEST LIGHT, BACKPROBE LH POWER WINDOW
SWITCH ASSEMBLY FROM TERM "F" TO GROUND.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT, BACKPROBE

THE LH POWER WINDOW
SWITCH ASSEMBLY BETWEEN
TERM "F" AND TERM "A".
IS TEST LIGHT "ON"?
.CHECK FOR POOR CONNECTION AT C200 TERM "E11 ".

IF OK, REPAIR OPEN IN CKT 341 BETWEEN WINDOWS
CIRCUIT BREAKER 15 AND LH POWER WINDOW
SWITCH ASSEMBLY CONN TERM "F".
CHECK LH-POWER WINDOW

SWITCH ASSEMBLY CONN ECTOR
FOR POOR CONNECTION.
CHECK FOR POOR CONNECTION AT G200.

LH POWER WINDOW SWITCH ASSEMBLY
CONN TERM" A" AND G200.
CHART #2
POWER WINDOWS INOPERATIVE FROM THE LH SWITCH,
RH SWITCH OPERATES RH WINDOW NORMALLY
IGNITION SWITCH IN THE "RUN" POSITION.

WITH A TEST LIGHT, BACKPROBE LH POWER WINDOW SWITCH ASSEMBLY FROM TERM "F" TO GROUND.
IS TEST LIGHT "ON"?
WITH A TESTLIGHT, BACKPROBE THE LH POWER WINDOW

SWITCH ASSEMBLY FROM TERM "D" TO TERM "E".
PRESS THE LEFT WINDOW "UP" AND WINDOW "DOWN"
SWITCH AT THE LH POWER WINDOW SWITCH.
IS TEST LIGHT "ON" IN BOTH CASES?
REPAIR OPEN IN CKT 341 BETWEEN 5208

AND TERM "F" OF THE LH POWER WINDOW'
SWITCH ASSEMBLY.
WITH A TEST LIGHT, BACK.PROBE EXPRES~ DOWN MODULE CONN

FROM TERM" A" TO TERM "E".
PRESS THE LEFT WINDOW ''UP" AND WINDOW "DOWN" SWITCH.
IS TEST LIGHT "ON"?

LH POWER WINDOW SWITCH CONN.
WITH A TEST LIGHT, BACKPROBE EXPRESS DOWN

MODULE CONN FROM TERM" A" TO TERM "D".
PRESS THE LEFT WINDOW "UP" AND WINDOW
"DOWN" SWITCH AT THE LH POWER WINDOW SWITCH.
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 1136 BETWEEN LH

POWER WINDOW SWITCH TERM "E" AND
EXPRESS DOWN MODULE TERM ''E''.
CHECK FOR OPEN IN CKT 164 FROM LH POWER
WINDOW SWITCH TERM "D" TO 5263 AND FROM
5263 TO EXPRESS DOWN MODULE TERM "A".
:
:
1
DISCONNECT LH WINDOW MOTOR CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERMINALS "A" AND"B" OF
THE LH WINDOW MOTOR CONNECTOR.
PRESS THE LEFT WINDOW "UP" AND WINDOW "DOWN" SWITCH.
IS TEST LIGHT "ON"?
-------------------------------------,
CHECK FOR POOR CONNECTIONS AT LH WINDOW MOTOR. :

IF OK, REPLACE LH WINDOW MOTOR.
:
REFER TO SECTION 10-6 FOR REPLACEMENT PROCEDURES. 1
L---------------------------------------J
CHECK FOR POWER CONNECTIONS AT

EXPRESS DOWN MODULE.
IF OK, REPLACE EXPRESS DOWN MODULE.

EXPRESS DOWN MODULE TERM "D" AND
LH WINDOW MOTOR TERM "A." ALSO
CHECK FOR OPEN IN CKT 164 FROM
EXPRESS DOWN MODULE TERM "A" TO
5263 AND FROM 5263 TO LH WINDOW
MOTOR TERM "B".
POWER WINDOWS (A31)

CHART #3
RH WINDOW INOPERATIVE FROM BOTH SWITCHES,
LH WINDOW OPERATES NORMALLY

WITH A TEST LIGHT, BACKPROBE THE RH POWER WINDOW l\,10TOR CONN FROM TERM" A" TO TERM "8".
WHILE OBSERVING THE TEST LIGHT, PRESS THE RH WINDOW "UP" AND WINDOW "DOWN" SWITCH.
IS THE TEST LIGHT "ON" IN BOTH CASES?
WITH A TEST LIGHT, BACKPROBE THE RH POWER

WINDOW SWITCH FROM CONN TERM "D" TO
TERM "C".
WHILE OBSERVING THE TEST LIGHT, PRESS THE RH
WINDOW "UP" AND WINDOW "DOWN" SWITCH.
WITH A TEST LIGHT, BACKPROBE RH POWER

WINDOW SWITCH CONN TERM "B" TO TERM "E ".
WHILE OBSERVING THE TEST LIGHT AND USING
THE LH WINDOW SWITCH, PRESS THE RH
------------------------------------,
CHECK POWER WINDOW MOTOR CONNECTOR FOR POOR

CONNECTION.
IF OK, REPLACE INOPERATIVE POWER WINDOW MOTOR.
REFER TO SECTION 10-6 FOR REPLACEMENT
PROCEDURES.
:
:
1
L--------------------------------------J
CHECK FOR OPEN IN CKT 666 OR CKT 667 BETWEEN RH

POWER WINDOW SWITCH AND RH WINDOW MOTOR.
WITH A TEST LIGHT, BACKPROBE LH POWER

WINDOW SWITCH CONN TERM "B" TO TERM "C".
WHILE OBSERVING THE TEST LIGHT AND USING
THE LH WINDOW SWITCH, PRESS THE RH
CHECK FOR POOR CONNECTIONS AT RH POWER

WINDOW SWITCH CONN.
IF OK, REPLACE RH POWER WINDOW SWITCH.
CHECK FOR POOR CONNECTIONS AT LH

POWER WINDOW SWITCH.
IF OK, CHECK FOR OPEN IN CKT 166 AND
CKT 167 BETWEEN LH POWER WINDOW
SWITCH AND RH POWER WINDOW SWITCH.
CHECK FOR POOR CONNECTIONS AT LH

POWER WINDOW SWITCH.
IF OK, REPLACE LH POWER WINDOW SWITCH.
CIRCUIT OPERATION
rn
Important:
The Power Windows System has voltage applied
from the Windows Circuit Breaker 15 which is
controlled by the Retained Accessory Power
(RAP) Module. Voltage is applied to the PWR
ACCY Fuse for up to 10 minutes after Ignition is
turned off or for 35 seconds after exiting the
vehicle and closing the doors or whenever a door
is open. For a complete understanding of
Retained Accessory Power (RAP) operation,
refer to SECTION 8A-15.
When the Ignition Switch is in the "RUN,"

"ACCY," or RAP voltage is applied from windows
Circuit Breaker 15 to the LH Power Window Switch
and the RH Window Switch through CKT 341. The
Window Motors and Switches receive ground through
the LH Power Window Switch Assembly, which is
grounded at G200. The RH Window can be operated
from the LH and RH Power Window Switch
Assemblies. The LH Front Window is operated
directly from the LH Power Window Switch.
The Power Windows are driven by reversible,
permanent magnet motors. Each motor is controlled
by a set of two switches, which are normally closed to
ground. When any Window Switch is moved to the
"UP" position, the "UP" switch will provide battery
voltage to the Window Motor through the DK BLU
wire. The Window Motor will receive ground through
the BRN wire, the "ON" switch, and the LH Power
Window Switch Assembly and drive the window up.
When the switch is released, the switch contacts will
return to their normal grounded position.
To lower the window, the "ON" switch will connect
the BRN wire to battery voltage. Ground will be
provided to the DK BLU wire through the "UP" switch
and the LH Power Window Switch Assembly. The
polarity across the motor will be reversed, causing the
motor to rotate in the opposite direction and lower the
window.
120 - 5
The Power Windows System also includes an

Express Down Feature for the LH Front Window. This
allows the LH Front Window to open fully when the
LH Front Window Switch is pressed momentarily. All
of the solid state circuitry controlling this feature is
contained within the Express Down Module.
Each motor is protected by an Electronic Circuit
Breaker (ECB). If a Window Switch is held in the
"UP" or "DN" position too long with the window
obstructed, or after the window is fully up or down, the
ECB will increase its resistance. By increasing its
resistance, the ECB will prevent the Window Motor
from overloading. The ECB will reset to normal
resistance when voltage to the Window Motor is
interrupted.
SA -
CONVERTIBLE TOP
HOT IN ACCY, RUN OR
DURING RETAINED
--,1/P
FUSE
WINDOWS
BLOCK
CIRCUIT
,-BREAKER
30AMP
rn
IMPORTANT:
rn
IMPORTANT:
THE RETAINED ACCESSORY

POWER (RAP) FEATURE IS ONLY
AVAILABLE ON VEHICLES
EQUIPPED WITH POWER DOOR
LOCKS (AU3).
3 BRN
341
SEE FUSE
BLOCK DETAILS
PAGESA-11-9
1. DONOTATIEMPTTO
OPERATE CONVERTIBLE TOP
UNLESS VEHICLE IS PARKED.
2. LATCHES MUST BE RELEASED
BEFORE LOWERING TOP AND
MUST BE RE-ENGAGED AFTER
RAISING THE TOP.
A
CONVERTIBLE
TOPSWITCH
UP
3 BLK
1350
(CHEVY) D
(PONn B
3 GRY
B
D
162
3 PPL
rn
163
---------
CONVERTIBLE
TOP PUMP
ASSEMBLY
(WITH MOTOR)
IMPORTANT:
THE MOTOR CONTAINS

BREAKER (ECB).

, TERMINALS.
HYDRAULIC HOSES
CYLINDER, LH
~ - , ._____________P~N~K;...._________~ ~ . .~---P-N-K~~
I
PUMP
BYPASS
VALVE
CONVERTIBLE TOP
PUMP ASSEMBLY
(WITH MOTOR)
WHITE
VWHITE
HYDRAULIC HOSES
CYLINDER, RH
COMPONENT
Convertible Top Pump
Assembly . . . . . . . . . . . . . .
Convertible Top Switch . . .
1/P Fuse Block . . . . . . . . . . .
LOCATION
G201
Near base of RH "A" pillar, bolted to 1/P Mounting Stud

behind kick panel (1 ring, 1 wire) ................. . 9 . . . . 16
I/P Harn, approx 35 cm from Convenience Center.
breakout
8253
201-PG
FIG.
LH side rear compartment behind ~arpeting . . . . . . . . . . 30 . . . 58

Left side of upper console (Chevy) or lower console (Pont) 42 . . . 78, 80
LH side of 1/P Carrier, on the side - . . .. . . . . . . . . . . . . . . . . 8 . . . . 15 . .
121 - 1
CONN
202-20
202-23
For a Service Part Cross Reference List and Information, refer to S~CTION 8A-200.

Diagnosis)
rn
Important:
To avoid misdiagnosis, check linkage for

mechanical binding which would prevent correct
system operation.
If a hydraulic problem is suspected, refer to
SECTION 10-9 for hydraulic diagnosis.
SYSTEM DIAGNOSIS
Per/orm the System Check and refer to the
procedures.
Check Windows Circuit breaker 15 for an open. If

open, check for a short to ground through
CKTs 341, 162 and 163.
2. Check that G201 is clean and tight.
1.

System
rn
Important:
For instructions on how to manually lower and
raise the Convertible Top, refer to SECTION
10-9.
SA-
CONVERTIBLE TOP
SYSTEM CHECK
NORMAL RESULTS
ACTION
[11
Remove all items that could obstruct the Convertible Top lowers quietly and smoothly with no
binding.
Convertible Top.
Lower both sun visors .
Release the two latches (one latch above each sun
visor).
Turn the Ignition Switch to "RUN" and lower all
side windows.
Move the Convertible Top Switch to. the DOWN
position.
[2]
Move Convertible Top Switch to the UP position .
Convertible Top raises quietly and smoothly with no

binding.
IMPORTANT:
For a better understanding of Retained
Accessory Power (RAP) operation, refer to
Circuit Operation at the end of this section.
SYMPTOM TABLE
SYMPTOM
Convertible Top inoperative.
PROCEDURE
PAGE NUMBER
Chart #1
SA-121-3
Convertible Top lowers but does not raise when using Replace Convertible Top Switch.
Convertible Top Switch.
Convertible Top raises but does not lower when using Replace Convertible Top Switch.
Convertible Top Switch (can be lowered manually).
121 - 3
CHART #1
rn
CONVERTIBLE TOP INOPERATIVE

IMPORTANT:
IF A HYDRAULIC PROBLEM IS SUSPECTED, REFER TO SECTION 10-9 FOR HYDRAULIC DIAGNOSIS. CHECK WINDOWS CIRCUIT
BREAKER 15 FOR OPEN. If OPEN, CH ECK FOR SHORT TO GROUND THROUGH CKTS 341, 162 AND 163.

WITH A TEST LIGHT TO GROUND, BACKPROBE CONVERTIBLE TOP SWITCH CONN TERM "C".
IS TEST LIGHT "ON"?
WITH A TEST LIGHT, BACKPROBE CONVERTIBLE TOP SWITCH

CONN FROM TERM "C" TO TERM" A".
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 341 BETWEEN WINDOWS

CIRCUIT BREAKER 15 ANO CONVERTIBLE TOP
SWITCH CONN TERM "C".
WITH A TEST LIGHT, BACKPROBE CONVERTIBLE TOP

SWITCH CONN FROM TERM "B" TO TERM "D".
WHILE OBSERVING TEST LIGHT, PRESS THE
CONVERTIBLE TOP SWITCH TO THE "UP" POSITION AND
THEN TO THE "DOWN" POSITION.
DOES THE TEST LIGHT ILLUMINATE IN BOTH POSITIONS?

If OK, REPAIR OPEN IN CKT 1350 BETWEEN
CONVERTIBLE TOP SWITCH CONN TERM" A"
ANDG201.
WITH A TEST LIGHT TO GROUND, BACKPROBE PUMP ASSEMBLY

CONN TERM "B" (1/P HARNESS SIDE OF CONNECTOR).
WHILE OBSERVING THE TEST LIGHT, PRESS THE CONVERTIBLE
TOP SWITCH TO THE oowN" POSITION.
IS TEST LIGHT "ON"?

CONVERTIBLE TOP SWITCH CONN.
If OK, REPLACE CONVERTIBLE TOP SWITCH.
WITH A TEST LIGHT TO GROUND, BACKPROBE PUMP

ASSEMBLY CONN TERM" A" (1/P HARNESS SIDE OF
CONNECTOR).
WHILE OBSERVING TEST LIGHT, PRESS THE CONVERTIBLE TOP
SWITCH TO THE "UP" POSITION.
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 163 BETWEEN CONVERTIBLE TOP

SWITCH AND CONVERTIBLE TOP PUMP ASSEMBLY
CONN.
CHECK FOR POOR CONNECTION AT CONVERTIBLE TOP PUMP

ASSEMBLY CONN.
IF OK, REPLACE CONVERTIBLE TOP PUMP ASSEMBLY.
REPAIR OPEN IN CKT 162 BETWEEN CONVERTIBLE TOP

SWITCH AND CONVERTIBLE TOP PUMP ASSEMBLY CONN.
SA -
121 - 4
ELECTRICAL DIAGNOSI.S
CONVERTIBLE TOP
CIRCUIT OPERATION
rn
Important:
The Convertible Top Pump Assembly has
voltage applied from the Windows Circuit
Breaker 15 which is controlled by the Retained
Accessory Power (RAP) Module. Voltage is
applied to the PWR ACCY Fuse for up to 10
minutes after Ignition is turned off or for 35
seconds after exiting the vehicle and closing the
doors or whenever a door is open. For a complete
understanding of Retained Accessory Power
(RAP) operation, refer to SECTION SA-15.
When the Ignition Switch is in the "RUN,"

"ACCY," or RAP voltage is applied from windows
Circuit Breaker 15 to the Convertible Top Switch
through CKT 341. The Convertible Top Pump
Assembly receives ground through the Convertible
Top Switch Assembly, which is grounded at G201.
The Convertible Top Pump is driven by a
reversible permanent magnet motor. The motor is
controlled by the Convertible Top Switch, which is
normally closed to ground. When the Convertible Top
Switch is moved to the "UP" position, battery voltage
is provided to the Convertible Top Pump Assembly
through the GRY wire. The Convertible Top Pump
Assembly will receive ground through the PPL wire,
the Convertible Top Switch, and drive the Convertible
Top up. When the switch is released, the switch
contacts will return to their normal grounded position.
To lower the Convertible Top, the Convertible Top
Switch will connect the PPL wire to battery voltage.
Ground will be provided to the GRY wire through the
Convertible Top Switch. The polarity across the motor
will be reversed, causing the motor to rotate in the
opposite direction and lower the Convertible Top.
The Convertible Top Pump Assembly has two
hydraulic hoses that go to the right hand cylinder and
two hydraulic hose that to go the left hand cylinder
that evenly control the up and down movement of both
cylinder simultaneously.
The motor within the Convertible Top Pump

Assembly is protected against an overload condition
internally by an Electronic Circuit Breaker (ECB): If
the motor in the Convertible Top Pump Assembly
becomes overloaded, the ECB will increase its
resistance. By increasing its resistance, the ECB will
prevent the motor from overloading. The ECB will
reset to normal resistance when voltage to the motor is
interrupted.
BLANK
121 - 5
SA -
130 - 0
POWER DOOR LOCKS {AU3)
r;-EE-;;,~R - -
-,11p
FUSE
I DISTRIBUTION
I PAGE BA-10-2
I BLOCK
I
I
PWR ACCY
FUSE 7
15 AMP
L----
--...J
.8 ORN
640
r------5211
.SORN
640
SEE FUSE
BLOCK DETAILS
PAGESA-11-8
L--~
---tlfl
.8 o:Nl64o
(lf1
~~Q------iJU"P5oo--~~
POWERf"'"~~~~~-ro~~~~~-.
DOOR
...,___
._.
LOCK
SWITCH,LH
UNLOCK
.8 ORN
640
--
:
POWERf"'"~~~~-A-.~~~~~--.
I
DOOR
I
LOCK
UNLOCK
LOCK
: SWITCH.RH
.....,__
LOCK
I
I
I
I
I
I
I
I
I
rn
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
I
I
.8GRY
295
.STAN
.8LTBLU
244
~-
.8BLK
294
esso4
es503
P500
P600
.8 TAN
.8 GRY
294
295
.STAN
.8GRY
294
295
DOOR LOCK ACTUATOR, LH
ECB
DOOR LOCK ACTUATOR, RH
5220
I
I
I
I
3 BLK
ECB
----11111!!--...
r----'
SEE GROUND
DISTRIBUTION
PAGES 8A-14-7
... 3 BLK
,,
650
750
750
130 - 1
12004680
5-WAY F PIN GRIP SERIES
BLK/WHT
POWER DOOR LOCK SWITCH, LH AND RH
201-PG
COMPONENT
LOCATION
Door Lock Actuator, LH

Door Lock Actuator, RH
I/P Fuse Block . . . . . . . . . . .
Power Door Lock Switch, LH
C200C (13 cavities)
Inside rear ofleft door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inside rear ofright door . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . .
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . .
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part ofI/P Harn, between LH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Between LH door and "A" pillar . . . . . . . . . . . . . . . . . . . . .
Between RH door and "A" pillar . . . . . . . . . . . . . . . . . . . . .
I/P Harn, approx 4 cm from antenna cable (Chevy) or
Cross Car Harn, approx 6 cm from Speaker breakout . .
Cross Car Harn, approx 3 cm from LH Power Door
Lock Switch breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Car Harn, approx 11 cm from Power Mirror
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C200D (48 cavities)

G200 . . . . . . . . . . . . . . . . . . . .
P500 . . . . . . . . . . . . . . . . . . . .
P600 . . . . . . . . . . . . . . . . . . . .
8211 . . . . . . . . . . . . . . . . . . . .
8220 . . . . . . . . . . . . . . . . . . . .
8500 . . . . . . . . . . . . . . . . . . . .
8503 . . . . . . . . . . . . . . . . . . . .
8504
FIG.
CONN
17 . . .
17 . . .
8 ....
18
18
31
31
15
33
33
202-23
202-24
202-24
25
49
202-2
25
49
202-2
9 . . . . 16
17
31
45 . . . 84
45
17
84
31
17
31
17
31
SA -


Diagnosis)
System
Check PWR ACCY Fuse 7 in 1/P Fuse Block. If

open, refer to Diagnostic Chart #4.
Check for poor connection at G200.
1.
2.
rn

SYSTEM DIAGNOSIS
Important:
For a better understanding of Retained Accessory Power (RAP) operation,
refer to Circuit Operation at the end of this section.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Power Door Locks will not operate from both Power

Door Switches.
Chart #1
Chart #2
Chart #3
SA-130-3
SA-130-4
SA-130-5
RH Door Lock Switch operates normally. LH Door Lock Check for B + at terminal "A" of LH Door Lock
Connector.
Switch does not "LOCK" or "UNLOCK."
- If not present, repair open in CKT 640.
- If present, replace LH Door Lock Switch.
LH Door Lock Switch operates normally. RH Door Lock
Switch does not.
Chart #1
SA-130-3
One Door Lock Switch "UNLOCKS" but does not Check for poor connection at suspect Door Lock
Switch. If OK, replace suspect Door Lock Switch.
"LOCK." Other switch OK.
One Door Lock Switch "LOCKS" but does not Check for poor connection at suspect Door Lock
Switch. If OK, replace suspect Door Lock Switch.
"UN LOCK." Other switch OK.
Power Door Locks either "LOCK" only or "UNLOCK"
only from both Door Lock Switches.
Chart #1
Chart #2
SA-130-3
SA-130-4
One door does not "LOCK" or "UNLOCK."
Chart #3
SA-130-5
PWR ACCY Fuse 7 repeatedly blows whenever Ignition

is "ON" or when attempting to use Power Door Locks.
Chart #4
SA-130-5
Power Door Locks do not operate when one or Refer to "Retained Accessory Power (RAP),"
both doors are opened.
page BA-15-0.
Power Door Locks only operate with Ignition
"ON," or for 10 minutes after Ignition is turned
"OFF" and exiting the vehicle and closing the
door(s).
130 - 3
CHART #1
rn
RH DOOR LOCK SWITCH TEST

IMPORTANT:
IF PWR ACCY FUSE CONTINUALLY BLOWS, REFER TO CHART #4.
BACKPROBE RH DOOR LOCK SWITCH CONNECTOR WITH

A TEST LIGHT BETWEEN TERM u A" AND GROUND.
IS TEST LIGHT "ON"?
BACKPROBE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS" A" & "C".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 640 BETWEEN RH DOOR

LOCK SWITCH AND PWR ACCY FUSE.
IF OK, REPAIR POWER FEED TO PWR ACCY FUSE.
BACKPROBE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS "A" & "D".
IS TEST LIGHT HON"?
CHECK FOR OPEN IN GROUND CKT 750 {G200)

TO TERM ''E'' OF CONNECTOR OR POOR
CONNECTION TO SWITCH.
IF OK, REPLACE RH DOOR LOCK SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT BETWEEN

TERMINALS ffC" & "E".
MOVE THE RH DOOR LOCK SWITCH TO THE "LOCK" POSITION
WHILE OBSERVING THE TEST LIGHT.
IS TEST LIGHT HON"?
CHECK FOR OPEN IN GROUND CKT 750

{G200) TO RH DOOR LOCK SWITCH
CONNECTOR TERM "B" OR POOR
CONNECTION TO SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT

BETWEEN TERMINALS "D" & uE".
MOVE THE RH DOOR LOCK SWITCH TO THE "UNLOCK"
POSITION WHILE OBSERVING THE TEST LIGHT.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT SWITCH.

CHECK CONTINUITY FROM TERM "C" OF RH DOOR LOCK SWITCH

CONNECTOR TO TERM ''E'' OF LH DOOR LOCK SWITCH CONNECTOR.
IS THERE CONTINUITY {NEARLY OOHMS)?
CHECK FOR POOR CONNECTION AT SWITCH.

CHECK CONTINUITY FROM TERM "D" OF RH DOOR LOCK SWITCH

CONNECTOR TO TERM "B" OF LH DOOR LOCK SWITCH CONNECTOR.
IS THERE CONTINUITY (NEARLY O OHMS)?
:
:
----------------------------------------~
NO TROUBLE FOUND WITH THE RH DOOR LOCK SWITCH.

:
IF LH DOOR LOCK SWITCH IS INOPERATIVE, REFER TO CHART #2, :
"LH DOOR LOCK SWITCH TEST," PAGE SA-130-4.
1
~--------- --------------------------------~
SA -
130 - 4

CHART #2
LH DOOR LOCK SWITCH TEST
rn
IMPORTANT:
CHART #1, "RH DOOR LOCK SWITCH TEST," PAGE SA-130-3 MUST BE
PERFORMED BEFORE PROCEEDING.
BACKPROBE LH DOOR LOCK SWITCH

CONNECTOR WITH A TEST LIGHT
BETWEEN TERM" A" AND GROUND.
IS TEST LIGHT "ON"?
BACKPROBE SAME CONNECTOR

WITH THE TEST LIGHT BETWEEN
TERMINALS "A" & "C".
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 640 BETWEEN

5500 AND LH POWER DOOR LOCK
SWITCH AT TERM" A".
BACKPROBE SAME CONNECTOR WITH THE TEST

LIGHT BETWEEN TERMINALS "A" & "D".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT LH SWITCH.

IF OK, REPLACE LH DOOR LOCK SWITCH.
BACKPROBE THE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS "C" & "E".
MOVE LH DOOR LOCK SWITCH TO "LOCK"
POSITION WHILE OBSERVING TEST LIGHT.
IS TEST LIGHT "ON"?

CHECK FOR POOR CONNECTION AT LH
SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST

LIGHT BETWEEN TERMINALS "D" & "E".
MOVE LH DOOR LOCK SWITCH TO THE "UNLOCK"
IS TEST LIGHT "ON"?


-----------------------,
L__
NO TROUBLE FOUND WITH LH DOOR :

LOCK SWITCH.
1
REFER TO CHART #3, "DOOR LOCK
:
ACTUATOR TEST," PAGE SA-130-5. _ j
CHART #3
DOOR LOCK ACTUATORS TEST
rn
IMPORTANT:
IF BOTH DOOR LOCK ACTUATORS DO NOT OPERA TE, PERFORM CHART #1,
"RH DOOR LOCK SWITCH TEST," PAGE SA-130-3 AND CHART #2,
"LH DOOR LOCK SWITCH TEST," PAGE SA-130-4 BEFORE PROCEEDING.
DISCONNECT SUSPECT DOOR LOCK ACTUATOR CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERM "B" OF CONNECTOR
ANDB+.
IS TEST LIGHT "ON"?
CONNECT THE TEST LIGHT BETWEEN

TERM" A" OF SUSPECT DOOR LOCK
MOTOR CONNECTOR AND B +.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT DOOR LOCK

ACTUATOR.
IF OK, REPLACE DOOR LOCK ACTUATOR.
CHART #4
PWR ACCY FUSE 7 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATIEMPTING TO OPERATE POWER DOOR LOCKS
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE A TT EMPTING TO
OPERA TE POWER DOOR LOCKS?
TEST POWER DOOR LOCK SWITCH ONE FUNCTION AT A

TIME UNTIL FUSE BLOWS.
WHEN THE FUSE BLOWS, USE SCHEMATICS TO
DETERMINE WHAT CIRCUITS OR COMPONENTS COULD
BE FAILING. USE A TEST LIGHT OR OVM TO NARROW IN
ON SHORT TO GROUND POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL WHEN
TRYING TO CHECK CIRCUITS THAT SHOULD NOT BE AT
A GROUND POTENTIAL.

THROUGH A FAULTY COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE
TERMINALS. START BY DISCONNECTING ONE COMPONENT
AT A TIME.
IF ALL RELATED COMPONENTS ARE DISCONNECTED AND
SHORT IS STILL PRESENT, LOCATE AND REPAIR SHORT IN
WIRING.
SA -
130 - 6

CIRCUIT OPERATION
rn
Important:
The Power Door Lock System has voltage
applied from the PWR ACCY Fuse which is
controlled by the Retained Accessory Power
(RAP) Module. Voltage is applied to the PWR
ACCY Fuse for up to 10 minutes after Ignition is
turned off or for 35 seconds after exiting the
vehicle and closing the doors. Voltage is also
applied whenever a door is open. For a complete
understanding of Retained Accessory Power
(RAP) operation, refer to "Retained Accessory
Power (RAP): with AU3," page SA-15-0.
When a Door Lock Switch is activated in the Power

Door Lock system, both doors will lock or unlock in
unison. Each lock can also be operated manually. The
locks are operated by reversible Actuators. The Door
Lock Switches operate the Actuators by applying a
voltage to one of the terminals and a ground to the
other terminal.
Battery voltage is applied to both Door Lock
Switches at terminal "A". When the LH Door Lock
Switch is moved to "LOCK," battery voltage is applied
to both Door Lock Actuators from the GRY (295) wires.
Both Actuators are grounded through the TAN (294)
wires, the contacts of the LH Door Lock Switch, the
DK BLU (245) wire, the contacts of the RH Door Lock
Switch and the BLK (750) wires to ground G200.
When the LH Door Lock Switch is moved to
"UNLOCK," battery voltage is applied to both Door
Lock Actuators in the opposite direction from the TAN
(294) wires. Both Actuators are grounded through the
GRY (295) wires, the contacts of the LH Door Lock
Switch, the LT BLU (244) wire, the contacts of the RH
Door Lock Switch and the BLK (750) wires to ground
G200.
When the RH Door Lock Switch is moved to
"LOCK," battery voltage is applied from the LT BLU
(244) wires, the contacts of the LH Door Lock Switch
and the GRY (295) wires to both Door Lock Actuators.
When the RH Door Loc.k Switch is moved to
"UNLOCK," battery voltage is applied from the DK
BLU (245) wire, the contacts of the LH Door Lock
Switch, and the TAN (294) wires to both Door Lock
Actuators in the opposite direction. During RH Door
Lock Switch operation, the Door Lock Actuators are
grounded similarly to the way they are grounded
during LH Door Lock Switch operation.
BLANK
130 - 7
SA -
132 - 0
KEYLESS ENTRY: AUO

(COUPE)
HOT IS ACCY, RUN OR DURING
------------------------~
rsE7P;:;E;- DISTRIBUTION
PAGE 8A10-2
I
I
I
I
\
PWRACCY
~
15AMP
L----
------------------------~
640
,,...~~~~~.,...~~~~~-.POWER
POWER
DOORLOCK
SWITCH, LH
DQORLOCK
SWITCH.RH
.8 DK BLU
245
.8BLK
750
,...,
RELAY
,.. .....
!!
LOCK
ALL
UNLOCK
DRIVER
,..,
,...,
UNLOCK
ALL
KEYLESS
ENTRY
RECEIVER
RELAY
!t],_
ILLUM!NATION
OUTPUT
LOW
I LLUM
INATION
BATTERY
GROUND
UNLOCK
ALL
OUTPUT
LOW
.8GRY
.8 TAN
295
294
.8GRY
295
DOOR LOCK
ACTUATOR, LH
rn
r-""~~~~"""""'IDOORLOCK
ACTUATOR, RH
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
UNLOCK
DRIVER
OUTPUT
LOW
LOCK
ALL
OUTPUT
LOW
132 - 1
HOT AT ALL TIMES
~E~O;;,R- DISTRIBUTION
\ PAGE 8A-10-3
I
I
IGN
(NOTUSED)
__ .J
'-.SORN
640
.8 PNK
1 ORN
3 ORN
39
40
40 (CHEVY WITH U82)
.SORN
r-
T
5206- , _
.35PNK
39
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-S
40
B
DOME
LAMP
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-8
@
C200D
C200C
E10
.5 ORN
.35 PNK
.SORN
39
SEE INTERIOR
LIGHTS
PAGE SA-114-0
40
40
A
.SGRYIS7
tI
B
REAR _ _.......__ _..
----
.35 WHT
1s6
s262
8.SV
SOLID STATE
LOGIC
HATCH
RELEASE
OUTPUT
LOW
-1--+---. RELAY
,. ' !!
DOME
LIGHT
SWITCH
HATCH
OPEN
.......
.5 WHT
156
El
IGNITION
ON INPUT
s210
.5 WHT
ciooc
C200D
__ .,
156
.5 WHT
A
156
B
HATCH
RELEASE
SWITCH
HATCH
RELEASE
.5 BLK
.5 BLK
SEE GROUND
DISTRIBUTION
PAGE SA-14-8
1576
3 BLK
650
3 BLK
750
SEE GROUND
DISTRIBUTION
PAGE SA-14-12
1550
SA -
KEYLESS ENTRY: AUO

(CONVERTIBLE)
HOTIS ACCY, RUN OR DURING
rsE7P~E;- DISTRIBUTION
PAGE SA-10-2
I
I
I
------------------------~
I
\
PWRACCY
~
15AMP
L----
------------------------J
TO POWER
MIRROR SWITCH
PAGE SA-147-0
.80RN1640
'A
.-~,,_,,_,,_,,_'"T"""",,_,,_,,_,,___,POWER
l""',,_,,_,,_,,_,,_"'lll";...,,_,,_,,_,,_--.powER
DOORLOCK
SWITCH, RH
DOORLOCK
SWITCH,LH
.8 DK BLU
245
3 BLK
.8BLK
750
RELAY
,...,
,...,
!!
-----
UNLOCK
DRIVER
LOCK
ALL
,...,
,..,
UNLOCK
ALL
KEY LESS
ENTRY
RECEIVER
RELAY
BATTERY
GROUND
Ill_
ILLUM!NATION
OUTPUT
LOW
i lLUMINATION
UNLOCK
ALL
OUTPUT
LOW
.8GRY
.8 TAN
295
294
.8GRY
295
[I] IMPORTANT:
DOOR LOCK
ACTUATOR, LH
I""'"",,_,,_,,_,,_""--, DOOR LOCK

ACTUATOR, RH
EACH MOTOR CONTAINS

BREAKER (ECB) ,

IF MOTOR IS OVERLOADE!).
TERMINALS.
UNLOCK
DRIVER
OUTPUT
LOW
LOCK
ALL
OUTPUT
LOW
650
ELECTRICAL DIAGNOSIS BA -132 - 3
r;E;;O;;,R- DISTRIBUTION
\ PAGE 8A-103
I
I
IGM
(NOTUSED)
L-
__ J
----------,-.
~ ................. R.NIIIIIIIIIIIIIII. . .
50
640
1 ORN
.8 PNK
40
39
5317
.5 ORN
40
r-
T
5206- ~
.35PNK
39
s210
COURTESY
i.~
RIGHT REAR
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-5
SEE FUSE
BLOCK DETAILS
PAGE 8A-118
G)
REAR
COM PARTMEN~
LAMP
G)
C200D
C200C
E10
.5 ORN
.35 PNK
.I
.8 ORN
39
TO REARVIEW ollllil
MIRROR
...
PAGE SA-114-1
40
40
REAR _ _ _ _ _ _,.
i-
.5 ORN
.5WHT
q.111111111. 5265
40
.8 ORN
C2
D
---1------------ - - - - - i l ) -
.35 WHT ~262 .5 WHT El .S WHT
iiiiiiiiii(
156
8.5V
SOLID STATE
LOGIC
HATCH
RELEASE
OUTPUT
LOW
,,.. '
156
156
DOME
LIGHT
SWITCH
!!l.
HATCH
RELEASE
HATCH
OPEN
5316
A
156
(NOT USED)
r z C ,~MMER
I
I
SEE INTERIOR
LIGHTS
PAGE8A-114-1
...__
C200C156
C200D
.5 WHT
+-
RELAY
IGNITION
ON INPUT
.5WHT
.40
156
I SWITCH
I
L=~
B
~:L~~SE
SWITCH
ON
' ~
.5 BLK
.5 B~K~50
:1e
S216---i
.35 BLK/W:Tf4;5- - - - - - - - - - - - - ~5-BL~i~6

F
.35 BLK/WHT
C240
1455
DATA LINK
CONNECTOR (DLC)
El 3
C200!'.;
C200D
1576
.5BLK
5244
_j
A
.5 BLK
3 BLK
650
1576
SEE GROUND
DISTRIBUTION
PAGE 8A-14-8
-----.5 BLK
11576
C2~
C1
- - - - - - - - - HATCH
RELEASE
RELAY
HATCH
RELEASE
ACTUATOR
.8 ORNiBLK 1434 (AUTOMATIC)

.35 TAN/WHT 33 (MANUAL)
II
GROUND PATH THROUGH

OR PARK BRAKE SWITCH
PAGE 8A-1350__L
5BLK1WHT
'~?=15BlK
56
A~B1550
5470
11111,,..
SEE GROUND
DISTRIBUTION
PAGES SA-14-12, 13
jiiP
llllii...._
..,.- -
- ------
.8 BLK 11550
~
____a2400
1550
KEYLESS ENTRY: AUO
~~G::?ct?
dJ c~:uf:n:21
12064766
12064998
8-WA Y F METRI-PACK 150 SERI ES
BLU
BLK
KEYLESS ENTRY RECEIVER (C1}
KEYLESS ENTRY RECEIVER (C2}
12004680
5-WA Y F PIN GRIP SERIES
BLKJWHT
POWER DOOR LOCK SWITCH, LH AND RH
201-PG FIG.
COMPONENT
LOCATION
Courtesy Lamp, Left Rear

Courtesy Lamp, Right Rear
Mounted in left sail panel

Mounted in right sail panel
Steering Column ............................................... .
On roof, near hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 6
Inside rear ofleft door . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 17
31
Inside rear of right door ........................... . 17
31
Center of end panel, in Cargo Compartment ......... . 30
57
Mounted to right side of SIR Bracket, behind 1/P ..... . 22
41 ..
Left of Steering Column, in knee bolster pad ........ . 31,38 60,67
Lower LH side of 1/P .............................. . 37,38 66,67
LH side ofl/P Carrier, on the side .................. . 8 .... 15
Behind RH side kick panel, in molded pocket ........ . 40
71
33 ..
33 ..
Center of rear compartment below Hatch Release
Actuator ....................................... . 30
58
Center of end panel, in Cargo Compartment ......... . 30
57
Steering Column ................................ . 25
49 ..
Dome Lamp ............ .

Door Lock Actuator, LH ..
Door Lock Actuator, RH ..
Hatch Release Actuator .. .
Hatch Release Relay .... .
Hatch Release Switch ... .
1/P Dimmer Switch ...... .
1/P Fuse Block .......... .
Key less Entry Receiver .. .
Power Door Lock Switch, LH
Rear Compartment Lamp .
Rear Dome Light Switch . .
C200C (13 cavities) . . . . . .
CONN
202-11
202-21
202-23
202-23
202-23
202-24
202-24
202-2
COMPONENT
LOCATION
201-PG
FIG.
CONN
49
37
37
202-2
202-19
C200D (48 cavities)

C240
C285
0200
G400
P500
P600
8206
8210
8211
8216
8220
8244
8262
8265
8316
8317
8470
8500
8504

Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(6 cavities) ........ . Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . .
(1 cavity) ......... . Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . .
................... . Near base of LH "A" pillar, bolted to 1/P Mounting Stud
Convertible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
breakout
l/P Harn, approx 4 cm from antenna cable (Chevy) or
Cross Car Harn, approx 9 cm from Rearview Mirror
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/P Harn, approx at rear edge of door below left sail panel
1/P Harn, approx at rear edge of door below left sail panel
1/P Harn, approx 24 cm from Hatch Release Actuator
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132 - 5
SYSTEM DIAGNOSIS
For Diagnosis, refer to SECTION 9K.
25
20
20
9 . . . . 16
30
17
45
57
31
84
45 . . . 84
45
84
45
84
17
31
17
31
8A - 133 -0 ELECTRICAL DIAGNOSIS
THEFT DETERRENT SYSTEM: PASS-KeyII

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
-7-.-:::i' :
HOT AT ALL TIMES
r-. I
ACCY
',
-,IGNITION
SWITCH
START , - -
LO;; ..,
_ _. . . .
L------"'i:i~ ,
OFF
RUN
T:T-i
S YEL
CS
SYEL
C200B
C200D
..............................................
s
S YEL
r1
I
I
CRANK
FUSE16
5223
-,11p
FUSE
BLOCK
,-
__ _,
3AMP
S YEL
TO DIAGNOSTIC
ENERGY RESERVE
MODULE
PAGE BA-47-0
., MANUAL
S YEL
el
TRA,NSMISSION
POSITION
SWITCH
CLUTCH[]
START
SWITCH
(CLOSED WITH
_
CLUTCH PEDAL
DEPRESSEDI
AUTOMATIC
el
r- - - - - - ,
I
I
\R
2 , I
I e., N @ D )I
I
,..._ .....
I
--, P
3"1M
c1
c2l
I
L
-~
~
SEE PAGE 8A-3-0
FOR PROPER
HANDLING
PROCEDURES
, STARTER
SOLENOID

LT1
--,~
r.---------------I
I
SEE POWER
DISTRIBUTION
PAGE 8A10-3
FUSE 4
10AMP
I
.5 PNK
SEE FUSE
BLOCK DETAILS
PAGE8A-11-5
.SORN
439
111...._
-
5205
340
1----
C14
All
INSTRUMENT r"
CLUSTER
I
I
~
I
I
>
.SPNK
439
l ---
"SECURITY"
INDICATOR
I
I
I
I
728
I
I
I
SEE FUSE
BLOCK DETAILS
PAGESA-11-7
L
23
25
.35 DK BLU
.8 ORN
32WAY
32WAY
32WAY
r -SV - - - ,
----~
c~:I :~~~it)
.35 GRV
A CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
---,
"1
32WAV
32WAV
32WAV
32WAV

WITH COLORED TPAs.
340
(CHEVY)
(POND
RED
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
5209
,SORN
,,..- -
I BLOCK
I
I
_ _ ...J
L----
A
B
C
D
FUSE
PCM BAT
133 - 1
POWERTRAIN
CONTROL
I MODULE (PCM)
I
I
~
>
FUEL
ENABLE
1!,_G~L..J
C (V6 VIN S)
(VS VIN P)
229
340
.8YEUBLK
625
A2
AS
At
r--~..;.;;;;~~~~~~~~~~~~....;--~~~~~~~-,~~~~~~~~~~~~"'"""""~~~~,THEFT.
DETERRENT
----,
M.QQlliJ.
I
I
I
I
I
I
I
IGNITION
INDICATOR CONTROL
L-
START
ENABLE
BATTERY
SOLID STATE
DETECTOR
AND TIMER
SVREF
SIGNAL
PWM
FUEL ENABLE
SIGNAL
- -
-1""1....rL.
GROUND
.35 WHT
rn
IMPORTANT:
ANY NEW THEFT
DETERRENT MODULE WILL
AUTOMATICALLY
PROGRAM TO THE
RESISTANCE OF THE KEV
(OR INTERROGATOR
SETTING) BEING USED AT
THE FIRST IGNITION "ON"
CYCLE. THIS CAN ONL V BE
DONE ONCE FOR THE LIFE
OF THE MODULE.
RESISTOR
SENSING
CONTACTS
0
IGNITION
KEV
Av.~
SEE PAGE SA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
8A -
133 - 2
THEFT DETERRENT SYSTEM: PASS-KeyII

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
12110259
GRN
THEFT DETERRENT MODULE

CAVITY
WIRE COLOR
CKT
A1
ORN
340
POWER FEED FROM PCM BAT FUSE #4
SA-11-7
A2
PNK
439
POWER FEED FROM PCM IGN FUSE #5
SA-11-5
A3
DKBLU
229
FUEL ENABLE SIGNAL
SA-133-1
A4
YEL/BLK
625
THEFT DETERRENT RELAY CONTROL
SA-133-0, 1
AS
GRY
728
"SECURITY" INDICATOR LAMP CONTROL
SA-133-1
BS
BLK/WHT
451
GROUND
SA-14-1,2,3
87
PPLIWHT
1074
IGNITION KEY RESISTOR RETURN
SA-133-1
BS
WHT/BLK
1073
IGNITION KEY RESISTOR FEED
SA-133-1
COMPONENT
DESCRIPTION
LOCATION
PAGE
201-PG
FIG.
Mounted to clutch pedal bracket, behind

Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 ..
Ignition Key Lock Cylinder Top RH side of Steering Column . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 63
Ignition Switch ......... . Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . 63 ..
Instrument Cluster ...... . LH side of I/P ................................................... .
35 . .
19
(PCM) (V8 VIN P) . . . . . . In Engine Compartment, rearward of RH Shock Tower
35 ..
19
Starter Solenoid . . . . . . . . . Bottom of RH side of Engine, above Starter Motor ..... 28,40 54,72
Theft Deterrent Module . . . In I/P, just right of Radio, attached to Air Bag Bracket . 8 . . . . 15 ..
41 ..
Theft Deterrent Relay . . . . Mounted to right side of SIR Bracket, behind I/P ..... . 22
42
Switch . . . . . . . . . . . . . . . . . Under console, on base of shift control lever ......... . 22
CONN
Clutch Start Switch
202-23
202-23
202-23
202-25
202-26
202-18
202-27
202-28
COMPONENT
LOCATION
C200B (18 cavities)

Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(1 ring, 1 wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM breakout
breakout
breakout
breakout
C200D (48 cavities)

C210 (4 cavities) ........ .
C230 (10 cavities) ....... .
G103 (LTl) ............. .
G104 (L32)
PllO ................... .
8109 (LTl)
8110 (L32)
8205
8209
8215
8223
SYSTEM DIAGNOSIS
For Diagnosis refer to SECTION 9D.
201-PG
133 - 3
FIG.
CONN
25
49
202-2
25
20
20
49
37
37
202-2
202-19
202-7
40
72
29
56
19
35
SA -
HATCH RELEASE {A90)
-,1/PFUSE
BLOCK
I
~
I
FUSES
15AMP
---.I
1 ORN
3 ORN
SEE FUSE
BLOCK DETAILS
PAGE SA-11-8
WITHAUO
40
40 (CHEVY WITH U82)
TO KEYLESS
ENTRY RECEIVER
PAGESSA-132-1, 3
5210. -
--......_
.....,......
SEEFUSE
BLOCK DETAILS
PAGESA-118
.SBLKt576
E13T
C200C
C2000
.5 ORN
40
.SBLK
1576
C1
~:L~':sE
RELAY
. . . .&.~~~~~~~--~---I
A1
.8 ORN/BLK
.35 TAN!WHT
434 (AUTOMATIC)
33 (MANUAL)
AUTOMATIC
MANUAL
HATCH_...,....,.
RELEASE
ACTUATOR
.8 ORN/BLK:r 34
SEE MULTIPORT
SEQUENTIAL
FUEL INJECTION
PAGES SA-20-6,
BA-21-6
.........___
.............. -
.35 ORN/BLBK
TRANSMISSION
POSITION
SWITCH
5234
SEE BRAKE
WARNING SYSTEM
434
r--
.1
..
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).
.

TERMINALS.
PAGE BA-41-0
- -,
I
Ip
I 'R -..
I
N
rn
.,ti2
.35 TAN/WHT
I
I
I
I
WITH
DAYTIME
RUNNING
LIGHTS (DRL)
33
WITHOUT
DAYTIME
RUNNING
LIGHTS (DRL)
L _____ .J
rl
.S BLK
'1:51
1550
.35 BLK,WH~
CONVERTIBLE
ONLY
----5215
.5 BLK/WHT
451
2
5470- -
C :~10
~ -
#:..nn
451
.....
-
'
G103 (VS VINP)

....:...a.210~ (V6 VIN S)
.SBLK,1550
.8 BLK
1550 (CONVERTIBLE)
_LG400
.8BLK1WHT
PARK BRAKE
SWITCH
CLOSED WITH
PARK BRAKE ON
PARKBRAKE[]
SWITCH
CLOSED WITH
PARK BRAKE ON
[ ]
-,
.1.
SEE GROUND
DISTRIBUTION
PAGE SA-14-12
ELECTRICAL .DIAGNOSIS SA -
COMPONENT
LOCATION
201-PG
1/P Compartment ............................... . 7 ....
Hatch Release Actuator .. . Center of end panel, in Cargo Compartment ......... . 30 ...
Hatch Release Relay .... . Mounted to right side of SIR Bracket, behind I/P ..... . 22 ...
Hatch Release Switch ... . Left of Steering Column, in knee bolster pad ........ . 31, 38
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side .................. . 8 ....
Park Brake Switch ...... . In console, at base of Park Brake Lever ............. . 43
Switch ................ . Under console, on base of shift control lever ......... . 22
C200C (13 cavities)
Steering Column ................................ . 25
C200D (48 cavities) ..... . Part ofl/P Harn, between LH kick panel and
Steering Column ................................ . 25
C210 (4 cavities) ........ . Under RH side ofI/P, behind RH kick panel ......... . 20
Gl03 (LTl) ............. . RH side of Engine Block, just above Starter
(2 rings, 2 wires) ................................ . 40
G104 (L32) ............. . 2 studs, 2 rings on each, interchangeable. Top RH side
G400
Convertible) .................................... . 30
PllO
Compartment ................................... . 19
S109 (LTl)
PCM breakout
SllO (L32)
breakout
S210
I/P Harn, approx 4 cm from antenna cable (Chevy) or
S211
S215 ................... . I/P Harn, approx 30 cm before DLC breakout
S228 ................... . 1/PHarn, approx 15 cm before DLC breakout.
S234 (Automatic) ....... . I/P Harn, approx 4 cm from G201 breakout
S244 ................... . I/P Harn, approx 7 cm from DERM breakout
S470 ................... . I/P Harn, approx 24 cm from Hatch Release Actuator
135 - 1
FIG.
CONN
12 ..
57
41 ..
60,67
15
81
202-20
202-21
202-23
42
202-28
49
202-2
49
37
202-2
202-19
72
56
57
35

Diagnosis)

2. Check PWR ACCY Fuse and Courtesy Fuse for
open. If either fuse is open, check for short to
ground through CKTs 640 and/or 40.
3. For vehicles with Manual Transmissions, the
"BRAKE" Indicator receives a ground through the
Park Brake Switch. Applying the Park Brake and
observing the "'BRAKE" Indicator can be used as a
quick check of the ground CKT below S228.
but
prove
"GOOD"
in
a
malfunction

Procedures," page 8A-40).
SYSTEM DIAGNOSIS
135 - 2
SA -
HATCH RELEASE (A90)
rn
Important:
For a better understanding of the Retained

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Hatch does not release when operating the Hatch

Release Switch.
Chart #1
8A-135-2
Hatch releases immediately at Ignition "ON" (in Park

or Neutral for Automatic Transmission or with Park
Brake "ON" for Manual Transmission).
Check for short to B + on CKT 1576 between Hatch

Release Switch and Hatch Release Relay.
Check for faulty Hatch Release Switch (stuck
closed).
If equipped with Keyless Entry, also refer to
SECTION 8A-132.
Hatch Release operates from Keyless Entry and does

not operate from Hatch Release Switch.
Chart #2
8A-135-4
CHART #1
HATCH DOES NOT RELEASE WHEN OPERATING THE HATCH RELEASE SWITCH
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, BACKPROBE HATCH RELEASE ACTUATOR TERM "A".
IS TEST LIGHT "ON"?

HATCH RELEASE RELAY TERM "C1" TO GROUND.
IS TEST LIGHT "ON"?
DISCONNECT HATCH RELEASE RELAY CONNECTOR.

MOMENTARILY CONNECT A FUSED JUMPER FROM
TERM "C1" TO TERM" A2" OF THE HATCH RELEASE
RELAY CONNECTOR.
DOES THE HATCH RELEASE ACTUATOR WORK?
CHECK COURTESY FUSE 8 FOR OPEN.

IF FUSE IS BLOWN, CHECK FOR SHORT TO GROUND THROUGH CKT 40.
CHECK FOR OPEN IN CKT 40 FROM 1/P FUSE BLOCK TO HATCH
RELEASE RELAY.
BACKPROBE HATCH RELEASE RELAY TERM "C2"

OPERATE HATCH RELEASE SWITCH.
DID TEST LIGHT ILLUMINATE WHEN SWITCH WAS
OPERATED?
RECONNECT FUSED JUMPER.

BACKPROBE HATCH RELEASE ACTUATOR CONN TERM" A"
IS TEST LIGHT "ON"?
CHECK FOR SHORT TO B + IN CKT 56 BETWEEN HATCH

RELEASE ACTUATOR AND HATCH RELEASE RELAY.
CHECK FOR FAUL TY HATCH RELEASE RELAY (STUCK CLOSED).
135;. 3
CONNECT A TEST,LIGHT FROM HATCH RELEASE RELAY

CONNECTOR TERMINALS" A 1" TO "C1 ".
SET PARK BRAKE
MANUAL TRANS.
PLACE IN PARK OR NEUTRAL FOR AUTO TRANS.
IS TEST LIGHT "ON"?
BACKPROBE HATCH RELEASE SWITCH CONN

TERM" A" WITH A TEST LIGHT TO GROUND AND
OPERATE HATCH RELEASE SWITCH.
DOES TEST LIGHT ILLUMINATE WHEN SWITCH IS
OPERATED?
BACKPROBE
HATCH RELEASE
SWITCH
TERM "B" WITH A
TEST LIGHT TO
GROUND.
IS TEST LIGHT
ON
MANUAL
TRANSMISSION
AUTOMATIC
TRANSMISSION
CHECK FOR OPEN IN

GROUND CKT 434 TO
TRANSMISSION
POSITION SWITCH
TERM "B".
CHECK TRANSMISSION
POSITION SWITCH.
CHECK FOR OPEN IN
GROUND CKT 451
BETWEEN
TRANSMISSION
POSITION SWITCH
AND GROUND.
CHECK FOR POOR
CONNECTION AT C210
TERM "B".
CHECK FOR OPEN

IN GROUND CKT 33
FROM HATCH
RELEASE RELAY TO
PARK BRAKE
SWITCH ORA
FAULTY PARK
BRAKE SWITCH.
IF EQUIPPED WITH
DAYTIME RUNNING
LIGHTS (DRL), ALSO
CHECK FOR POOR
CONNECTIONS AT
DAYTIME RUNNING
LIGHTS MODULE
CONNC1
TERMINALS "D"
AND"E".
CHECK DIODE IN
DRL MODULE FOR
OPEN.
CHECK FOR OPEN
IN CKT 1134 TO
PARK BRAKE
SWITCH.
CHECKFOR
POOR
CONNECTIONS
AT HATCH
RELEASE
RELAY.
IF OK, REPLACE
HATCH
RELEASE
RELAY.
"ON"?
CHECK PWR ACCY

FUSE 7 FOR OPEN.
IF FUSE IS OPEN,
CHECK FOR SHORT
TO GROUND
THROUGH CKT 640.
CHECK FOR OPEN
IN CKT640
BETWEEN 1/P FUSE
BLOCK AND HATCH
RELEASE SWITCH.
DISCONNECT HATCH RELEASE ACTUATOR.

CONNECT A TEST LIGHT TO THE HATCH RELEASE
ACTUATOR CONNECTOR FROM TERM" A" TO
TERM "B".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT HATCH

RELEASE ACTUATOR.
IF OK. REPLACE HATCH RELEASE ACTUATOR.
CHECK FOR POOR

CONNECTION AT HATCH
RELEASE SWITCH OR FOR
OPEN IN CKT 1576
BETWEEN HATCH RELEASE
SWITCH AND HATCH
RELEASE RELAY.

BETWEEN HATCH RELEASE RELAY
AND HATCH RELEASE ACTUATOR.

HATCH RELEASE ACTUATOR AND G400,
OR FOR POOR CONNECTION AT G400.
CHECK FOR POOR

CONNECTIONS AT
HATCH RELEASE SWITCH.
IF OK, REPLACE HATCH
RELEASE SWITCH.
SA -
135 - 4
ELECTRICAL D1AGNOSIS
HATCH RELEASE (A90)

CHART #2
HATCH RELEASE OPERAT~S FROM KEYLESS ENTRY AND DOES NOT
OPERATE FROM HATCH RELEASE SWITCH
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, BACKPROBE HATCH RELEASE SWITCH
TERM" A" AND OPERA TE HATCH RELEASE SWITCH.
IS TEST LIGHT "ON" WHEN OPERATING SWITCH?
BACKPROBE HATCH RELEASE SWITCH TERM "B"

IS TEST LIGHT "ON"?

HATCH RELEASE SWITCH AND 5244.
CHEtK PWR ACCY FUSE 7 FOR OPEN.

IF FUSE IS OPEN, CHECK FOR SHORT TO
CHECK FOR OPEN IN CKT 640 BETWEEN 1/P
FUSE BLOCK AND HATCH RELEASE SWITCH.
CIRCUIT OPERATION
The Hatch Release Relay has voltage applied from
the PWR ACCY Fuse which is controlled by the
Retained Accessory Power (RAP) Module. Voltage is
applied to the PWR ACCY Fuse for up to 10 minutes
after the Ignition is turned off, or for 35 seconds after
exiting the vehicle and closing the doors or whenever a
door is open. For a complete understanding of the
Retained Accessory Power (RAP) operation, refer to
SECTION SA-15.
The Hatch Release can be activated from within
the vehicle by operating the Hatch Release Switch
when the Ignition is in "ACCY'', "RUN" or
"RETAINED ACCESSORY POWER" with the Park
Brake set for Manual Transmission or in "PARK" or
"NEUTRAL" position for Automatic Transmission.
Battery voltage is applied at all times to the
normally open contacts of the Hatch Release Relay
from Courtesy Fuse 8.

HATCH RELEASE SWITCH.
IF OK, REPLACE HATCH RELEASE SWITCH.
When the Hatch Release Switch is operated, the

switch closes and battery voltage is applied to the coil
of the Hatch Release Relay. On vehicles with
Automatic Transmissions, the Hatch Release Relay
Coil receives a ground through the Transmission
Position Switch to G103 (V8 VIN P) or G104
(V6 VIN S), the Hatch Release Relay can only be
energized with the Gear Selector in the "PARK" or
"NEUTRAL" position. On vehicles with Manual
Transmissions, the Hatch Release Relay Coil receives
a ground through the Park Brake Switch when the
Park Brake is "ON." For vehicles equipped with
Daytime Running Lamps (DRL), ground is provided
through the Park Brake Switch and a Circuit Isolation
Diode within the DRL Module.
When the Hatch Release Relay is energized and
the relay contacts close, battery voltage is applied to
the Hatch Release Actuator. The Hatch Release
Actuator contains an Electronic Circuit Breaker
(ECB). ECB resistance increases if motor is
overloaded. Resistance returns to normal after voltage
is removed from actuator terminals.
BLANK
135- 5
SA -
BRAKE TRANSMISSION SHIFT INTERLOCK

(AUTOMATIC TRANSMISSION)
-,1/P
I ruse
BLOCK
IGN
,--
(NOT USED)
I
I
L-------- --'
.8 PNK
39
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-5
-
ArC2
SEE CRUISE CONTROL
PAGE 8A34-1
TO POWERTRAIN
....
.35 LT BLU/BLK
583
.35 LT BLU/BLK
CONTROL MODULE .......

- - - - - - - - . 5238
PAGE 8A-20-6 (V6 VIN S)
583
_ LT BLU/BBLK. 5-83
35
PAGE 8A-21-6 (V8 VIN P)
TR
ANSM~[g]
SHIFT
INTERRUPT
(BTSI) SOLENOID
(GEAR SELECTOR CAN
NOT BE SHIFTED WHEN
SOLENOID IS ENERGIZED)
A
.35TAN1WHT
816
ISOLATION
DIODE (BTSI)
(1AMP)
[I.-------'4-
.35 ORNIBLK
TO HATCH
.35 ORN/BLK
RELEASE RELAY
PAGE 8A-135-0
..
434
5234
434
.35 ORN/BLK
434
.35 ORN/B~K"434
TRANSMISSION
P.OSITION
SWITCH
r- - - - - - I
__
.____
L--
1
2 /
D ;,
, ...... ,..
.35 BLK1W:r~51
.S BLK/WHTJ:-;;21
$C 0
.S BLK/W
1
TI .,,.L..- L.- -
P110
- -
I
I
I
I
____ J
------5215
SEE GROUND
DISTRIBUTION
PAGES 8A-14-1, 2, 3
5109 (V8 VIN P)

-S110(V6VINS)
.8BLKWHT14~
-- - ,
G_1_Q1(V8VINP)
~ 1 0 4 (V6 VIN S)
....
TO POWERTRAIN
CONTROL MODULE
PAGE 8A-206 (V6 VIN 5)
PAGE 8A-216 (V8 VIN P)
COMPO"'ENT
Brake Switap Assembly
Brake Transmissi<m Shift
Interrupt (BTSI) ~olenoid
I/P Fuse Block ... L ..... .
Isolation Diode (BTSp ... .
Switch ................ .
C210 (4 cavities) ........ .
G103 (LTl) ............. .
G104 (L32)
PllO ................... .
8109 (LTl)
SllO (L32)
8206
8215 ................... .
8234 (Automatic) ....... .
8238 (Automatic) ....... .
LOCATION
201-PG FIG.
same switch for both ............................. . 0 .... 1
In console, under PRNDL Display .................. . 22 ... 42
LH side ofl/P Carrier, on the side .................. . 8 .... 15
Sealed in Harn, approx 6 cm from DERM breakout
Under console, on base of shift control lever ......... .
Under RH side ofl/P, behind RH kick panel ......... .
RH side of Engine Block, just above Starter
(1 ring, 1 wire) .................................. .
of Engine, 1 stud in head, 1 stud in Intake Manifold ..
Compartment ................................... .
PCM breakout
breakout
breakout
I/P Harn, approx 4 cm from G201 breakout
I/P Harn, approx 7 cm from Center Console breakout
22
20
42
37
40
72
29
56
19
35
138 - 1
CONN
202-23
202-28
202-19
Diagnosis)
1. If Gages Fuse #9 is open, refer to Chart #3 in this
section.
2. Check Brake Switch Assembly for proper
adjustment.
3. If Transmission Shifter does not shift out of
"PARK," check linkage and cable for binding.
malfunction but prove ''GOOD" in a

SYSTEM DIAGNOSIS
SYMPTOM
PROCEDURE
PAGE NUMBER
Transmission does not shift out of "PARK" with brake

pedal depressed and Ignition Switch in "RUN."
Chart #1
SA-138-2
Transmission shifts out of "PARK" with Ignition Switch

in "RUN" and brake pedal not depressed.
Chart #2
SA-138-2
Gages Fuse #9 repeatedly blows whenever Ignition is

"ON" or when attempting to depress the brake pedal.
Chart #3
SA-138-3
SA -
138 - 2
BRAKE TRANSMISSION SHIFT INTERLOCK

(AUTOMATIC TRANSMISSION)
CHART #1
TRANSMISSION DOES NOT SHIFT OUT OF "PARK" WITH BRAKE PEDAL
DEPRESSED AND IGNITION SWITCH IN "RUN"

DISCONNECT BRAKE SWITCH ASSEMBLY CONN C2.
WITH A TEST LIGHT TO GROUND, BACKPROBE BRAKE
TRANSMISSION SHIFT INTERRUPT SOLENOID TERM "B".
IS TEST LIGHT "ON"?
RECONNECT BRAKE SWITCH ASSEMBLY CONN C2.

DEPRESS BRAKE PEDAL.
WITH A TEST LIGHT TO GROUND, BACKPROBE BRAKE
TRANSMISSION SHIFT INTERRUPT SOLENOID TERM "B".
IS TEST LIGHT "ON"?
CHART #2
TRANSMISSION SHIFTS OUT OF "PARK" WITH IGNITION SWITCH
IN "RUN" AND BRAKE PEDAL NOT DEPRESSED

TRANSMISSION IN "PARK" POSITION.
DISCONNECT BRAKE TRANSMISSION SHIFT INTERRUPT SOLENOID CONN.
CONNECT A TEST LIGHT FROM BRAKE TRANSMISSION INTERRUPT SOLENOID CONN TERM "B" TO GROUND.
IS TEST LIGHT "ON"?

BRAKE SWITCH ASSEMBLY CONN C2 TERM "A".
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN BRAKE TRANSMISSION

SHIFT INTERRUPT SOLENOID CONN TERMINALS" A" AND "B".
IS TEST LIGHT "ON"?

GROUND, BACKPROBE
BRAKE SWITCH ASSEMBLY
CONN C2 TERM "B".
IS TEST LIGHT "ON"?
REPAIR OPEN IN
CKT 583 BETWEEN
BRAKE SWITCH
ASSEMBLY AND
INTERRUPT SOLENOID.
CHECK FOR POOR

CONNECTIONS
AT BRAKE
TRANSMISSION SHIFT
INTERRUPT SOLENOID.
IF OK, REPLACE
BTSI SOLENOID.

BETWEEN FUSE BLOCK AND
BRAKE SWITCH ASSEMBLY.
IF FUSE IS OPEN, GO TO
CHART #3.
CHECK FOR POOR

CONNECTIONS AT BRAKE
SWITCH ASSEMBLY.
IF OK, REPLACE BRAKE
SWITCH ASSEMBLY.
IF HATCH RELEASE SYSTEM

OPERATES PROPERLY, REPAIR
OPEN IN CKT 434 BETWEEN
INTERRUPT SOLENOID AND 5234.
IF HATCH RELEASE SYSTEM DOES
NOT OPERA TE, CHECK FOR AN
OPEN IN GROUND CKT 451 UP TO
AND INCLUDING TRANSMISSION
POSI.TION SWITCH.
ALSO CH ECK FOR AN OPEN IN
CKT 434 BETWEEN TRANSMISSION
POSITION SWITCH AND 5234.
ELECTRICAL DIAGNOSIS SA ~
138 - 3
CHART #3
\\
GAGES FUSE #9 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"

OR WHEN A TIEMPTING TO DEPRESS THE BRAKE PEDAL
PLACE BLOWN FUSE .

D ES FUSE BLOW BEFORE ATTEMPTING TO
D RESS BRAKE PEDAL?
IF FUSE BLOWS WHEN BRAKE PEDAL

IS DEPRESSED, CHECK FOR SHORTED
BRAKE SWITCH ASSEMBLY AND
CONNECTIONS AT BRAKE SWITCH.
CIRCUIT OPERATION
The Brake Transmission Shift Interlock (BTSI) is
designed to interrupt shifting when energized. The
BTSI is energized whenever the Ignition Switch is in
"RUN," "BULB TEST" or "START" and is disabled
when the brake pedal is depressed.
The Brake Switch Assembly receives Ignition
voltage from Gages Fuse #9 in "RUN," "BULB TEST"
and "START." The TCC/Shift Interrupt Switch is part
of the Brake Switch Assembly and is normally closed,
providing voltage to the Brake Transmission Interrupt
(BTSI) Solenoid. The BTSI Solenoid gets its ground
path through CKT 434 then through the Transmission
Position Switch only when the Transmission Position
Switch is in the "PARK" or "NEUTRAL" position and
then to ground through CKT 451. When the BTSI
Solenoid receives voltage and the Transmission
Position Switch is in the "PARK" or "NEUTRAL"
position, the BTSI Solenoid is energized and prevents
the Transmission Shift Lever from being moved out of
"PARK" or "NEUTRAL."
When the brake pedal is depressed, the Brake
Swit~h opens, removing volta,ge from the BTSI
Solenoid. This de-energizes the BTSI Solenoid,
allowing operation of the Shift Lever.

CIRCUITS FOR A SHORT TO GROUND POTENTIAi,., EITHER
THROUGH A FAUL TY CONNECTOR OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE TERMINALS.
START BY DISCONNECTING ONE COMPONENT AT A TIME.
IF All RELATED COMPONENTS ARE DISCONNECnD AND SHORT
IS STILL PRESENT, LOCATE AND REPAIR SHORT IN WIRING.
SA..- .140 .. 0 ELECTRICAL DIAGNOSIS
UP
ENTIRE
SEAT
UP
-
-,1/PFUSE
BLOCK
S252
REAR
OF SEAT
DOWN
DOWN
ENTIRE
FORWARD~
SEAT
_.BACK
SEAT ACTIONS
1240
llli, TO
REAR
5 ORN
i111111111111illl_mi
______
DEFOGGER
1240
3 ORN
FRONT
OF SEAT
I
I
5 ORN
UP
PAGE 8A610, 1
1240
SEAT
ASSEMBLY.
DRIVER
FORWARD
ENTIRE
SEAT
REAR
HEIGHT
BACK
FRONT
HEIGHT
FRONT
HEIGHT
,DOWN
I
I
REAR
HEIGMJ
I
I'
...J,.,
DOWN,
ENTIRE
SEAT
WN
ENTIRE
SEAT
"''"
-------------
.-------------------------------------tl-------------------...----......------...------......
""IPOWER
SEAT
ACTUATOR
- - - - - - - - - - - - - - - - - - - -.. FRONT
ASSEMBLY'
HEIGHT
MOTOR
. .._____________________.... FORWARD/
- - - - - - - - - - - - - - - - - - - - - - - R E A R HEIGHT
BACK
MOTOR
MOTOR
2 BLK
[I] IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
SEE GROUND
DISTRIBUTION
PAGE BA-14-11
1450
Eo
oom
140- 1
[]o o
co
FODO
----
12085013
8-WA Y F PIN GRIP SERIES
BLK
POWER SEAT SWITCH (AC3)
COMPONENT
Forward/Back Motor
Front Height Motor . . . . . .
1/P Fuse Block . . . . . . . . . . .
Power Seat Actuator
Assembly . . . . . . . . . . . . . .
Power Seat Switch . . . . . . .
Rear Height Motor . . . . . . .
C310 (2 cavities) . . . . . . . . .
G305 . . . . . . . . . . . . . . . . . . . .
201-PG
LOCATION
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . .
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . .
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . .
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On left side of Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . .
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Between rear mounting bolt of Driver Seat near #3 Rail
without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8252 . . . . . . . . . . . . . . . . . . . . 1/P Harn, approx 17 cm back from HVAC Controls
(Pont) or RR Defogger Switch/Timer (Chevy) .
41
41
41
6 ....
FIG.
76
76
15 . .
76
76 . .
76
CONN
202-23
202-24
11
6 . . . . 11

Diagnosis)
Check Defog/Seats Circuit Breaker #12 by
operating the Rear Defogger.
2. Check that ground G305 is clean and tight.
3. Check for poor connections at Power Seat Switch
Connector or Motor Assembly connections.
4. If Defog/Seats Circuit Breaker opens whenever the
Power Seat Switch is operated, check for short to
ground through CKTs 282, 283, 284, 285, 286 and
287. Disconnecting motors one at a time can be
helpful.
malfunction
but
prove
"GOOD"
m
a
1.

SYSTEM DIAGNOSIS
BA -
140 - 2

SYMPTOM TABLE
'
SYMPTOM
PROCEDURE
PAGEN,-:JMBER
All Power Seat functions inoperative.
Chart #1
faA-140-2
Entire seat will not go "FORWARD" or "BACK," "UP"

or "DOWN" functions operate normally.
,,
Chart #2
Front Height wi II not go "UP" or "DOWN,"

"FORWARD" or "BACK" functions operate normal,ly.
Chart #3
Rear Height will not go "UP" or "DOWN,"

"FORWARD" or "BACK" functions operate normally.
Chart #4
SA-140-5
Entire seat will not go "UP" or "DOWN," "FORWARD"

or "BACK" functions operate normally.
Chart #5
SA-140-6
I
j
SA-140-3
SA-140-4
CHART #1
ALL POWER SEAT FUNCTIONS INOPERATIVE
BACKPROBE POWER SEAT SWITCH

CONNECTOR WITH A TEST blGHT BETWEEN
TERM "F" AND GROUND.
DOES NOT LIGHT

BACKPROBE POWER SEAT
SWITCH CONNECTOR WITH
THE TEST LIGHT BETWEEN
TERMINALS "F" & "C".

C310 TERM "A" OR OPEN IN CKT 1240.
LIGHTS
DOES NOT LIGHT

ATC310TERM "B" OR OPEN IN
CKT 1450.
CHECK FOR POOR

CONNECTION AT
POWER ,SEAT SWITCH.
IF OK, REPLACE POWER
SEAT SWITCH.
\~~~~~~~~~~~~~~~~~~~E.L~E_CT_R_I_CA_L_D_I_A_G_N_O_S_IS_._8A~1_4_0_-_3
\\
CHART #2
ENTIRE SEAT WILL NOT GO "FORWARD" OR "BACK,"
"UP" OR "DOWN" FUNCTIONS OPERATE NORMALLY
BACKPROBE FORWARD/BACK MOTOR CONN WITH A

TEST LIGHT FROM TERM" A" TO GROUND.
POWER SEAT SWITCH TO "FORWARD."
LIGHTS
DOES NOT LIGHT
I
BACKPROBE FORWARD/BACK MOTOR CONN
WITH A TEST LIGHT FROM TERM "B" TO GROUND.
POWER SEAT SWITCH TO "BACK."
LIGHTS
DOES NOT LIGHT
BACKPROBE FORWARD/BACK MOTOR CONN WITH

A TEST LIGHT FROM TERM" A" TO TERM "B".
POWER SEAT SWITCH TO "FORWARD."
POWER SEAT SWITCH TO "BACK."
r----------------------------------,
'
I
I
I
CHECK FOR OPEN OR SHORT TO GROUND

IN CKT 285 OR POOR CONNECTION AT
POWER SEAT SWITCH CONN TERM "E" .
IF OK, REPLACE POWER SEAT SWITCH.
LIGHTS IN BOTH
POSITIONS
CHECK FOR POOR CO~N.~CTION AT ~0.~WARD/BACK :

MOTOR CONN TERM A OR TERM B .
IF OK, REPLACE MOTOR ASSEMBLY.
1
REFERTOSECTION10-10:
I
L---------------------- ------------J
CHECK FOR OPEN OR SHORT TO GROUND

IN CKT 284 OR POOR CONNECTION AT
POWER SEAT SWITCH CONN TERM "D" .
IF OK. REPLACE POWER SEAT SWITCH .
I
LIGHTS IN ONE POSITION OR
DOES NOT LIGHT AT ALL
I
REPLACE POWER SEAT SWITCH.
SA -
140 - 4

CHART #3
FRONT HEIGHT WILL NOT GO "UP" OR "DOWN,"
"FORWARD" OR "BACK" FUNCTIONS OPERATE NORMALLY
BACKPROBE FRONT HEIGHT MOTOR CONN WITH

A TEST LIGHT FROM TERM "B" TO GROUND.
POWER SEAT SWITCH TO "FRONT HEIGHT UP:"
LIGHTS
DOES NOT LIGHT
BACKPROBE FRONT HEIGHT MOTOR

CONN WITH A TEST LIGHT FROM
TERM "A" TO GROUND.
POWER SEAT SWITCH TO "FRONT
HEIGHT DOWN."

POWER SEAT SWITCH CONN TERM "G"
OR OPEN IN CKT 286.
LIGHTS
DOES NOT LIGHT
I
TERM "B" TO TERM "A".
POWER SEAT SWITCH TO "ENTIRE
SEAT UP."
LIGHTS
DOES NOT LIGHT
I
TERM "B" TO TERM" A".
SEAT DOWN."

POWER SEAT SWITCH CONN TERM "H"
OR OPEN IN CKT 287.
LIGHTS
DOES NOT LIGHT
r-1------------------------------,
CHECK FOR POOR CONNECTION AT FRONT
I
I
II
II
I
I
HEIGHT MOTOR CONN TERM II B " OR TERM A . 1

IF OK, REPLACE MOTOR ASSEMBLY.
:
REFER TO SECTION 10-10.
I
L--------------------------------J
CHART #4
REAR HEIGHT WILL NOT GO "UP" OR "DOWN,"
BACKPROBE REAR HEIGHT MOTOR CONN WITH A

TEST LIGHT FROM TERM" A" TO GROUND.
POWER SEAT SWITCH TO "REAR HEIGHT UP."
LIGHTS
DOES NOT LIGHT
BACKPROBE REAR HEIGHT MOTOR

TERM "B" TO GROUND.
POWER SEAT SWITCH TO "REAR
HEIGHT DOWN."

POWER SEAT SWITCH CONN TERM "A"
OR OPEN IN CKT 282.
LIGHTS
DOES NOT LIGHT

TERM "A" TO TERM "B".
SEAT UP."

POWER SEAT SWITCH CONN TERM "B"
OR OPEN IN CKT 283.
I
I
LIGHTS
DOES NOT LIGHT

I
REPLACE POWER SEAT SWITCH. ,

TERM "A" TO TERM "B".
SEAT DOWN."
LIGHTS
,_) _________________________ ,
'
I

REAR HEIGHT MOTOR CONN TERM " A ,.
OR TERM "B".
IF OK, REPLACE MOTOR ASSEMBL V.
REFER TO SECTION 10-1 O.
I
I
L---------------------------J
DOES NOT LIGHT
140 - 5
8A -
140- 6 ELECTRICAL DIAGNOSIS

CHART #5
ENTIRE SEA TWILL NOT GO "UP" OR "DOWN,"
CAN FRONT HEIGHT ONLY, BE ADJUSTED?

POWER SEAT SWITCH CONN OR
MOTOR ASSEMBLY CONNECTOR.
CIRCUIT OPERATION
There are three reversible motors that operate the
Power Seats. The front and back height of the seat are
operated by different motors. They can be raised or
lowered independently of each other. When the Entire
Seat Switch is pushed to the "UP" or "DOWN"
position, both motors run to move the front and back of
the seat at the same time.
The Forward/Back Motor is operated by the Entire
Seat Switch. When it is held in the "FORWARD"
position, battery voltage is applied through the switch
contacts and CKT 285 to the Forward/Back Motor.
The motor is grounded through CKT 284 and the
contact of the Entire Seat Switch to ground G305. The
motor runs to drive the seat forward until the switch is
released.
In the "BACK" position, CKT 284 receives battery
voltage and CKT 285 is grounded. This reversed
polarity causes the motor to run in the opposite
direction and drive the seat backward.
REFER TO CHART #3, "FRONT HEIGHT WILL NOT GO

'UP' OR 'DOWN,' 'FORWARD' OR 'BACK' FUNCTIONS
OPERATE NORMALLY,'' PAGE SA-140-4.
The Front and Rear Motors work in a similar way

when the Front or Rear Height Switch is operated.
To raise the entire seat, the Entire Seat Switch is
held in the "UP" position. This applies battery voltage
through CKT 282 and CKT 286 to the Rear Seat and
Front Seat Motors. The motors are grounded through
CKT 283 and CKT 287 and the Power Seat Switch to
G305. Both motors run to drive the entire seat up. A
similar action occurs to move the entire seat down.
Each Motor contains an Electronic Circuit Breaker
(ECB). ECB resistance increases if motor is
overloaded. Resistance returns to normal after voltage
is removed from motor terminals.
BLANK
140- 7
POWER SEATS: ULTIMA (AQ9)
----,~
rS:P=E;- DISTRIBUTION
PAGESA-10-1
FUSE
I
I
DEFOG!SEATS
CIRCUIT
BREAKER 12
30AMP
leLOCK
I
I
____ J
TO REAR
1240
SORN
es2s2
DEFOGGER .....
- . .- ----
TIMER/RELAY
...
1240
30RNt.240
PAGE SA-61-1
A
C310
30RNfim
3 ORN
5320.
SEAT
ASSEMBLY,
DRIVER
3 ORN
c
3 ORN
3 ORN
1240
1240
(300
1240
e 5330
1240
3 OR: A1240
POWER
SEAT
SWITCH,
DRIVER
DEFLATE
--------LUMBAR
INFLATE
DEFLATE
LATERAL
INFLATE
... _,,.
.SWHT
.SWHT
766
.SGRY
766
764
,,wlTIJ
DE.FLA. T E w n
LATERAL
BLADDER
LUMBAR
BLADDER
LATERAL
BLADDER
POWER
seA'r
CONTROL
MODULE
1 WHT
766
1 GRY
764
1 GRY1BLK
628
JORN
1240
r-----------------1"-------------------------------------------------------------WSEAT
ASSEMBLY,
3 ORN
1240
PASSENGER
POWER.-------.--------------------------------------------------------.
SEAT
SWITCH,
PASSENGER DEFLATE
INFLATE
DEFLATE
LATERAL
INFLATE
LUMBAR
.5 GRY
764
.5 WHT
766
LUMBAR
BLADDER
.5 BLK,WHT
l
l
l
1WHT
766
1 GRY
764
1 GRY BLK
628
769
LATERAL
BLADDER
LATERAL
!!LADDER
SA -
141 - 2
it? ctj:H{jl ct?

ri:u:~ rfn:~
12064998
BLK
POWER SEAT CONTROL MODULE
12033944
BLK
POWER SEAT SWITCH, DRIVER
POWER SEAT SWITCH, PASSENGER
12064769
NAT
SOLENOID VALVE ASSEMBLY
COMPONENT
201-PG
LOCATION
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side .. .. .. .. .. .. . .. .. ..

Power Seat Control Module Under Driver's Seat ...............................
Power Seat Switch, Driver
On left side of Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . .
Power Seat Switch,
Passenger ............. . On right side of Passenger Seat .................... .
Pump Assembly ......... . Under Driver's Seat .............................. .
Solenoid Valve Assembly .
Under Driver's Seat .............................. .
C300 (6 cavities) ....... . Under Driver Seat Assembly ...................... .
C305 (6 cavities) ....... . Under Passenger Seat Assembly ................... .
C310 (2 cavities) ........ . Between rear mounting bolt of Driver Seat near #3 Rail
G305 ................... . Bolted to Floor Pan Bar #2, under Driver's Seat
without AC3/AQ9) ...............................
S252
I/P Harn, approx 17 cm back from HVAC Controls
S320
Seat Jumper Harn, near rosebud under Driver Seat
S330
Switch Conn
S335
Control Module Conn
S340
Control Module Conn
S345
Driver Seat Harn, approx 18 cm from C300
S350
Driver Seat Harn, approx 11 cm from C300
,S355
Driver Seat Harn, approx 20 cm from Solenoid Valve
Assembly Conn
S360
Passenger Seat Harn, approx 22 cm from Power Seat
Switch Conn
FIG.
CONN
8 .. .. 15 ..
47
86 ..
47
86 ..
202-23
202-24
202-24
86 ..
86
85, 86
86 ..
85
11
202-24
47
47
46,47
47
46 ...
6 ....
202a27
202-19
202-19
6 . .. . 11

Diagnosis)
1.
2.
If both Passenger and Driver Seat Functions

(Lumbar and Lateral) are inoperative, check
DEFOG/SEATS Circuit Breaker 12 for open.
Check that G305 is clean and tight.
Check for poor connections at C300.
Check for poor connections at C310 terminals
"A" and "B".
If Passenger Seat is inoperative and Driver's Seat
operates normally, check for poor connections at
C300 and C305, and for open in Seat ,Jumper
Harness.

SYSTEM DIAGNOSIS

diagnostic procedure(s):
SA -
141 - 4

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Important:
Charts # 1 through #5 to be used for diagnosis of both Driver and/or Passenger Seat(s) .
Both seats inoperative and pump does not run.
Chart #1
8A-141-4
Lumbar bladder inoperative, but lateral bladders

operate normally within the same seat.
Chart #2
BA-141-6
Lateral bladders inoperative, but lumbar bladder

operates normally within the same seat.
Chart #3
8A-141-7
Bladder(s) inflate but do not deflate.
Chart #4
BA-141-7
Pump Assembly operates, but bladder(s) do not

inflate.
Chart #5
8A-141-8
Passenger Power Seat inoperative, Driver Power Seat

operates normally.
Chart #6
8A-141-9
Driver Power Seat inoperative, Passenger Power Seat

operates normally.
Chart #7
8A-141-10
One lateral bladder inoperative, and one lateral Check for:

bladder operates normally within the same seat.
- Pinched or punctured bladder tubing.
- Punctured bladder.
Stuck Solenoid Valve within Solenoid Valve
Assembly.
Open in CKT 765 from 5355 or 5360 to Solenoid
Valve Assembly terminal "H" or terminal "J".
CHART #1
BOTH SEATS INOPERATIVE AND PUMP DOES NOT RUN
WITH A TEST LIGHT TO GROUND, BACKPROBE C300 TERM "C" AND C305 TERM "C".
CONNECT A TEST LIGHT BETWEEN TERMINALS "C"

AND "D" OF C300.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE THE

POWER SEAT CONTROL MODULE CONN TERM ''f''.
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT(S) 1240 TO DRIVER AND/OR PASSENGER

SEAT IN CIRCUIT(S) THAT DID NOT ILLUMINATE TEST LIGHT.
CHECK FOR POOR CONNECTIONS AT C310 TERM "A".
CHECK FOR OPEN IN DEFOG/SEATS CIRCUIT BREAKER 12.
IF CIRCUIT BREAKER 12 IS OPEN, CHECK FOR SHORT TO
CHECK FOR OPEN IN GROUND CKT 1450 FROM C300

TERM "D" TO G305.
CHECK FOR POOR CONNECTION AT C310 TERM "B".
DISCONNECT THE POWER SEAT CONTROL MODULE CONNECTOR.

CONNECT A TEST LIGHT FROM TERM "F" TO TERM "E" AT THE
POWER SEAT CONTROL MODULE CONNECTOR.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT FROM TERM "F" TO TERM "B"

AT THE POWER SEAT CONTROL MODULE CONNECTOR.
IS TEST LIGHT "ON"?
REPAIR OPEN IN GROUND CKT 1450 BETWEEN POWER SEAT

CONTROL MODULE CONN TERM 'T' AND C300 TERM "D".
CHECK THE TERMINALS IN THE POWER SEAT CONTROL MODULE

CONNECTOR FOR POOR CONNECTIONS.
WAS THERE ANY TERMINAL(S) CAUSING A POOR CONNECTION?
REPAIR OPEN IN GROUNDCKT 1450 BETWEEN POWER SEAT

CONTROL MODULE CONN TERM "B" AND (300 TERM "D".
RECONNECT POWER SEAT CONTROL MODULE.

DISCONNECT PUMP ASSEMBLY CONNECTOR UNDER DRIVER SEAT.
CONNECT A TEST LIGHT BETWEEN TERMINALS" A" AND "B" OF
THE PUMP ASSEMBLY CONNECTOR.
WHILE OBSERVING TEST LIGHT, OPERATE THE DRIVER POWER SEAT
SWITCH (LUMBAR OR LATERAL) TO THE "INFLATE" POSITION.
DOES TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
REPAIR OR REPLACE TERMINALS AS NECESSARY

TO ASSURE GOOD TERMINAL CONTACT.
RECONNECT PUMP ASSEMBLY CONNECTOR.

WITH AT EST LIGHT, BACKPROBE TERMINALS "C" AND "G" OF
THE POWER SEAT CONTROL MODULE CONNECTOR.
WHILE OBSERVING TEST LIGHT, OPERATE DRIVER POWER
SEAT SWITCH (LUMBAR OR LATERAL) TO THE "INFLATE" AND
"DEFLATE" POSITIONS.
DOES TEST LIGHT ILLUMINATE IN BOTH "INFLATE" AND
"DEFLATE" POSITIONS WHEN OPERATING SWITCH?
CHECK FOR POOR CONNECTIONS AT PUMP

ASSEMBLY CONNECTOR.
IF OK, REPLACE PUMP.
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT

CONTROL MODULE CONNECTOR TERM "D".
WHILE OBSERVING TEST LIGHT, OPERA TE DRIVER POWER SEAT
SWITCH (LUMBAR OR LATERAL) TO THE "INFLATE" POSITION.
CHECK FOR OPEN IN CKT 100, OR FOR OPEN

IN CKT 101 FROM POWER SEAT CONTROL
MODULE TO PUMP ASSEMBLY.
CHECK FOR POOR CONNECTION AT C300 TERM "C".

IF OK, REPAIR OPEN IN CKT 1240 BETWEEN C300 TERM "C"
AND POWER SEAT CONTROL MODULE TERM "F".
SA -
141 6

BOTH SEATS INOPERATIVE AND PUMP DOES NOT RUN
{CONTINUED FROM PREVIOUS PAGE)
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER

SEAT SWITCH CONN TERM "E".
WHILE OBSERVING TEST LIGHT, OPERATE DRIVER POWER SEAT
SWITCH {LUMBAR OR LATERAL) TO THE "INFLATE" POSITION.
CHECK CONNECTIONS AT POWER

SEAT CONTROL MODULE.
IF OK, REPLACE POWER SEAT
CONTROL MODULE.
CHECK FOR POOR CONNECTIONS AT DRIVER POWER SEAT SWITCH.

IF OK, REPLACE THE DRIVER POWER SEAT SWITCH.
CHECK FOR OPEN IN CKT 766 FROM POWER

SEAT CONTROL MODULE TERM "D" TO 5340.
CHART #2
LUMBAR BLADDER INOPERATIVE, BUT LATERAL BLADDERS
OPERATE NORMALLY WITHIN THE SAME SEAT
WITH A TEST LIGHT TO GROUND, BACKPROBE SOLENOID VALVE

ASSEMBLY CONN TERM "K".
WHILE OBSERVING TEST LIGHT, OPERA TE LUMBAR BLADDER WITH
THE POWER SEAT SWITCH TO "INFLATE" OR "DEFLATE" POSITION.

SWITCH CONN TERM "B".
WHILE OBSERVING TEST LIGHT, OPERA TE LUMBAR BLADDER WITH
THE POWER SEAT SWITCH TO "INFLATE" OR "DEFLATE" POSITION.
DOES THE TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
CHECK FOR OPEN IN CKT 763 BETWEEN POWER SEAT SWITCH

TERM "B" AND SOLENOID VALVE ASSEMBLY TERM "K".
CHECK FOR POOR CONNECTION AT SOLENOID VALVE

CONN TERM "K".
CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING.
CHECK FOR PUNCTURED LUMBAR BLADDER.
IF ABOVE ARE OK, REPLACE SOLENOID VALVE ASSEMBLY.
CHECK FOR POOR CONNECTION AT POWER

SEAT SWITCH CONN TERM "B".
ELECTRICAL DIAGNOSIS 8A - 141
-7
CHART #3
LAlERAL BLADDERS INOPERAllVE, BUT LUMBAR BLADDER
OPERA TES NORMALLY WITHIN THE SAME SEAT
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "A".
WHILE OBSERVING TEST LIGHT, OPERA TE LATERAL BLADDER USING THE POWER SEAT
SWITCH TO THE "INFLATE" OR "DEFLATE" POSITION.
DOES THE TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
WITH A TEST LIGHT TO GROUND, BACKPROBE SOLENOID VALVE CONN TERM "H".
WHILE OBSERVING TEST LIGHT, OPERA TE LATERAL BLADDER USING THE POWER
SEAT SWITCH TO THE "INFLATE" OR "DEFLATE" POSITION.

POWER SEAT SWITCH CONN TERM "A".
CHECK FOR POOR CONNECTION AT SOLENOID VALVE CONN TERMINALS "H" AND" J".
CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING.
IF ABOVE ARE OK, REPLACE SOLENOID VALVE.

POWER SEAT SWITCH CONN TERM "A"
AND SOLENOID VALVE CONN
TERMINALS "H" AND "J".
CHART #4
BLADDER(S) INFLATE BUT DO NOT DEFLATE
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "C"
WHILE OBSERVING TEST LIGHT, OPERATE POWER SEAT SWITCH TO THE "DEFLATE" POSITION .

CONTROL MODULE CONN TERM "1:1".
.
WHILE OBSERVING TEST LIGHT, OPERATE POWER SEAT
SWITCH TO THE "DEFLATE" POSITION.
CHECK FOR POOR CONNECTION AT POWER SEAT CONTROL

MODULE TERM "H".
IF OK, REPLACE POWER SEAT CONTROL MODULE.
CHECK FOR POOR CONNECTION AT 110WER

SEAT SWITCH TERM '.'C".
IF OK, RE Pt.ACE POWER SEAT SWITCH.
(DRIVER SEAT):
REPAIR OPEN IN CKT 764 BETWEEN DRIVER POWER SEAT SWITCH
TERM "C" AND POWER SEAT CONTROL MODULE TERM "H".
(PASSENGER SEAT):
CHECK FOR OPEN IN CKT 764FROM PASSENGER POWER SEAT
SWITCH TO C305 TERM "A".
CHECK FOR OPEN IN CKT 764 IN SEAT JUMPER HARNESS FROM
(305 TERM "A" TO C300 TERM "A".
CHECK FOR OPEN IN CKT 764 FROM C300 TERM" A TO 5345 TO
POWER SEAT CONTROL MODULE TERM "H".
SA - 141 8 ELECTRICAL DIAGNOSIS

CHART #5
PU MP ASSEMBL V OPERATES, BUT BLADDER(S) DO NOT INFLATE
{LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "A".
{LUMBAR BLADDER): WITH A TEST LIGHT TO GR OU Np, BACKPROBE POWER SEAT SWITCH CONN TERM "B".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT,
9
{LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND,
BACKPROBE SOLENOID VALVE CONN TERM "H" AND TERM" J".
{LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "F".
..
DISCONNECT POWER SEAT CONTROL MODULE.

USING A TEST LIGHT, PROBE POWER SEAT CONTROL MODULE
CONN TERM "A" TO GROUND.
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE
OBSERVING TEST LIGHT.
RECONNECT POWER SEAT CONTROL MODULE.

DISCONNECT SOLENOID VALVE ASSEMBLY CONNECTOR .
CONNECT A TEST LIGHT BETWEEN SOLENOID VALVE
CONNECTOR TERMINALS "K" AND "F".
USING LUMBAR CONTROL, PRESS POWER SEAT SWITCH TO
"INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
CHECK FOR OPEN BETWEEN POWER SEAT SWITCH AND

SOLENOID VALVE ASSEMBLY IN CKTS 763 AND/OR 765.
{LUMBAR BLADDER): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "F".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION
WHILE OBSERVING TEST LIGHT.
CHECK FOR POOR CONNECTIONS AT POWER SEAT SWITCH

{LUMBAR BLADDER): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "K".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE
OBSERVING TEST LIGHT.
DOES TEST LIGHT ILLUMINATE ON ALL CIRCUITS WHEN
OPERA TING SWITCH?
CHECK FOR POOR CONNECTIONS AT SOLENOID VALVE.

CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING
WITHIN INDIVIDUAL SEATS; ALSO CHECK BLADDER TUBING
IN SEAT JUMPER HARNESS.
CHECKFORPUNCTUREDBLADDER
IF ABOVE CHECKS ARE OK, THE SOLENOID VALVE
ASSEMBLY MAY BE STUCK OR FAULTY. REPLACE SOLENOID
VALVE ASSEMBLY.
CHECK FOR POOR CONNECTIONS AT SOLENOID

VALVE ASSEMBLY .
IF OK, REPLACE SOLENOID VALVE ASSEMBLY.
{DRIVER SEAT): REPAIR OPEN IN CKT 769 BETWEEN SOLENOID

VALVE AND POWER SEAT CONTROL MODULE.
{PASSENGER SEAT): CHECK FOR OPEN IN CKT 769 FROM

SOLENOID VALVE TO (305 TERM "F".
CHECK FOR OPEN IN CKT 628 FROM C305 TERM "F" TO (300
TERM "F".
CHECK FOR OPEN IN CKT 769 BETWEEN C300 TERM "F" AND
POWER SEAT CONTROL MODULE TERM "A"', INCLUDING 5350.
CHECK FOR POOR CONNECTIONS AT POWER SEAT

CONTROL MODULE CONN TERM "A".
IF OK, REPLACE POWER SEAT CONTROL MODULE.
SA-141 - 9
CHART #6
PASSENGER POWER SEAT INOPERATIVE, DRIVER POWER SEAT OPERATES NORMALLY
WITH A TEST LIGHT TO GROUND, BACKPROBE C305 TERM "C".

IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE PASSENGER

POWER SEAT SWITCH CONN TERM "F".
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 1240 IN SEAT JUMPER

HARNESS FROM C305 TERM "C" TO 5320.
WITH A TEST LIGHT TO GROUND, BACKPROBE C300 TERM "B".

PRESS PASSENGER POWER SEAT SWITCH (LUMBAR OR LATERAL)
TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
CHECK FOR POOR CONNECTION AT C305 TERM "C".

IF OK, REPAIR OPEN IN CKT 1240 BETWEEN C305
AND PASSENGER POWER SEAT SWITCH.
WITH A TEST LIGHT TO GROUND, BACKPROBE C305 TERM "B".

PRESS PASSENGER POWER SEAT SWITCH (LUMBAR OR LATERAL)
TO '~INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
DOES TEST LIGHT ILLUMINATE WHEN OPERA TING SWITCH?

IF OK, REPAIR OPEN IN CKT 766 BETWEEN C300 AND S340.
WITH A TEST LIGHT TO GROUND, BACKPROBE PASSENGER POWER

SEAT SWITCH CONN TERM ''E''.
PRESS THE PASSENGER POWER SEAT SWITCH (LUMBAR OR
LATERAL) TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
CHECK FOR OPEN IN SEAT JUMPER HARNESS CKT 766

BETWEEN C305 AND (300.
CHECK FOR POOR CONNECTIONS AT PASSENGER POWER

SEAT SWITCH CONN TERM "E".
IF OK, REPLACE PASSENGER POWER SEAT SWITCH.

IF OK, REPAIR OPEN IN CKT 766 BETWEEN C305 AND
PASSENGER POWER SEAT SWITCH.
BA-141-10 ELECTRICAL DIAGNOSIS

CHART #7
DRIVER POWER SEAT INOPERATIVE,
PASSENGER POWER SEAT OPERATES NORMA LL V
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER SEAT SWITCH CONN TERM "F".
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER SEAT SWITCH

CONN TERM ''E''.
PRESS DRIVER POWER SEAT SWITCH (LUMBAR OR LATERAL) TO "INFLATE"
REPAIR OPEN IN CKT 766 BETWEEN DRIVER POWER SEAT

SWITCH TERM "E" AND 5340.
CIRCUIT OPERATION
Each seat incorporates a power inflate/power
deflate pneumatic system used for altering the contour
of the seat. This is accomplished by inflating and
deflating air bladders within each seat.
Both Power Seats utilize the same Power Seat
Control Module and Pump Assembly for operation.
The Power Seat Control Module and Pump Assembly
are mounted under the Driver Seat. A Seat Jumper
Harness from the Driver Seat connects the circuitry
and bladder tubing to the Passenger Seat.
Voltage is supplied at all times to both Power Seat
Switches through CKT 1240 from the DEFOG/SEATS
Circuit Breaker 12. When lateral/lumbar support is
requested, the Power Seat Switch applies voltage to
the selected solenoid at the Solenoid Valve Assembly.
CHECK FOR OPEN IN CKT 1240 BETWEEN DRIVER

POWER SEAT SWITCH TERM "F" AND 5330.
CHECK FOR POOR CONNECTIONS AT DRIVER

POWER SEAT SWITCH CONN TERMINALS "F"
AND"E".
IF OK, REPLACE DRIVER POWER SEAT SWITCH.
The Solenoid Valve Assembly is grounded through

the Power Seat Control Module. At the same time, the
Power Seat Switch applies battery voltage to the
selected inflate or deflate relay within the Power Seat
Control Module. The Power Seat Control Module
applies power to the Pump Assembly in either the
forward direction (inflate) or the reverse direction
(deflate).
The ground to the Solenoid Valve is electriGally
opened when a pressure switch inside the Power Seat
Control Module senses a bladder full/empty condition.
In response to thes.e. conditions the .Power Seat Control
Module shuts off the pump by opening the ground to
the Inflate or Deflate Relay until the Power Seat
Switch is released.
ELECTRICAL DIAGNOSIS SA-141 -11
BLANK
POWER MIRRORS (DG7) (CH EVY)
rsEE-POWER
---
---,1,P
I FUSE
l!b_OCK
~I
15AMP
I
I DISTRIBUTION
I PAGESA-10-2
I
PWR ACCV
.SORN
640
[I] IMPORTANT:
... --5211
E9
SEE FUSE
BLOCK DETAILS
PAGE SA-11-8
EACH MOTOR CONTAINS

BREAKER (ECB}.

TERMINALS.
.80RN1640
.SORN
L-
C200D
lOOC
PSOO
640
-s5oo
.50RN16~
H+35BLK
750
------- ------
- ---
MIRROR
POSITION
RIGHT
LEFT
------- -------
- --UP
PSOO
r--5220
DOWN
SEE GROUND
DISTRIBUTION
PAGE SA-14-7
~750
--A.2200
.35WHT
81
.35 RED/
WHT
----.35 LT BLU
UP/
DOWN
MOTOR
ECB
---------.35LT B:Uy82
.35 LT BLU
82
5501
82
.35 GRV
RIGHT/
LEFT
MOTOR
ELECTRICAL DIAGNOSIS SA-147 -1
POWER MIRRORS (DG7) (PONTIAC)
rsEE-PDWER
--I DISTRIBUTION
I PAGE 8A-10-2
- -
- ,1,p
FUSE
PWR ACCY
FUSE7~
15AMP
I
.8 ORN
I BLOCK_
640
,.. - -g,_,
l
f.
rn
.80RN1640
Eg
SEE FUSE
BLOCK DETAILS
PAGE SA-11-8
.SORN
C200D
2
00C
P500
640
L--,:F"
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
.----11---<1...---1~-<11--~-+~---~~,~----------...
so
1
.35 BLK
- '
UP
LEFT
- '
RIGHT
- '
r
RIGHT
LEFT
-P500
---5220
RIGHT
SEE GROUND
DISTRIBUTION
PAGE 8A-14-7
3 BLK
750
---.Jj200
.35WHT
81
88
~i
DOWN
MOTOR
UPI
DOWN
RIGHT/
LEFT
MOTOR
Mori:,-R
.35 LTBLU
.35 LT BLU
82
.35 BRN,WHT
...............................................................
1498
.35 LT BLU
5501
82
MIRROR
MOTOR
PACK
OUTSIDE
MIRR.OR,
f!!:!
POWER MIRRORS {DG7)

(PONT)
(CHEVY)
12045688
12064862
8-WA Y M METRI-PACK 150 SERIES
BLK
BLK
201-PG FIG.
COMPONENT
LOCATION
1/P Fuse Block . . . . . . . . . . .

Outside Mirror, LH . . . . . . .
Outside Mirror, RH . . . . . .
Power Mirror Switch . . . . .
C200C (13 cavities)
LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . .

LH front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/P Harn, approx 4 cm from antenna cable (Chevy) or
Cross Car Harn, approx 9 cm from 9200 breakout . . . . .
Cross Car Harn, approx 14 cm inboard of P600 . . . . . . . .
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Car Harn, approx 7 cm from Outside
Mirror breakout
C200D (48cavities)
G200 . . . . . . . . . . . . . . . . . . . .
P500 . . . . . . . . . . . . . . . . . . . .
P600 . . . . . . . . . . . . . . . . . . . .
5211 . . . . . . . . . . . . . . . . . . . .
5220
S261
S500
S501
5610
....................
....... .............
....................
........ .... ........
8 .... 15
17
31
17
31 ..
18
33
CONN
202-2:3
202-24
202-24
202-24
25
49
202-2
25
49
202-2
9 . . . . 16
17
31
45 . . . 84
45 . . . 84
45
84
17
31
17
31
For a Service Part Cross Reference List and In.formation, refer to SECTION SA-200.

Diagnosis)
4.
System
1. Check PWR ACCY Fuse 7 in I/P Fuse Block. If

open, refer to Diagnostic Chart #5.
2. If both mirrors are inoperative, check for poor.
connections at the Power Mirror Switch.
Ifonly one mirror operates properly, check for poor

connections at LH Outside Mirror or RH Outside
Mirror.
Refer to SECTION 10-6 for Outside Mirror
replacement.

continuity/voltage .check with a system
147 - 3
SYSTEM DIAGNOSIS

procedures.
rn
Important:
For a better understanding of Retained
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Move Mirror Select Switch to "LEFT" position. LH Outside Mirror moves smoothly upward and
Operate Mirror Position Switch in "UP" and downward.
"DOWN" positions.
[2]
Operate Mirror Position Switch in the "LEFT" and LH Outside Mirror moves smoothly to the left and
"RIGHT" positions.
right.
[3]
Move Mirror Select Position to "RIGHT" position. RH Outside Mirror moves smoothly upward and
Operate Mirror Position Switch in "UP" and downward.
"DOWN" positions.
[4]
Operate Mirror Position Switch in the "LEFT" and RH Outside Mirror moves smoothly to the left and
"RIGHT" positions.
right.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Both mirrors do not operate in either ("UP/DOWN" or

"LEFT/RIGHT") mode.
Chart #1
8A-147-4
One mirror does not operate in the "UP/DOWN"

mode ("LEFT/RIGHT" mode operates normally).
Chart #2
8A-147-4
One mirror will not operate in the "LEFT/RIGHT"

mode ("UP/DOWN" mode operates normally).
Chart #3
8A-147-5
One mirror will not operate in either ("UP/DOWN" or

"LEFT/RIGHT") mode.
Chart #4
8A-147-6
P-WR AC-CY Fu-se- 7repeatedly blows whenever Ignition

is "ON" or when attempting to operate Power
Mirrors.
Chart #5
8A-147-7
SA -
147 - 4
POWER MIRRORS (DG7)

CHART #1
BOTH MIRRORS DO NOT OPERATE IN EITHER ("UP/DOWN" OR "LEFT/RIGHT") MODE
WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH

CONN TERM "A" (CHEVY)ORTERM "H" (PONT)TO GROUND.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT, BACKPROBE BETWEEN POWER

MIRROR SWITCH CONN TERM "A" AND TERM "H".
IS THE TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT C200 TERM

"E9" OR AT POWER MIRROR SWITCH CONN.
IF OK, REPAIR OPEN IN CKT 640 FROM FUSE BLOCK
TO POWER MIRROR SWITCH CONN.

POWER MIRROR SWITCH CONN.

CHECK FOR POOR CONNECTION AT POWER MIRROR CONN
TERM "H" (CHEVY) OR TERM "A" (PONT).
IF OK, REPAIR OPEN IN CKT 750 FROM G200 TO POWER MIRROR
SWITCH CONN TERM "H" (CHEVY) OR TERM" A" (PONT).
CHART #2
ONE MIRROR DOES NOT OPERATE IN THE "UP/DOWN"
MODE ("LEFT/RIGHT" MODE OPERATES NORMALLY)
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "B" TO
TERM "C" (CHEVY) OR TERM "C" TO TERM ''E'' (PONT).
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "G" TO
TERM "F" (CHEVY) OR TERM "C" TO TERM "F" (PONT).
PRESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING THE TEST LIGHT .
I
(LH): WITH A TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN TERM "D" TO TERM "C".
(RH): WITH A TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN TERM "D" TO TERM "C".
PRESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING THE TEST LIGHT .
~
.
. I
. I
CHEVY
PONT
(LH): CHECK FOR OPEN IN CKT 88 BETWEEN

POWER MIRROR SWITCH TERM "B" AND
OUTSIDE MIRROR CONN TERM "D".
IF OK, CHECK FOR OPEN IN CKT 82 BETWEEN
5501 AND OUTSIDE MIRROR CONN TERM "C".
(RH): CHECK FOR OPEN IN CKT 1498

BETWEEN POWER MIRROR SWITCH TERM "G"
AND OUTSIDE MIRROR CONN TERM "D".
5610 AND OUTSIDE MIRROR CONN TERM "C".
CHECK FOR POOR

CONNECTION AT POWER
MIRROR SWITCH CONN.
IF OK, REPLACE POWER
MIRROR SWITCH.
(LH): CHECK FOR OPEN IN CKT 88 BETWEEN

OUTSIDE MIRROR CONN TERM "D" AND 5261.
OUTSIDE MIRROR CONN TERM "C" AND
POWER MIRROR SWITCH TERM "E".
(RH): CHECK FOR OPEN IN CKT 88 B.ETWEEN
OUTSIDE MIRROR CONN TERM "D" ANDS261.
IF OK, CHECK FOR OPEN IN CKT 1498
BETWEEN OUTSIDE MIRROR CONN TERM "C"
AND POWER MIRROR SWITCH CONN
TERM ''F''.
(LH): CHECK FOR POOR

CONNECTION AT OUTSIDE
MIRROR CONNECTOR. IF
OK, REPLACE THE MIRROR
MOTOR PACK WITHIN
THE POWER MIRROR.
(RH): CHECK FOR POOR

CONNECTION AT OUTSIDE
MIRROR CONNECTOR.
IF OK, REPLACE THE
MIRROR MOTOR PACK
WITHIN THE POWER
MIRROR.
CHART #3
ONE MIRROR WILL NOT OPERATE IN THE "LEFT/RIGHT"
MODE ("UP/DOWN" MODE OPERATES NORMALLY)
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "D"
TO TERM "C" (CHEVY) OR TERM "D" TO TERM "B" (PONT).
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "E"
TO TERM "F" (CHEVY) OR TERM "G" TO TERM "B" (PONT).
PRESS MIRROR POSITION SWITCH TO "LEFT" WHILE OBSERVING THE TEST LIGHT .
s
I
(LH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN
TERM "B" TO TERM "A".
(RH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN
TERM "B" TO TERM" A".

POWER MIRROR SWITCH CONN.
IF OK, REPLACE POWER MIRROR
SWITCH.
PRESS MIRROR POSITION SWITCH TO "LEFT" WHILE OBSERVING THE TEST LIGHT .
NO
I
CHEVY
PONT
(LH): CHECK FOR POOR CONNECTION

AT OUTSIDE MIRROR CONNECTOR.
IF OK, REPLACE THE MIRROR MOTOR
PACK WITHIN THE POWER MIRROR.
(RH): CHECK FOR POOR CONNECTION

AT OUTSIDE MIRROR CONNECTOR.
(LH): CHECK FOR OPEN IN CKT 81

BETWEEN POWER MIRROR SWITCH
CONN TERM "D" AND OUTSIDE
MIRROR CONN TERM" A".
BETWEEN 5501 AND OUTSIDE MIRROR
CONN TERM "B".

CONN TERM "E" AND OUTSIDE MIRROR
CONN TERM "A" .
BETWEEN 5610 AND OUTSIDE MIRROR
CONN TERM "B".

CONN TERM "D" AND OUTSIDE
MIRROR CONN TERM "A".
BETWEEN 5501 AND OUTSIDE
MIRROR CONN TERM "B".
CONN TERM "G" AND OUTSIDE
MIRROR CONN TERM "A".
BETWEEN OUTSIDE MIRROR CONN
TERM "B" AND 5501.
SA -
147 - 6
POWER MIRRORS (DG7}

CHART #4
ONE MIRROR WILL NOT OPERATE IN EITHER
("UP/DOWN" OR "LEFT/RIGHT") MODE
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN
TERM "B" TO TERM "C" (CHEVY) OR TERM "C" TO TERM "E" (PONT).
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN
TERM "G" TO TERM ''F'' (CHEVY) OR TERM "C" TO TERM "F" (PONT).
PRESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING THE TEST LIGHT.
(LH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE

MIRROR CONN TERM "D" TO TERM "C".
(RH): WITH THE TEST LIGHT BACKPROBE FROM
OUTSIDE MIRROR CONN TERM "D" TO TERM "C".
PRESS THE MIRROR POSITION SWITCH TO "UP" WHILE

OBSERVING THE TEST LIGHT.
(LH): REPAIR OPEN IN CKT 82

CONN TERM "C" AND 5501.

OUTSIDE MIRROR SWITCH CONN
TERM "C" AND 5261.
(RH): REPAIR OPEN IN Cl<T 90

CONN TERM "F" AND 5610.

BETWEEN OUTSIDE MIRROR SWITCH
CONN TERM "E" AND OUTSIDE
MIRROR CONN TERM"(".

TERM "F" AND OUTSIDE MIRROR
CONN TERM "C".

AT POWER MIRROR SWITCH.
IF OK, REPLACE POWER MIRROR
SWITCH.
(LH): CHECK FOR POOR CONNECTION

AT OUTSIDE MIRROR CONN.
(RH): CHECK FOR POOR CONNECTION

AT OUTSIDE MIRROR CONN.
ELECTRICALDIAGNOSIS
SA-147 - 7
CHART #5
PWR ACCY FUSE 7 REPEA TEDLV BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATTEMPTING TO OPERATE ~OWER
MIRRORS
o,;,i
"
,i
'
>
,.'
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE POWER MIRRORS?
TEST POWER MIRROR SWITCH ONE FUNCTION AT A TIME UNTIL

FUSE BLOWS.
WHEN THE FUSE BLOWS, USE SCHEMA TICS TO DETERMINE
WHAT CIRCUITS OR COMPONENTS COULD BE FAILING ..
A
TEST LIGHT OR DVM TO NARROW IN ON SHORT TO GROUND
POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL WHEN TRYING TO
CHECK CIRCUITS THAT SHOULD NOT BE AT A GROUND
POTENTIAL.
us~
CIRCUIT OPERATION
The Power Mirror System has voltage applied from
the PWR ACCY Fuse which is controlled by the
Retained Accessory Power (RAP) M.odule. Voltage is
applied to the PWR ACCY Fuse for up to 10 minutes
after Ignition is turned ''OFF" or for 35 seconds after
exiting the vehicle and closing the doors. Voltage is
also applied whenever a door is open. For a complete
understanding of Retained Accessory Power (RAP)
operation, refer to "Retained Accessory Power (RAP):
with AU3," page 8A-15-0.
Each Outside Mirror has two reversible motors.
One adjusts the mirror up and down, and the other
adjusts the mirror right and left. These motors are
controlled by the Power Mirror Switch. The Power
Mirror Switch contains a Mirror Position Switch. The
Mirror Position Switch controls the polarity of the
voltage to the motors. The Power Mirror Switch also
contains a Mirror Select Switch, which directs the
voltage to either the RH or LH Outside Mirror. The
Power Mirror Switch receives battery voltage from the
PWR ACCY Fuse through CKT 640 and is
permanently grounded at G200.
When the LH Outside Mirror is selected, the
Mirror Position Switch will control the motors of the
LH Outside Mirror. When the Mirror Position Switch
UP position is selected, voltage is applied to the
Up/Down Motor of the LH Outside Mirror through
CKT 88. Ground will be provided to the Up/Down
Motor by the Outside Mirror Switch through CKT 82
(Chevy) or CKT 89 (Pont). The Up/Down Motor in the
LH Outside Mirror will run and turn the LH Outside
Mirror up.
USE SCHEMATICS AN.D DVM TO CHECK SUSPECT ?OWER

THROl)GH A FAULTY COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOL TAGEACROSS FUSE
TERMINALS. START BY DISCONNECTING ONE COMPONENT
ATA TIME.
IF All RELATED COMPONENTS ARE DISCONNECTED AND
SH ORTIS STILL PRESENT, LOCATE AND REPAIR SHORT IN
WIRING.
When the Mirror Position Switch DOWN position

is selected, voltage is applied to the Up/Down Motor of
the LH Outside Mirror through CKT 82 (Chevy) or
CKT 89 (Pont), and ground is provided through CKT
88. This will cause the Up/Down Motor to rotate in the
opposite direction and turn the LH Outside Mirror
down.
The Left/Right Motor of the LH Outside Mirror
operates in a similar manner. When the Mirror
Position Switch LEFT po9ition is selected, voltage is
applied to the Left/Right Motor of the LH Outside
Mirror through the CKT 81. Ground will be provided
to the Left/Right Motor by the Outside Mirror Switch
through CKT 82. The Left/Right Motor will run and
turn.the LH Outside Mirror to the left.
When the Mirror Position Switch RIGHT position
is selected, voltage is applied to the Left/Right Motor of
the LH Outside Mirror through the CKT 82 and
ground is provided through CKT 81. This will cause
the Left/Right Motor to rotate in the opposite direction
and turn the LH Outside Mirror to the right.
The RH Outside Mirror is adjusted in the same
way when the Mirror Select Switch is moved to the RH
position, and the appropriate position switch is
operated.
SA - 150 - 0 EL~CTRICAL DIAGNOSIS
RADIO
UN6 OR U1C RADIO WITH UQO (COUPE) OR U62 (CONVERTIBLE)
SEE INTERIOR LIGHTS
HOT AT All TIMES
HEADLIGHT
SWITCH
I - -\- ,
1-
I HEAD
I
I
L--
.SBRN
-
1/P DIMMER
FUSE 13
SAMP
I I
11L
I
-
-- __.
__ .J
CJ
SEE EXTERIOR.LIGHTS
PAGES SA-110-2, 3, 4, 5
OFF
PARK
.5 GRV
.5 VEL
SEE INTERIOR
LIGHTS DIMMING
PAGES SA-117-1, 3
43
-5226
1 ORN
40
5224- -
'",_------'"'_---------------' -------------'"
.............,.........,....,........,....,..........,....,..................._..................,..,.......;;;;........;;;;..............,........,........~~~....... RADIO
.-~~~
ILLUMINATION
(NIGHT CONDITION
INPUT)
ILLUMINATION
(DIMMING INPUT)
BATTERY
IGNITION INPUT
UN~CASSETTE
U1C - COMPACT DISC
! IMPORTANT:
SPEAKER NEGATIVE CONNECTIONS ARE NOT AT GROUND POTENTIAL.
LEFT
REAR
NEG
LEFT
REAR
POS
RIGHT
REAR
NEG
RIGHT
REAR
POS
20
.S BRN
199
.SVEL
LEFT
FRONT
NEG
LEFT
FRONT
POS
RIGHT
FRONT
NEG
RIGHT
FRONT
POS
GROUND
---,r--~::~1-..:---.r----
BARBLESS
TYPE
CONNECTOR
GR~r~
116
STAN
A
201
.SLTGRN
C
200
C240
ANTENNA
.SGRV
118
1 BLK
.5 TAN
SPEAKER,
LEFT
REAR
(tr]
.5 LT BLU
.5 LT GRN
201
115
10
Q
A
(t(]
.5 DK BLU
rn
SPEAKER,
RIGHT
REAR
IMPORTANT:
WITH U62 THE
SPEAKERS ARE
COAXIAL SPEAKERS.
10
Q
A
46
.5 DK GRN
200
650
150 - 1
RADIO
STEERING WHEEL RADIO CONTROLS: UK3
(INCLUDED .WITH UT6 OR UP3 RADIO ONLY)
1/PDIMMER
FUSE 13
5AMP
L-
.5 VEL
.SGRV
43
9
.5 VEL
r---S224
SEE INTERIOR
LIGHTS DIMMING
PAGESSA-117-1,3
.5 GRV
RADIO r'" UT6 - CASSETIE WITH EQ

OR
UP3 DISK WITH EQ
I
I
43
-,
L...--1
.S DK BLU
- - -A
C4 (ONE WIRE
- IN CONNECTOR)
1796
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i C 2 1 7 (BLK)
,~....~
SIR COIL
-~----------------------------------------A
(BLK)
- - - - - - ~ - -. . .- -. . .- - - - - - - - - - - - - - - - - - - - - - ~ -. . .----.STEERING
WHEEL
coiiiTROL S,
RADIO
ILLUMINATION
\VLAMPS
LH
1.~.
\V
RH
1270
294
348
475
715
1180
2370
6980
VOLTAGE CHART (utilized in Charts #17 AND #19)

VOLTAGE MEASURED
FROM
C217
TERM "C" TO GROUND (BACKPROBED
WITH SYSTEM CONNECTED).
VOLTAGE RANGE IN VOLTS
3 BLK
LOW
HIGH
PRE-SET
4.29
4.75
VOLUME(UP)
3.61
4.12
VOLUME (DOWN)
3.07
3.51
PWR
2.50
2.98
AM/FM
1.97
2.41
SEEK(UP)
1.42
1.88
SEEK(DOWN)
.874
1.33
RCL
.285
.779
650
3 BLK
750
SEE PAGE 8A-30

FOR PROPER
HANDLING
PROCEDURES
BUTTON PRESSED
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
SA -
RADIO {CH EVY)

DELCO-BOSE: (UU8 CASSETTE RADIO OR U1T DISC RADIO) WITH U82 SPEAKERS
HOT AT ALL TIMES
HEADLIGHT
SWITCH
rI - - \ - , I
I
1-
HEAD
II
L--
I11L
PARK
.5BR~f
IIPDIMMER
FUSE 13
5AMP
I I
OFF
RADIO
FUSE 17
15AMP
_ _ _ .J
..---s
__ ...J
3 ORN
40
---.
-1
r
;~:;..'.~:,. ,., ":' '
~
:
.
-- - ---- '
AA~r--------------------------,
.5GRY
112 1
111 0 -
~ see INTERIOR
5226
5224. -
LIGHTS DIMMING
1 ORN
PAGESA-1171
ILLUMINATION
(NIGHT CONDITION
INPUD
- - -- -
ILLUMINATION
(DIMMING INPUT)
10
IGNITION INPUT
BATIERY
SYSTEM
POWER
CONTROL
I
.1
I
I
I
I
SPEAKER COMMON CONNECTION IS NOT AT GROUND POTENTIAL.
.35 BRN
19
"
1,
18
.35 DK
BLU
599
.35 DK
GRN/WHT
.,,.
RIGHT
REAR
REAR
20
------17
.,,.
I
----
--- --
' ....
3 ORN
1051
1 BLK
514
360
1051
........
--- -- ........
---.....
RELAY
.,,..,,.
--- '-
----
"
1 BLK
.35 BARE
689
.-...;.r---.....,pi-"""IBOSE
546
'
40
314
- ---
! IMPORTANT:
LEFT
REAR
3 ORN
40
.8 PNK
- - - - -- -
(DELCO-BOSE)
UU8. CASSETIE
UH - COMPACT DISC
SEE FUSE
BLOCK DETAILS
PAGESA-11-8
-------1 J
-------------
__ _
1 ORN
360
1 ORN
1 ORN
.-------------------------SPEAKER/AMP,
LEFT
AUD RIGHT
POWER REAR (BOSE)
REAR
REAR
AUD+
AUD+
AUDIO SIGNAL
GROUND
1 BLK
~-------E
1 BLK
1 BLK
1051
1051
1 BLK
(NOT USED)
1051
3BLK
1051
----111)t:J~----t(
~258
360
360
1051
ELECTRICAL DIAGNOSIS. SA - 150 3
LEFT
FRONT
L-
-S~Ll~- -
~~
RIGHT
FRONT
FRONT
_:~~~~~;;?r 5~~----_-::::::::~
2
.35BAR:f 14 ____
~M_!:!0~ -
- A.!!_D .:_ j
',
,,~~
'
.]STAN
511
.JSLTGRN
'
512
',
)
/I
rn
__ _
------ ------- --- ------- ------ ------- --- --.....
IMPORTANT:
BARE WIRE CKT 514 AND THE
ALUMINUM SHIELD WRAPPED AROUND
THE SPEAKER CIRCUITS STOP
APPROXIMATEL V 10 CM FROM
SPEAKER/AMP CONNECTOR.
TO PROTECT AGAINST INTERFERENCE,
SPEAKER/AMP WIRES ARE TWISTED A
MINIMUM OF 9 TIMES PER FOOT.
,'
I
I
I
I
I
........ ,
~,
'
.......
__ _
I
I
'I
.,, ,,
----- ------- --- ---
I
/
al---------~
.35WHT
513
.35 TAN
.35WHT
513
.35 BARE
511
r'., --"
.35 LTGRN
512
--
514
'
'I
,/1
I
I ,,_
I
I
I
I
I
I
I
I
I
I
I
I
:/,, ... __
I
.,-
'
--
.,
1 ORN
360
... ,,I
-1 ORN
360
+- - ,
A
SPEAKER/AMP,
LEFTFRONT
(BOSE)
----------
~[IJ
AUDIO SIGNAL
GROUND
---o"l:S"F~
(PLUGGED)
(PLUGGED)
1051
1 BLK
1051
---------------------SPEAKER/AMP,
POWER
RIGHTFRONT
-,.,(BOSE)
AUDIO SIGNAL
1 BLK
RADIO (PONTIAC)
UT6 (CASSETTE WITH EQ) OR UP3 (DISC WITH EQ) WITH
UW2 (10 SPEAKER SOUND SYSTEM)
SEE INTERIOR LIGHTS
HOT AT ALL TIMES
HEADLIGHT,- SWITCH
-~ -
I
I
II
1-
HEAD
PARK
L--
,- -
I
I
II IL
OFF
'I:
r - - -1
PAGESBA-110-2,3, 5
- - - - - - - .lSGR7Y
I
I LEFT
1/P FUSE
BLOCK
I-I
I
.J
SEE FUSE
BLOCK DETAILS
PAGE8A118
1,
.S YEL
5210
SEE INTERIOR
LIGHTS DIMMING
PAGE SA-117-3
TO STEERING WHEEL
RADIO CONTROLS
P~~E~~-~5~-~ -
B ---- - - - --- - - - - - - 9
-IL;:;;M;A;,N- (DIMMING 1NPun
15 AMP
UT6-CASSETTEW~~D~~rlL~M-;A;,;- uPl. Disc wiTH EQ (NIGHT coNDmoN

1NPun
COURTESY
FUSE 8
5224 -
SEE POWER
DISTRIBUTION
PAGE 8A-101
.5 GRY
5226
.5 BRN
1/PDIMMER
FUSE 13
SAMP
--.J
.5 BR~
SEE EXTERIOR
LIGHTS
HOT AT ALL TIMES
~N-;;:;O;N;;;T- -
1 ORN
40
- - - - - - 10
-B;;.E~ -
1 ORN
40
! IMPORTANT:
SPEAKER NEGATIVE CONNECTIONS ARE NOT AT GROUND POTENTIAL.
LEFT
LF~N!.; - - - -
RIGHT
.!_R~T .!.
- -
RIGHT
~R~T.;. -
.!,.R~T ,!_ -
AMPLIFIER
- G~U~ - C2!!T~l ~0!!_= !_::)
syQ
.SGR:l18_______ .STA:~01-- .SDKGR:r17 ------.SLTGR:~00 - - - - - - - - - - - - - ST ___

:1S4PNK
1 2
'
l
.5GRY
)
5304----------------------------------------.,,
118
.STAN }
5307-----------------------1111111----------t.,
201
.5 DK GRN
~1
.5 GRY
118
.5 TAN
201
.5 DK GRN-
.SGRY
I
--------------------__ :J,m,
117
.SLTGRN}
----------200--(,
118
.5 DK GRN
.5DKGRN
117
1 BLK
ml~
.SLTGRN
. .- - - - - - - - - . 5511
.STAN
201
SPEAKER,
~
FRONT
MIDRANGE
1 BLK
200
650
5217--,
- - - - - - -...- - - . SPEAKER,
RIGHT
FRONT
MIDRANGE
SPEAKER,
LEFT
FRONT
TWEETER
650
117
3 BLK
650
SEE GROUND
DISTRIBUTION
PAGES BA-14-7, 8, 9
118
.SG*Ay
PSOO
.5 GRY
(1fl
-----SS~0-118---lJU
ANTENNA
'
1 ORN
40
SPEAKER
ASSEMBLY,
LEFT REAR
(IN REAR QUARTER
TRIM PANEL)
~4
I'
I'-
/M
/
T
r--t--r~
I
D
R
A
N
w
E
E
T
E
R
10
R
A
N
SPEAKER
ASSEMIILY,
RIGHT REAR
(IN REAR~
QUARTER
..__ _ _ _ _ _ _ _-"II'_ _ _ _ TRIM PANEL)
..........
~ I/
Ay
I
D
10
..........
A)'
.5 YEL
5302
116
'
'\
.35 PNK
'
.5 GRY
'
.STAN
'
314
118
201
.5YEL
.5 DK GRN
116
117
.5 BRN
.5 LTGRN
199
.5 LT
BLU
200
115
.5 DK
46
BLU
.-----....;;..,;;..._...;;...;;_ _..;...;._ _.;....;..._...;;...;;_ _._.__....;;...;;..._..;....;.._.....;...;;_ _ _ _ _ _ _ _...., AMPLIFIER
~
SUBWOOFERS
ONLY)
RIGHT-
.5 LT BLU1
BLK
B
SPEAKER,
RIGHT REAR
SUB WOOFER
(IN SAIL PANEL)
SPEAKER(il]
LmREAR
SUBWOOFER
(IN SAIL PANEL)
Al
150 5
315
'
SA -
150- 6
RADIO
12110088
LTGRY
AMPLIFIER
PAGE
CAVITY
WIRE COLOR
CKT
ORN
40
POWER FEED FROM COURTESY FUSE 8
BLK
650
GROUND
PNK
314
RADIO SIGNAL - ON
BA-150-5
DKBLU
46
RIGHT REAR SPEAKER FEED (POS)
BA-150-5
10
BRN
199
LEFT REAR SPEAKER FEED (POS)
BA-150-5
11
LTGRN
200
RIGHT FRONT SPEAKER FEED (POS)
SA-150-4, 5
12
TAN
201
LEFT FRONT SPEAKER FEED (POS)
BA-150-4,5
13
LTBLU/BLK
315
RIGHT SUBWOOFER SPEAKER RETURN (NEG)
BA-150-5
14
DKGRN
1795
RIGHT SUBWOOFER SPEAKER FEED (POS)
SA-150-5
15
LTGRN/BLK
1794
LEFT SUBWOOFER SPEAKER RETURN (NEG)
BA-150-5
16
DKBLU/WHT
346
LEFT SUBWOOFER SPEAKER FEED (POS)
SA-150-5
21
LTBLU
115
RIGHT REAR SPEAKER RETURN (NEG)
BA-150-5
22
YEL
116
LEFT REAR SPEAKER RETURN (NEG)
BA-150-5
23
DKGRN
117
RIGHT FRONT SPEAKER RETURN (NEG)
BA-150-4, 5
24
GRY
118
LEFT FRONT SPEAKER RETURN (NEG)
BA-150-4, 5
DESCRIPTION
BA-11-8
'
BA-14-9
C3
150- 7
20
17
12047531
12047530
10-WAV F MICRO-PACK
BLK
4-WA V F MICRO-PACK
BLU
ElDDDDDEJ
[1] [] [1] [I] [] [] [1]
12065873
BLK
RADIO
(PONTIAC)
WIRE COLOR
CKT
GRY
118
8A-150-0,4
TAN
201
LEFT FRONT SPEAKER FEED(POS)
8A-150-0, 4
DKGRN
117
8A-150-0,4
LTGRN
200
8A-150-0, 4
BLK
650
GROUND
8A-14-7, 8, 9
BRN
PARK LAMP FEED
8A-150-0,4
GRY
8A-150-0, 4
PNK
314
(WITH UW2) RADIO SIGNAL ON
8A-150-4, 5
YEL
43
POWER FEED FROM RADIO FUSE #17
8A-150-0, 1, 4
10
ORN
40
8A-11-8
17
LTBLU
115
RIGHT REAR SPEAKER RETURN
8A-150-0, 5
18
DKBLU
46
RIGHT REAR SPEAKER FEED
8A-150-0, 5
19
YEL
116
LEFT REAR SPEAKER RETURN
8A-150-0, 5
20
BRN
199
LEFT REAR SPEAKER FEED
8A-150-0, 5
1796
STEERING WHEEL RADIO CONTROL SIGNAL
8A-150-1, 5
CAVITY
DESCRIPTION
PAGE
C1
C3
C4(WITH UK3)
6
DKBLU
8A -
150- 8
RADIO
(CHEVY)
PAGE
WIRE COLOR
CKT
GRY
118
TAN
201
LEFT FRONT SPEAKER FEED (PCS)
DKGRN
117
LTGRN
200
RIGHT FRONT SPEAKER FEED (PCS)
BA-150-0
BLK
650
GROUND
BA-14-7,8,9
CAVITY
DESCRIPTION
C1 (BASE)
;s,,,
8A-150-0
,:,
BA-150-0
"'
BA-150-0
C1 (DELCO-BOSE)
1
BARE
514
DRAIN WIRE
BA-150-3
TAN
511
SPEAKER SIGNAL LEFT FRONT
BA-150-3
WHT
513
SPEAKER RETURN LEFT AND RIGHT
BA-150-3
LTGRN
512
SPEAKER SIGNAL RIGHT FRONT
BA-150-3
BLK
1051
GROUND
BA-14-10
C1 (ALL RADIOS)
6
BRN
PARK LAMP FE ED
BA-150-0,2
GRY
BA-150-0,2
PNK
314
(WITH U82 ONLY) RADIO SIGNAL - ON
8A-150-2
YEL
43
BA-150-0,2
10
ORN
40
8A-11-8
17
LTBLU
115
BA-150-0
18
DKBLU
46
8A-150-0
19
YEL
116
8A-150-0
20
BRN
199
8A-150-0
C3 (BASE)
C3 (DELCO-BOSE)
17
BARE
514
DRAIN WIRE
BA-150-2
18
DKBLU
546
REAR PRE AMP FEED (RIGHT SIGNAL)
8A-150-2
19
DKGRN/WHT
689
REAR PRE AMP RETURN
BA-150-2
20
BRN
599
REAR PRE AMP FEED (LEFT SIGNAL)
BA-150-2
150 - 9
SPEAKER AMP/ASSEMBLIES
12052848
12064752
BLK
BLK
SPEAKER/AMP,
LEFT AND RIGHT FRONT (BOSE)
CROSS CAR HARNESS TO 1/P HARNESS

BLOWER RESISTOR
SPEAKER/AMP, REAR (BOSE)
COMPONENT
LOCATION
201-PG
Amplifier (part ofUW2
Speaker Option) . . . . . . . . Mounted behind Right Rear Armrest, on Rail ....... . 44 . . .
Antenna . . . . . . . . . . . . . . . . Right rear quarter panel .......................... . 22,25
Bose Relay . . . . . . . . . . . . . . Below center A/C Duct, mounted to SIR Bracket ..... . 22 ...
Headlight Switch . . . . . . . . LH side ofl/P .................................... . 37,38
I/P Fuse Block . . . . . . . . . . . LH side of I/P Carrier, on the side .................. . 8 . . . .
Radio . . . . . . . . . . . . . . . . . . . Center of 1/P Carrier .............................. . 36 . . .
SIR Coil Assembly . . . . . . . Top of Steering Column ........................... . 3,34.
Speaker/Amp, Left Front
(Bose) . . . . . . . . . . . . . . . . . Mounted in left door .............................. . 17 . . .
Speaker/Amp, Rear (Bose)
Mounted in left rear Cargo Compartment trim ...... . 5 ....
Speaker/Amp, Right Front
(Bose) . . . . . . . . . . . . . . . . . Mounted in right door ............................. . 17 . . .
Speaker Assembly, Left Rear
(with UW2 Speakers) . . . Mounted in left Cargo Compartment trim ........... . 5 ....
Speaker Assembly, Right Rear
(with UW2 Speakers) . . . Mounted in right Cargo Compartment trim . . . . . . . . . . 44
Speaker, Left Front
(Base - UQO) . . . . . . . . . . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Front Midrange
(with UW2 Speakers) : . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Front Tweeter
(with UW2 Speakers) . . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Rear
(Base - UQO) . . . . . . . . . . . Mounted in left sail panel . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speaker, Left Rear Subwoofer
(with UW2 Speakers) . . . Mounted in left sail panel . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speaker, Right Front
(Base - UQO) . . . . . . . . . . . Mounted in right door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . .
Midrange (with UW2
Speakers) . . . . .. . . . .. .. . Mounted in right door . .. .. .. .. .. . .. . . .. . .. . . .. .. . . . 17 .. .
FIG.
CONN
83 ..
41, 48
41 . .
66,67
15 ..
65 ..
5,51
202-9
31 ..
8 . ..
20227
202-27
31 ..
202-27
202-21
202-15
202-23
202-16
8
83
31
31
31
8
8
31
31
RADIO
COMPONENT
Tweeter (with UW2
Speakers) ............. .
,
Speaker, Right Rear
(Base - UQO) .......... .
Speaker, Right Rear
Subwoofer (with UW2
Speakers) ............. ,
Radio (UK3) .......... .
C217 (4 cavitie~) ........ .
C240 (6 cavities) ........ .
G200 ................... .
G201
P500
P600
8210
8216.
si11
8221
8224
8226
8258 ....................
8264 ....................
8300 ....................
LOCATION
201-PG
8302 ....................
8304 ....................
8305 ....................
8307 ....................
Mounted in right sail panel ........................ . 44
8511 ....................
83
.,q8
Mounted in right sail panel ........................ . 44 ... 83

,~f '.} "'1;
On Steering Wheel ............................... .

Near base of Steering Column ..................... .
behind kick panel (2 rings,. 2 wires) ..... '.......... .
Near base of RH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (1 ring, 1 wire) ................. .
Between LH door and "A" pillar .................... .
Between RH door and "A" pillar . , ......... , ........ .
1/P Harn, approx 5 cmfrom Convenience, Center (Pont)
1/P Harn, approx 23 cm befon;i DLC breakout
1/P Har;n, approx 4 cm from Instrument Cluster (Pont)
breakout
1/P Harn, approx 4 cm from antenna cable breakout
Cross Car Harn, approx 20 cm from P600 . ............
1/P Harn, approx 15 cm from last rosebud on RH
rocker panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . .
rocker panel .....................................
I/P Harn, approx 8 cm from last rosebud on RH
.
.
rocker panel .....................................
rocker panel ......................................
rocker panel ............... ,,, ....................
rocker panel .............. ......................
Mirror breakout .................................
Cross Car Harn, approx 7 cm from Power
Mirror breakout .................................
','
8510 ....................
CONN
Mounted in right door ............................. . 17 ... 31
8301 ....................
FIG.
2 . . . . 3 ...
34
63
20 ... 37
9
16
9
16
17
31
45 ... 84
45
. ..
84
10
10
10
10
10
10
45
84
17
31
202-27
202-19
202-19
{Perform before beginning

Diagnosis)
6.
System
Radio Inoperative:
1.
2.
3.
4.
150 - 11
For checking a speaker, use a "C" or "D" cell

Battery and momentarily connect and disconnect
it across the circuits to that speaker while
listening for a sli:ght popping sound or watching for
the cone of the speaker to move in and out. If
either happens, the speaker and circuitry are
usually OK.
Check Fuse 8. If open, check for a short to ground
through CKT 40.
Check Fuse 17. If open, check for a short to ground
through CKT 43.
Make sure ground G200 is clean and tight.
Radio Noise:
A noise "sniffer" may be used to aid in troubleshooting

Radio noise, see details on page 8A-150-30. (For
definitions of the different types of Radio noise, refer to
"Noise Entry," page 8A-150-33.)
1. Test the Radio outside with the hood down.
2. Ignition noise on FM indicates a possible defective
High Energy Ignition (HEI) System. Refer to
SECTION 604.
3. Check antenna coax connectors for corrosion or
bad connections.
4. If a test antenna is used, ground the base of the
antenna to the vehicle body.
5. When shielding components, use aluminum foil
tape (nickel tape works best for magnetic
interference) and ground both ends of the shield.
Most noise can be found on weak AM Stations near

low end of Radio band.
7. Coated screws or bolts can act as poor grounds.
8. Most hoses are conductive unless they have a
white stripe.
9. Before removing a speaker, check all accessible
wiring and connectors to that speaker.
General:

continuity/vo 1tage check with a system
SYSTEM DIAGNOSIS
Determine type of audio complaint.
Try to duplicate condition (listen to AM or FM,
start vehicle, put in a good CD or cassette, test
switches, etc.).
RADIO
The purpose of the System Performance Check is
to distinguish between noise or poor reception. Some
noises induced into the system may not be audible but
can cause poor reception.
SYSTEM PERFORMANCE CHECK

ACTION
01
,,,
Ignition in "ACCESSORY" mode, Radio "ON."
[2]
Seek up (88-108 FM) (550-1600 AM) .

Count number of valid Radio Stations tuner stops
at.
Listen for various noise problems .
Ignition "ON," Engine off. Repeat step 2.
Same number of stations are received as above.
Ignition "ON," Engine running. Repeat step 2.
Same number of stations are received as above.
[3]
[4]
NORMAL RESULTS
A certain number of Radler stations will be

received .
Sometimes Radio will stop at dead spots on the
display where there is no audible information.
These dead spots should not be counted as valid
stations.
NOTICE TO TECHNICIANS: Electromagnetic interference (EMI) can cause a fewer number of stations to be
r~ceived in one of the three modes. The EMI can be caused by various vehicle components. This may be the cause
of the differences in reception. Check for components powered up in the three various key positions. This may
eliminate Engine running components, Ignition on components, etc. For example, if the same number of stations
are received with the Engine running as when the Engine was off, the components active with the Engine
running are not causing the interference.
DEVELOPMENT QUESTIONS
If an equal number of stations are counted in all key positions vehicle related, interference is not indicated.
Some vehicle systems may interfere in all key positions.
If noise is determined not to be causing interference, refer to "Poor Reception."
ELECTRICAL DIAGNOSIS 8A - 150 - ,13
[I] Important:
For a better understanding of Retained Accessory Power (RAP) operation, refer to "Retained Accessory
Power (RAP): AU3", page 8A-15-0.
SYMPTOM TABLE
PERFORMANCE COMPLAINTS
?TJ
,,,_,;~~
(Noise or Reception Symptoms}
To distinguish between noise or poor reception, perform the System Performance Check on the previous page.
CHEVY AND PONTIAC

Ui
PROCEDURE
PAGE NUMBER
Radio noise.
Chart #10
SA-150-20
Poor reception.
Chart #4
8A-150-17
Switch pop or Accessory Noise.
Chart #16
8A-150-26
SYMPTOM
CHEVY
Noise in one or more Bose Speaker/Amps, caused by Suppress noise using Capacitor (P/N 1227894) across
suspect component: motor, switch or solenoid.
the use of power options.
Noise from Delco-Bose Speaker/Amps with Radio Check for a stuck Bose Relay or for short to B+
"OFF."
CKT 360 or CKT 314.
in
PONTIAC
Noise caused by the use of power options in Suppress noise using Capacitor (PIN 1227894) across
suspect component: motor, switch or solenoid.
Subwoofer Speakers only (UW2).
HARDWARE RELATED FAILURES

(No Audio, Display Problems, Inoperative Functions, etc.}
CH EVY AND PONTIAC

SYMPTOM
No sound from any speaker, blank digital display.
PROCEDURE
PAGE NUMBER
Chart #1
SA-150-15
No sound from any speaker, digital display operates Check for disconnected connector C3 with major
normally, seek/scan and presets appear to operate wiring damage to front speakers or with balance to
normally (UQO or U62).
rear only. If OK, service Radio.
Display does not dim when Park Lamps or Headlamps Check for open in CKT 9 to the Radio or poor
are turned "ON."
connection at Radio Connector C1 terminal "6". If OK,
service Radio.
Display dimming does not vary when using the 1/P Check for open in CKT 8 to Radio or poor connection
Dimmer Switch (assumes 1/P Dimmer Switch Circuit is at connector C1 terminal "7", refer to "Interior Lights
operating normally elsewhere).
Dimming," page 8A-117-0. If OK, service Radio. Refer
to SECTION 9A.
Cassette Tape Player inoperative.
Chart #5
8A-150-17
-
SA-
150 -14 ELECTRICAL DIAGNOSIS
RADIO
SYMPTOM TABLE
PROCEDURE
SYMPTOM
PAGE NUMBER
Cassette Tape Player weak.
Inspect and clean moving parts. Use a known good

cassette tape to retest. If Cassette Tape Player is still
weak, service Radio. Refer to SECTION 9A.
Compact Disk Player inoperative or skips.
Skipping over hard bumps may occur. Make sure disk

being used is not smudged or scratched. Smudges or a
scratch that is in a circular direction_can cause the laser
to track improperly, causing skiPJling. If excessive
skipping occurs, service Radio. Ref~r to SECTION 9A.
Chart #6
No sound from one speaker (UQO or U62).
::;,,;aA-150-18
Some Radio functions are operational, others are not Service Radio, refer to SECTION 9A.
operational.
Check CKT 40 and connector C1 terminal "1 O" for an
open or poor connection. If OK, service Radio.
Loss of memory.
CHEVY
PROCEDURE
SYMPTOM
Chart #2
No sound from any speaker, digital display operates

normally, seek/scan and presets appear to operate
normally (Delco-Bose).
Chart #7
No sound from one speaker (Delco-Bose).
PAGE NUMBER
SA-150-15
SA-150-18
PONTIAC
Digital Display illuminated, with all Radio functions Check for a short to B + in CKT 1796 (UT6 or UP3 only).
If OK, service Radio. Refer to SECTION 9A.
inoperative.
rn
All lights in Steering Wheel Control Buttons
inoperative (some lights are operational).
Important:
An open in CKT 1796 between DVM measuring
point and Radio will cause a reading of B + with
any button pressed, though there will not be a
short to B + in the circuit.
Chart #3
SA-150-16
One or more lights in Steering Wheel Control Buttons Replace Steering Wheel Radio Controls.
inoperative (some lights are operational).
Compact Disk Radio displays "ERR" for 5 seconds and The Optical Sensor is impaired by moisture or the disk
stays in Radio mode when a disk is inserted.
is in upside down.
No sound from one speaker (UW2).
Chart #8
SA-150-19
Both Subwoofer Speakers inoperative (UW2).
Chart #9
SA-150-19
All Steering Wheel Radio Controls inoperative (or

operate erratically).
Chart #17
SA-150-27
One or more Steering Wheel Radio Controls

inoperative (some controls are operational).
Chart #19
SA-150-31
ELECTRICAL DIAGNOSIS SA -150 - 15
CHART #1
NO SOUND FROM ANY SPEAKER, BLANK DIGITAL DISPLAY
REMOVE RADIO.
DISCONNECT RADIO CONN C1.
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, PROBE RADIO CONN C1 TERM "9".
IS TEST LIGHT "ON"?
CONNECT TEST LIGHT FROM RADIO CONN C1 TERM "10"

TO GROUND,
IS TEST LIGHT ~ON"?
CONNECT A TEST LIGHT BETWEEN RADIO

CONN C1 TERM "5" AND TERM "9".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 40, OR FOR SHORT TO GROUND

THROUGH CKT 40 CAUSING FUSE 8 TO BLOW.
rI
CHECK FOR OPEN IN CKT 43, OR FOR SHORT TO GROUND

THROUGH CKT 43 CAUSING FUSE 17 TO BLOW.
-----------------------------,
1
CHECK FOR POOR CONNEC:TIONS AT RADIO.
IF OK, SERVICE RADIO. REFER TO SECTION 9A. :
L-------------------------------J
CHART #2 {CHEVY)
NO SOUND FROM ANY SPEAKER, DIGITAL DISPLAY OPERATES NORMALLY,
SEEK/SCAN AND PRESETS APPEAR TO OPERATE NORMALLY (DELCO-BOSE)
DISCONNECT BOSE RELAY.

CONNECT TEST LIGHT FROM RELAY CONN TERM "C1 '' TO GROUND.
IS TEST LIGHT "ON"?
CONNECT THE TEST LIGHT FROM RELAY

CONN TERM "C1" TO TERM "A1".
IS TEST LIGHT "ON"?
CONNECT THE TEST LIGHT FROM RELAY

CONN TERM "C2" TO TERM" A 1 ".
IGNITION SWITCH TO "ACCY".
IS TEST LIGHT "ON"?
IGNITION STILL "ON."

RADIO ON WITH VOLUME AT A NORMAL LEVEL.
,e CONNECT A FUSED JUMPER, WITH A 15 AMP FUSE,
FROM BOSE RELAY CONN TERM "C1" TO TERM" A2".
IS RADIO NOW WORKING WITH SOUND EMITTING
FROM SPEAKERS?
CHECK FOR FOR POOR CONNECTIONS AT BOSE RELAY.

IF OK, REPLACE RELAY.
REPAIR OPEN IN CKT 314 OR POOR CONNECTION

TO RADIO AT CONN C1 TERM "8".
CHECK FOR OPEN IN CKT 360 BETWEEN 5308 AND REl,.AY.

IF OK, CHECK FOR POOR GROUND SPLICE AT 5221.
IF ALL ARE OK, SERVICE RADIO.
.
RADIO
CHART #3 {PONTIAC)
ALL LIGHTS IN STEERING.WHEEL CONTROL BUTTONS INOPERATIVE
ARE OTHER INTERIOR LIGHTS OPERATIONAL AND DIMMING PROPERLY?
-------
DISCONNECT CONN C217.

PARK LIGHTS "ON."
TURN 1/P DIMMER SWITCH ALL THE WAY "ON"
(MAXIMUM BRIGHTNESS).
CONNECT A TEST LIGHT ACROSS C217 (HARNESS
SIDE) FROM TERM "B" TO TERM "D".
IS TEST LIGHT "ON"?
RECONNECT CONN C217.

DISABLE THE SUPPLEMENTALINFLATABLE RESTRAINT
SYSTEM (SIR) AND REMOVE AND DISCONNECT INFLA TOR
MODULE FROM STEERING WHEEL.
REFER TO SECTION 9JB, THEN RETURN TO THIS CHART.
CONNECT TEST LIGHT ACROSS COIL SIDE OF BLK 4-WAY CONN
UNDER INFLATOR MODULE FROM TERM "B" TO TERM "D".
IS TEST LIGHT "ON"?
:
1
---------,
REPAIR LIGHTING SYSTEM. :

REFER TO "INTERIOR LIGl'l"l'S I
DIMMING," PAGE 8A-11l;o. :
------------------~-

C217 TERM "B" TO GROUND.
IS TEST LIGHT "ON"?
REPAIR OPEN IN
GROUND CKT 650.
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
CHECK FOR POOR

CONNECTIONS.
IF OK, REPLACE STEERING
WHEEL RADIO CONTROLS.

BETWEEN 5224 AND C217.
CHECK FOR POOR

CONNECTION ATC217
TERM "B" AND TERM "D".
IF OK, REPLACE SIR COIL
ASSEMBLY.

{SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and
ELECTRICAL DIAGNOSIS 8A 150 - 17
CHART #4
rn
POOR RECEPTION
IMPORTANT:
THE SYSTEM PERFORMANCE CHECK SHOULD BE PERFORMED BEFORE CONTINUING WITH THIS CHART.
IF SUBSTITUTING AN ANTENNA OR CABLE, BE SURE TO USE A BARBLESS TYPE CONNECTOR. INCORRECT CONNECTORS MAY CAUSE
POOR RECEPTION OR DAMAGE TO CONNECTORS.
IS THERE A NOISE THAT ACCOMPANIES THE POOR RECEPTION COMPLAINT?
: REFER TO "RADIO NOISE," CHART #10
FM ONLY WEAK?
:=EA~M~A~N~D~F~M~O~R~A~M~O~N~LY~W~E=A~K;;?~-------------~~~B!IEF-=O-=R-=E-=C-=0-=N-=T-=IN-=U~ING WITH THIS CHART.

AM AND FM OR AM ONLY WEAK
FM ONLY WEAK
SUBSTITUTE A KNOWN GOOD ANTENNA.

KEY IN" ACCESSORY" POSITION.
GROUND THE BASE OF THE ANTENNA TO THE VEHICLE BODY OR CHASSIS.
RECEPTION STILL WEAK?
COMPARE FM RECEPTION TO ANOTHER

VEHICLE WITH SIMILAR EQUIPMENT.
TUNE TO A WEAK STATION.
BOTH RADIOS RECEPTION SIMILAR?
. . . - - J L - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ - - - . . - - a - ~ ~ ~ ~ ~ - - , . . . - - J L - ~ ~ ~ ~ ~ ~ ~ ~ ~....... r- --------,
WEAK FM RECEPTION MAY
1
CHECK FOR I
SUSPECT A VEHICLE COMPONENT IS CAUSING THE
REFERTO
HAVE BEEN DUE TO SIGNAL
POOR RECEPTION.
"CHECKING RADIO
:
SERVICE
:
I
BULLETINS. I
STRENGTH, TERRAIN OF THE
TRY AND ISOLA TE A GROUP OF CIRCUITS,
MAST
AREA, ELECTRICAL
ANTENNAS," PAGE
REMOVE FUSES, CIRCUIT BREAKERS OR FUSIBLE
: SERVICE
:
I
RADIO.
I
INTERFERENCE OR
LINKS UNTIL THE RECEPTION IMPROVES.
SA-150-29.
ATMOSPHERIC CONDITIONS.
DID THE RECEPTION IMPROVE?
REPAIR ANTENNA
: REFER TO
:
IL __________
SECTION 9A. J
EXPLAIN TO THE CUSTOMER
SYSTEM AS
THAT THE RADIO RECEPTION IS
NECESSARY.
NORMAL. REFER TO
CUSTOMER TIPS TO HELP
EXPLAIN NORMAL RECEPTION
OR HOW TO ACHIEVE BETTER
rI
RECEPTION. IF POOR
TRY THE FOLLOWING FIXES:
: SERVICE
RECEPTION IS STILL PERCEIVED,
REINSTALL ALL FUSES, CIRCUIT BREAKERS OR
I
RADIO.
:
CONTACT TECHNICAL
FUSIBLE LINKS. DISCONNECT COMPONENTS ON
: REFER TO
:
ASSISTANCE.
THE SUSPECT CIRCUIT UNTIL THE RECEPTION
I
SECTION 9A. 1
IMPROVES.
L----------~
CHECK THE INTEGRITY OF THE COMPONENT
WIRING, INCLUDING ANY COMPONENT GROUND
WIRES. REROUTE ANY COMPONENT WIRING THAT
IS ROUTED WITH THE AUDIO WIRING OR THE
ANTENNA COAX.
CHECK FOR SERVICE BULLETINS.
SERVICE RADIO, REFER TO SECTION 9A.
--------------------------------,r- --------,
----------------------------------J
CHART #5
CASSETIE TAPE PLAYER INOPERATIVE
CHECK PLAYER FOR OBSTRUCTIONS.
NO OBSTRUCTION FOUND
SUBSTITUTE A KNOWN GOOD CASSETTE TAPE.

DOES CASSETTE PLAYER WORK?
OBSTRUCTION FOUND
r1
------------
-----------,
REMOVE OBSTRUCTION.
REFER TO SECTION 9A.
NOTICE: IMPROPERREMOVALMAY :
DAMAGE CASSETTE TAPE PLAYER.

~--------------------------~
I
SERVICE RADIO.
:
REFER TO SECTION 9A. 1
~----------------~
SA-150-18 ELECTRICAL DIAGNOSIS
RADIO
CHART #6
NO SOUND FROM ONE SPEAKER {UQO OR U62)
DISCONNECT SPEAKER.
MEASURE AND NOTE RESISTANCE OF SPEAKER.
IS RESISTANCE APPROXIMATELY 4 Q (FRONT) OR 10 Q (REAR)1
DISCONNECT THE COMBINED RADIO CONNECTORS C1 AND Cl.

CHECK THE SUSPECT CIRCUITS FOR A SHORT TO B + OR GROUND.
ARE CIRCUITS OK?
RECONNECT SPEAKER CONNECTOR.

MEASURE THE RESISTANCE AT THE RADIO CONNECTOR
THROUGH THE SUSPECT CIRCUITS AND SPEAKER.
IS THE RESISTANCE APPROXIMATELY THE SAME AS
WHEN MEASURED RIGHT AT THE SPEAKER?
CHECK FOR POOR CONNECTION AT RADIO CONNECTOR.

IF OK, SERVICE RADIO (IF AVAILABLE, TRY REPLACING SPEAKER
WITH A KNOWN GOOD SPEAKER BEFORE SERVICING RADIO).
REPAIR OPEN OR HIGH RESISTANCE

IN SUSPECT CIRCUITS.
CHART #7 (CHEVY)
NO SOUND FROM ONE SPEAKER {DELCO-BOSE)
IGNITION "ON."
RADIO "ON."
CONNECT TEST LIGHT ACROSS SPEAKER/AMP CONNECTOR TERM" A" TO TERM ''E''
(BACKPROBE CONNECTOR FROM SPEAKER/AMP SIDE OF CONNECTOR).
IS TEST LIGHT "ON"?
RADIOOFF.
REMOVE AND DISCONNECT SPEAKER FROM SPEAKER/AMP HOUSING.
MEASURE RESISTANCE OF SPEAKER.
RESISTANCE BETWEEN .8 Q AND 2 Q?
CHECK AUDIO SIGNAL CIRCUITS FOR OPENS, POOR

CONNECTIONS, OR SHORTS TO GROUND OR TO SHIELD.
ARE THEY OK?
REPLACE SPEAKER/AMP (FOR REAR SPEAKER/AMP IF STILL

NOT OPERATIONAL AFTER REPLACEMENT, SERVICE RADIO).
REPAIR OPEN OR POOR CONNECTION

IN CKT 360 ORCKT 1051.
ELECTRICAL DIAGNOSIS SA 150 - 19
CHART #8 {PONTIAC)
NO SOUND FROM ONE SPEAKER (UW2)
DISCONNECT SPEAKER.
MEASURE AND NOTE RESISTANCE OF SPEAKER.
IS RESISTANCE APPROXIMATELY EQUAL TO RESISTANCE SHOWN ON THE SCHEMATIC (3-10 Q) FOR THAT
SPEAKER? (FOR THE REAR QUARTER TWEETER AND MIDRANGE SPEAKERS WIRED TOGETHER AS PART OF THE UW2
SPEAKER PACKAGE, MEASURE ACROSS EACH SPEAKER COIL SEPARATELY.)
GD
0
DISCONNECT THE COMBINED RADIO CONNECTORS C1 AND C3,

OR THE AMPLIFIER CONNECTOR FOR THE SUBWOOFERS.
CHECK THE SUSPECT CIRCUITS FOR A SHORT TO B + OR GROUND.
ARE CIRCUITS OK?
REPLACE SPEAKER.
GD
E]
RECONNECT SPEAKER CONNECTOR.

MEASURE THE RESISTANCE AT THE RADIO CONNECTOR OR AMPLIFIER
CONNECTOR THROUGH THE SUSPECT CIRCUITS AND SPEAKER.
IS THE RESISTANCE APPROXIMATELY THE SAME AS WHEN
MEASURED RIGHT AT THE SPEAKER?
REPAIR AS NECESSARY.
CHECK FOR POOR CONNECTION AT RADIO OR AMPLIFIER CONNECTOR.

IF OK, SERVICE RADIO OR AMPLIFIER (IF AVAILABLE, TRY REPLACING SPEAKER
WITH A KNOWN GOOD SPEAKER BEFORE .REPLACING RADIO OR AMPLIFIER).
CHECK FOR POOR CONNECTION AT SPEAKER.

IF OK, REPAIR OPEN OR HIGH RESISTANCE IN
SUSPECT CIRCUITS.
CHART #9 {PONTIAC)
BOTH SUBWOOFER SPEAKERS INOPERATIVE (UW2)
DISCONNECT AMPLIFIER CONN.

CONNECT A TEST LIGHT FROM CONN TERM "1" TO TERM "4".
IS TEST LIGHT "ON"?
IGNITION "ON."
RADIO"ON."
USE A DVM TO CHECK
VOLTAGE AT AMPLIFIER CONN
TERM"8".
IS VOLTAGE APPROX B +?
CONNECT A TEST LIGHT FROM TERM "1" TO GROUND.

IS TEST LIGHT "ON"?
IGNITION "OFF."
RADIO "OFF."
DISCONNECT RADIO
CONNECTORS C1 AND C3.
CHECK AUDIO SIGNAL CIRCUITS
FOR OPENS BETWEEN
AMPLIFIER AND RADIO OR FOR
MAJOR WIRING DAMAGE.
TO AMPLIFIER.
IF OK, SERVICE AMPLIFIER.
REMOVE RADIO WHILE LEAVING CONNECTED.

RADIO STILL "ON."
DVM STILL SET ON VOLTAGE, BACKPROBE RADIO CONN C1 TERM "8".
IS VOLTAGE APPROX B +?
CHECK FOR POOR CONNECTION AT Cl TERM "8"

OR FOR SHORT TO GROUND IN CKT 314.
IF OK, SERVICE RADIO.
8A -
150 - 20
RADIO
rn
CHART #10
RADIO NOISE
IMPORTANT:
IF THERE ARE AFTERMARKET COMPONENTS INSTALLED OR IN USE IN VEHICLE THAT MAY BE CAUSING COMPLAINT. REFER TO
CHART #11 THEN RETURN TO THIS CHART.
IF NOISE IS IN CONJUNCTION WITH POOR RECEPTION, GO TO CHART #4, "POOR RECEPTION."
TO DISTINGUISH BETWEEN NOISE OR POOR RECEPTION, PERFORM THE SYSTEM PERFORMANCE CHECK ON PAGE SA-150-12
IF NOISE IS ONLY PRESENT WHEN A SWITCH IS ACTIVATED, REFER TO CHART #16, "SWITCH POP OR ACCESSORY NOISE,"
BEFORE PROCEEDING.
CHECK FOR ANY. TECHNICAL SERVICE BULLETINS ON RADIO NOISE.
PUT RADIO AND VEHICLE IN SIMILAR MODE WHERE NOISE OCCURS (AM OR FM, STATION FREQUENCY, ETC).
IF A VEHICLE SYSTEM IS SUSPECTED, IT SHOULD BE TURNED "ON."
IS NOISE IN ALL SPEAKERS?
PUT IGNITION IN "ACCESSORY."

DOES NOISE OCCUR IN THE" ACCESSORY" MODE?
r- - - - - - - - - - - - - - - ,
: REFER TO CHART #20,
:
1 "HARNESS RELATED
I
: NOISE," PAGE BA-150-32. :
L----------------~
WITH THE IGNITION "ON" AND ENGINE "OFF," DOES THE NOISE APPEAR?
DISCONNECT ANTENNA
COAX FROM RADIO.
IS NOISE STILL PRESENT?
WITH THE ENGINE "ON" AND

THE ENGINE "RUNNING," DOES
THE NOISE APPEAR?
: REFER TO CHART #4, :

: "POOR RECEPTION" :
I PAGE BA-150-17.
1
RECONNECT ANTENNA COAX

TO RADIO.
UNFASTEN RADIO AND LEAVE
CONNECTORS CONNECTED.
WHILE LISTENING TO THE
NOISE: MOVE THE RADIO IN
AND OUT OF ITS ORIGINAL
LOCATION. MOVE
HARNESSES AWAY FROM
RADIO IF NECESSARY.
DOES THE NOISE DISAPPEAR
OR DECREASE WHEN THE
RADIO IS MOVED FROM ITS
ORIGINAL LOCATION?
: REFER TO CHART #13, "RADIO NOISE ENTERING :

: THROUGH HARNESS (BACKWAY NOISE) WHILE :
I ENGINE RUNNING ONLY," PAGE SA-150-23.
1
~------------------------------...1
: REFER TO CHART #18, :

: "RADIO NOISE
I ENTERING THROUGH
: ANTENNA SYSTEM
: (FRONTWAY NOISE),"
I PAGE BA-150-28.
L.--------------...1
r- ----------------,
r- ----------------------,
: REFER TO CHART #11,

:
1 "RADIO NOISE ENTERING
I
: THROUGH RADIO (SIDEWAY :
~NOISE)," PAGE BA-150-21. __
: REFER TO CHART #12, "RADIO NOISE

I ENTERING THROUGH HARNESS
I
: (BACKWAY NOISE)WHILE ENGINE NOT:
~RUNNING)," PAGE BA-150-22. ______ j
ELECTRICAL DIAGNOSIS SA-150- 21
CHART #11
rn
RADIO NOISE ENTERING THROUGH RADIO {SIDEWAY NOISE)

IMPORTANT:
ONLY PERFORM THIS CHART IF SENT HERE FROM CHART #10, "RADIO NOISE."
CHECK FOR TECHNICAL SERVICE BULLETINS RELATING TO RADIO NOISE BEFORE PROCEEDING.
ARE THERE ANY AFTERMARKET ADD-ON COMPONENTS INSTALLED IN VEHICLE? (PHONE, RADAR DETECTOR, ETC.)
r-
------------------
CHECK FOR A TIGHT GROUND G201 OR G200.

CHECK ROUTING OF HARNESSING NEAR AUDIO
COMPONENTS. MOVE AWAY OR REROUTE IF POSSIBLE.
ATTACH A SEPARATE BRAIDED GROUND STRAP FROM
THE CASE OF THE RADIO TO A CLEAN SOLID GROUND.
REMOVE THE ORIGINAL GROUND.
IF NOISE STILL PERSISTS, TRY WRAPPING HARNESS
NEAR RADIO WITH ALUMINUM TAPE (NICKEL TAPE
WORKS BEST). BE SURE NOT TO LEAVE GAPS BETWEEN
THE WRAPS OF TAPE. ADD A BRAIDED GROUND STRAP
IN THE TAPE AT THE BEGINNING AND END OF THE
WRAPPING. ATTACH THE ENDS TO A SOLID GROUND
(ALSO TRY GROUNDING ONLY ONE SIDE OF THE STRAP).
IF NOISE PERSISTS, REFER TO CHART #12, "RADIO NOISE
ENTERING THROUGH HARNESS (BACKWAY NOISE)
WHILE ENGINE NOT RUNNING," OR CHART #13, "RADIO
NOISE ENTERING THROUGH HARNESS (BACKWAY
NOISE) WHILE ENGINE RUNNING ONLY."
:
1
1
I
:
:
I
DISCONNECT COMPONENT.
----------------,
L-------------------------------------~
CHECK FOR ANY HARNESS RUNNING NEAR

AFTERMARKET COMPONENT. MOVE AWAY AS
NECESSARY.
CHECK FOR SOLID GROUND TO COMPONENT.
TRY INSTALLING A FILTER (PIN 1224205) BETWEEN
COMPONENT POWER FEED(S) AND GROU~D.
IF NOISE PERSISTS WHEN COMPONENT IS
PLUGGED IN, CONSULT MANUFACTURER OF
COMPONENT OR LEAVE REMOVED FROMVEHICLE.
REFERENCE SOUND SERVICE GUIDE FOR CORRECT
INSTALLATION OF AFTERMARKET COMPONENTS.
SA -
150 - 22
RADIO
rn
CHART #12
RADIO NOISE ENTERING THROUGH HARNESS (BACKWAY NOISE) WHILE ENGINE NOT RUNNING
IMPORTANT:
BEFORE PROCEEDING:
- CHECK FOR ANY TECHNICAL SERVICE BULLETINS ON RADIO NOISE.
IGNITION IN POSITION WHERE COMPLAINT OCCURS.

RADIO SET TO SIMILAR MODE WHERE COMPLAINT OCCURS.
REMOVE ONE FUSE AT A TIME FROM THE FUSE BLOCKS (DO NOT
REMOVE THE "COURTESY" OR "RADIO" FUSES).
IS NOISE ELIMINATED WHEN A PARTICULAR FUSE IS REMOVED?
NOISE MAY HAVE BEEN DUE TO A POOR

RECEPTION AREA.
REINSTALL ALL FUSES, CIRCUIT BREAKERS,

OR FUSIBLE LINKS.
ONCE THE "NOISY" CIRCUIT HAS BEEN
ISOLATED, IDENTIFY THE "NOISY"
COMPONENT BY DISCONNECTING EACH
COMPONENT ON THAT CIRCUIT UNTIL THE
NOISE STOPS.
CAN NOISE BE STOPPED?

REMOVE THE RADIO GROUND WIRE AND ATTACH A BRAIDED
GROUND STRAP TO THE RADIO CASE. CONNECT THE OTHER
END TO A GOOD CHASSIS GROUND.
REROUTE RADIO SYSTEM HARNESSES AWAY FROM OTHER
VEHICLE WIRING AND ELECTRICAL COMPONENTS. REMOVE
RADIO SYSTEM WIRING FROM HARNESSES WHEN BUNDLED
WITH OTHER VEHICLE WIRING.
ESTABLISH A NEW COMPONENT GROUND IF CURRENTLY
SHARED WITH THE AUDIO SYSTEM. IF ROUTED TOGETHER
WITH AUDIO SYSTEM WIRING, SEPARATE AND SHIELD THE
COMPONENT WIRING. THE WIRING CAN BE SHIELDED BY
WRAPPING IT WITH NICKEL TAPE. BE SURE NOT TO LEAVE GAPS
BETWEEN THE WRAPS OF THE TAPE. GROUND EACH END OF
THE SHIELD BY TAPING A BRAIDED GROUND STRAP TO IT AND
A TT ACHING THE STRAPS TO A GOOD CHASSIS GROUND.
INSTALL A FILTER PACKAGE, 1224205, ONLY ON THE POWER
FEEDS TO THE "NOISY" COMPONENT. INSTALL THE FILTER
WITH THE BLACK LEAD AWAY FROM THE COMPONENT. ALSO
TEST FOR BEST RESULTS WITH THE BLACK LEAD GROUNDED
AND UNGROUNDED.
FOR CDM RADIO'S, USE .47 CAPACITOR ON IGNITION LINE.
REMOVE ANY RADIO INPUT LINE, SUCH AS: DATA LINE, DIM
LINE, POWER ANTENNA LINE, STEERING WHEEL CONTROL LINE,
AND CHECK IF NOISE DISAPPEARS. IF NOISE STILL PRESENT,
CONTACT TECHNICAL ASSISTANCE.
INSTALL A FILTER (P/N 1224205) BETWEEN RADIO CONN C1

TERM "10" AND GROUND.
IF NOISE IS STILL PRESENT, THEN ATTACH A BRAIDED
GROUND STRAP FROM THE RADIO CHASSIS TO NEAREST
GROUND POINT. REMOVE ORIGINAL RADIO GROUND
FROM RADIO CONN C1 TERM "5".
IS NOISE ELIMINATED?
IF DELCO-BOSE SYSTEM,
REMOVE THE BOSE RELAY AND JUMPER
BETWEEN TERMINALS "C1" AND" A2"
OF RELAY CONNECTOR.
IF NOISE IS ELIMINATED, REPLACE
RELAY.
IF NOISE IS. NOT ELIMINATED, SUSPECT
THE RADIO.
IF COMPONENT CAN BE
NOISE FIL TE RED, REFER TO
NOISE SUPPRESSION
COMPONENTS LIST AND
SUPPRESS AS NECESSARY.
IS NOISE ELIMINATED?
NO FURTHER
DIAGNOSIS IS
NECESSARY.
CHECK WIRING
AND GROUND TO
THE COMPONENT.
IF OK, REPLACE
COMPONENT.
ELECTRICAL DIAGNOSIS SA -150- 23
CHART #13
RADIO NOISE ENTERING THROUGH HARNESS (BACKWAY NOISE)
WHILE ENGINE RUNNING ONLY
IMPORTANT:
BEFORE PROCEEDING:
- SERVICE ANY KNOWN DRIVEABILITY PROBLEMS.
- CHECK FOR ANY TECHNICAL SERVICE BULLETINS
ON THIS TYPE OF RADIO NOISE.
SET RADIO TO MODES WHERE NOISE OCCURS.

DISCONNECTGENERATOR4-WAY CONNECTOR.
START ENGINE.
IS NOISE STILL PRESENT1
- - - - - - - - - - - - - - - , r-
-----------------------,
STOP ENGINE AND

REINSTALLGENERATOR
CONNECTOR.
PERFORM CHART #14,
"IGNITION NOISE."
STOP ENGINE.
INSTALLAGENERATORCAPACITOR
(P/N 1227895)TOGENERATOR.
CAPACITOR SHOULD BE INSTALLED
IN PARALLEL BETWEEN THE WIRE
ATTACHED ON OUTPUT STUD IN
:
:
1
L---- -- --- --------.!
BACK OF THE GENERATOR AND

NEAREST GOOD GROUND.
REINSTALL4-WAY CONNECTOR
AND RESTART ENGINE. IF NOISE
PERSISTS, PERFORM CHART #15,
"GENERATOR WHINE (VARIES WITH
ENGINE SPEED)."
~-------------------------
SA -
150 - 24
RADIO
CHART #14
IGNITION NOISE
CHECK FOR LOOSE OR DEFECTIVE SPARK PLUG WIRES.

POOR CONNECTION OR BAD WIRES FOUND?
CHECK SPARK PLUG WIRING FOR PROPER FACTORY ROUTING.

SPARK PLUG WIRE ROUTING GOOD?
CHECK AND CLEAN PLUG WIRE BOOTS AND CAPS FOR SILICONE
GREASE MELTDOWN.
DAMAGED BOOTS OR CAPS OR SILICONE GREASE MELTDOWN?
CHECK AND CLEAN BATTERY CONNECTIONS AND CHASSIS GROUNDS.

BATTERY CONNECTIONS AND CHASSIS GROUNDS OK?
INSTALL P/N 3906145 IN POWER FEED TO IGNITION

COIL (FOR VS VIN P) OR TO ELECTRONIC IGNITION
MODULE (FOR V6 VIN S).
IF NOISE IS STILL PRESENT, ADD A BRAIDED GROUND
STRAP FROM THE CASE OF THE RADIO TO NEAREST
GROUND POINT. REMOVE ORIGINAL RADIO GROUND.
NOISE STILL PRESENT?
r-
-------------~
: CHECK FOR TECHNICAL :

t SERVICE BULLETINS ON t
: IGNITION NOISE .
:
~---------------~
ELECTRICAL DIAGNOSIS SA
150 - 25
CHART #15
GENERATOR WHINE
(VARIES WITH ENGINE SPEED)
IGNITION "OFF."
DISCONNECT GENERATOR COMPLETELY .
START ENGINE .
GJ
RECONNECT GENERATOR .
START ENGINE .
NOISE PRESENT?
:F
ALL ACCESSORIES TO "OFF."

IGNITION SWITCH TO "OFF."
USING DIGITAL MULTIMETER J 39200, MEASURE VOLTAGE FROM NEGATIVE BATTERY
TERMINAL TO GENERATOR CASE .
GREATERTHAN0.1VQC
I:
.
'
CHECK FOR FAUL TY MOUNTING OF GENERATOR TO ENGINE.

MAKE SURE ALL GROUND STRAPS BETWEEN ENGINE AND FRAME ARE CLEAN AND TIGHT.
---------------------,-----------------------------,
:
I
I
I
I
I
:
:
1
LESS
THAN
0.1V
DC
INSTALL BRAIDED GROUND STRAP FROM RADIO RECEIVER CASE TO NEAREST GROUND POINT, REMOVE ORIGINAL RADIO GROUND.
s.
,.:
I
I
L-------------------~
Ge]
: REFER TO CHART #10, "RADIO :

I NOISE.''..PAGE SA-150-20.
1
CHECK GROUND TERM ON BATTERY.

CHECK FOR COATED MOUNTING BOLTS ON GENERATOR BRACKET.
RUN A TEMPORARY SEPARATE BRAIDED GROUND STRAP FROM GENERATOR BODY TO A SOLID GROUNP POINT .
~
r------------------,

INSTALL A FILTER (P/N 1224205) IN THE BATTERY FEED TO THE RADIO AT CONN C1
TERM "10".
TRY INSTALLING THE FILTER WITH THE FOLLOWING VARIATIONS IF NOISE IS NOT
ELIMINATED.
- INSTALL THE FILTER WITH THE SINGLE WIRE SIDE TOWARD THE RADIO AND THE
GROUND WIRE ATTACHED TO A GOOD GROUND.
- REMOVE GROUND TO THE FILTER.
-REVERSE FILTER TO HAVE TWO WIRE SIDE TOWARD RADIO WITH GROUND WIRE
ATTACHED.
- REMOVE GROUND TO THE FILTER.
IF NOISE IS STILL PRESENT, INSTALL ANOTHER FILTER (P/N 1224205) IN THE IGNITION
FEED TO THE RADIO AT CONN C1 TERM "9". INSTALL USING THE SAME
VARIATIONS AS THE FIRST FILTER. IF THE INSTALLATION OF THIS FILTER CAUSES
TURN "ON" OR TURN "OFF" DELAYS OR OTHER NOTICEABLE PERFORMANCE
PROBLEMS, REMOVE IT AND INSTALL A .47 t CAP TO GROUND IN ITS PLACE.
IF NOISE IS STILL PRESENT, CHECK THE CHARGING SYSTEM. RE-FER TO SECTION 603.
IF THE CHARGING SYSTEM IS FUNCTIONING NORMALLY, CHECK FOR TECHNICAL
SERVICE BULLETINS ON GENERATOR WHINE.
CALL TECHNICAL ASSISTANCE.
REMOVE ANY UNNEEDED Fil TERS AFTER REPAIR, BEFORE REASSEMBLING VEHICLE.
1
I
:
:
I
:
t
~------------------------------------------------------~
IF ANY OTHER ELECTRICAL

ACCESSORIES CAUSE RADIO NOISE,
REMOVE THE BRAIDED GROUND STRAP
AND ATTACH THE ORIGINAL RADIO
GROUND TO THE STEERING COLUMN
OR NEAREST GROUND POINT.
RETEST FOR NOISE.
BA -
150- 26
RADIO
CHART #16
SWITCH POP OR ACCESSORY NOISE
(FOR NOISE RELATED TO THE ACTIVATION OR OPERATION OF A SWITCH OR ACCESSORY. FOR EXAMPLE, A POP
WHEN THE BRAKES ARE APPLIED OR A HUM WHEN THE A/C IS USED.)
DOES NOISE OCCUR ONLY WHEN TURNING A SWITCH ON OR OFF?
DETERMINE WHICH ACCESSORY IS CAUSING THE NOISE.

IS A MOTOR NOISE SUSPECTED?
TRY THESE REPAIRS:
CHECK FOR A GOOD GROUND

TO THE MOTOR.
INSTALL A CAPACITOR (P/N

3906145)ATTHE POWER FEED
TO THE MOTOR TO A KNOWN
GOOD GROUND.
TRY THESE REPAIRS:
CHECK THE GROUND CIRCUIT FOR

THE SUSPECT MODULE OR
COMPONE,NT.
REROUTE ANY AUDIO

HARNESSES OR THE ANTENNA
COAX AWAY FROM THE MODULE
OR COMPONENT.
INSTALL A.FILTER PACKAGE

1224205 ONLY IN THE POWER
FEED TO THE MODULE OR
COMPONENT. INSTALL THE
FILTER WITH THE BLACK LEAD
AWAY FROM THE MODULE OR
COMPONENT. ALSO, TEST FOR
THE BEST RESULTS WITH THE
BLACK LEAD GROUNDED AND
UNGROUNDED.
INSTALL A .47 tCAPACITOR IN

THE B + AND IGNITION FEEDS TO
THE RADIO.
IF NOISE IS STILL PRESENT TRY A

. KNOWI\I GOOD MODULE OR
COMPONENT.
.
.
IF NOISE STILL PERSISTS, REFER

TO "BACKWAY/ELECTRICAL
NOISE" CHARTS, THEN IF
NECESSARY CALL TECHNICAL
ASSISTANCE.
rn
TRY INSTALLING A .47 t

CAPACITOR (IN PARALLEL TO
GROUND)ATTHE B+ AND
IGNITION HEDS TO THE.RADIO.
IF NOISE IS STILL PRESENT, TRY
A KNOWN GC)OD MOTOR .
IF NOISE STILL PERSISTS, R.EFER
TO "BACKWAY/ELECTRICAL
NOISE" CHARTS, THEN IF
NECESSARY CALL TECHNICAL
ASSISTANCE.
INSTALLCAPACITOR
(P/N 1227894) AT
LOCATION@.
POP STILL PRESENT?
INSTALLCAPACITOR
(PIN 1227894) AT
LOCATION@.
POP STILL PRESENT?
IMPORTANT:
FOR A BLOWER MOTOR
NOISE INSTALL A "FEED
THROUGH" CAPACITOR
(P/N 3906187) IN THE
POWER FEED TO THE
BLOWER MOTOR.
DETERMINE WHICH SWITCH IS

CAUSING A POP WHEN ACTIVATED.
DETERMINE SWITCH .
CONFIGURATION, SEE F.IGURE 1 OR
FIGURE 2.
INSTALL CAPACITOR (P/N 1227894)
'
.
ATLOCATION .
POP STILL PRESENT?
r-
------------,
CHECK FOR TECHNICAL I

: SERVICE BULLETINS ON :
I SWITCH POP.
1
I
L---------------J
B+
B+
B+
1
USER
ACTIVATOR
----------------,
I
I
I
*
I
I
I
I
SWITCH
I
I
I
.47
----------,
I
I
I
_._
.47
,,-. .47
*
I
@)
.47
---------,
t
_._
Figure 1 - Direct Switch Activated Device
I
I
I
LOAD
...L
.47
_._
I
I
I
I
...L
----.---------,
,,-. .47
__._
Figure 2 Relay Activated Device
CHART #17
ALL STEERING WHEEL RADIO CONTROLS INOPERATIVE (OR OPERATE ERRATICALLY)
IMPORTANT:
AN ADDITIONAL RADIO INPUT TEST CAN BE FOUND ON PAGE SA-150-31.
IGNITION "0111."
RADIO "ON."'!
J ' !:
BACKPROB FftOM CONN C217 TERM "C" TO
GROUND US,!NG J 39200 DVM SET TO VOLTAGE.
MEASURE AND NOTE THE VOLTAGE WHILE
PRESSING EACH OF THE STEERING WHEEL RADIO
CONTROL BUTTONS.
COMPARE THE VOLTAGES TO THE CHART ON
PAGE SA-150-1.
DO THE VOLTAGES CHECK OUT OK?
DISCONNECT RADIO CONN C4 ONLY.

RADIO"ON."
ARE ALL RADIO FUNCTIONS OPERATIONAL AT RADIO?
--- ,------,
,-: SERVICE RADIO. :

I . REFER TO
I
:
SECTION 9A.
:
L------------~
. - - ~ - - - - - - - - - - - - - - - - - r- --------------,
:
'--..---------------------' 1
SERVICE RADIO.
:
L----------------~
-------------------------------.
.......
~-
.A.
t~1,,.
DISCONNECT RADIO CONN C4.

DISCONNECTCONNC217.
CHECK CKT 1796 FOR SHORT TO GROUND.
IS CIRCUIT OK?
CONNECT TEST LIGHT FROM C217

TERM" A" (HARNESS SIDE) TO GROUND.
IS TEST LIGHT "ON"?
r-
------------------- --------------,
DISA~LE THE SUPPLEMENTAL INFLATABLE RESTRAINT :
(SIR) SYSTEM AND REMOVE AND DISCONNECT
I
INFLATOR MODULE FROM STEERING WHEEL(REFER
TO S~CTION 9JB, THEN RETURN TO THIS CHART).
CHEtK CKTS 43 AND 1796 OF TH~SIR COIL ASSEMBLY
FOR OPENS OR SHORTS TO GROUND.
IF OK, REPLACE STEERING WHEEL CONTROLS.
IF STILL INOPERATIVE, SERVICE RADIO.
REFER TO SECTION 9A.
CHECK FOR OPEN IN CKT 1796 BETWEEN C217 AIIID _

RADIO, OR FOR pOOR CONNECTION AT RADIO. ,
IF OK, SERVICE RADIO.
CHECK FOR OPEN IN CKT 43 TO (217

TERM "A", OR FOR OPEN FUSE 17.
IF FUSE 17 IS OPEN, CHECK FOR SHORT
TO GROUND THROUGH CKT 43.
L------------------------------------

see PAGE BA-30

FOR PROPER
HANDLING
PROCEDURES
SA -
150 - 28
RADIO
CHART #18
RADIO NOISE ENTERING THROUGH ANTENNA SYSTEM (FRONTWA Y NOISE)
rn
IMPORTANT:
IF SUBSTITUTING AN ANTENNA OR CABLE, BE SURE TO USE A BARBLESS TYPE CONNECTOR.
INCORRECT CONNECTORS MAY CAUSE POOR RECEPTION OR DAMAGE TO CONNECTORS.
SUBSTITUTE A KNOWN GOOD ANTENNA WHILE USING ORIGINAL CABLE.

GROUND BASE OF ANTENNA TO VEHICLE BODY OR CHASSIS.
SUBSTITUTE A KNOWN GOOD CABLE.

rn
IMPORTANT:
MAKE SURE ANTENNA WAS PROPERLY

MOUNTED AND GROUNDED AND ALL
MOUNTING SCREWS ARE CLEAN AND TIGHT.
IF OK, REPLACE ANTENNA.
LEAD-IN CABLE MUST HAVE A BARBLESS TYPE

CONNECTION AT RADIO.
---------------------,
CHECK ALL (bAX CONNECTORS FOR c0RROSION AND TIGHTNESS.

ORIGINAL ANTENNA CABLE WAS DEFECTIVE OR MAY HAVE BEEN ROUTED
THROUGH AN AREA THAT WAS PICKING UP NOISE. TRY MOVING THE
COAX AWAY FROM OTHER ELECTRICAL COMPONENTS AND THEIR
WIRING ...~ .
IF NOISE COMES BACK WHEN NEW CABLE IS INSTALLED, NARROW IN ON
NOISY AREA AND SHIELD CABLE WITH ALUMINUM TAPE. A NOISE
SNIFFER SHOWN ON PAGE SA-150-30 IS HELPFUL (SEE "CHECKING LEAD-IN
CABLES" BEFORE REPLACING CABLE).
ALSO TRY: REMOVING THE RECEIVER HARNESS GROUND WIRE AND
ATTACHING A BRAIDED GROUND STRAP TO THE RADIO CASE. CONNECT
THE OTHER END OF THE STRAP TO A GOOD CHASSIS GROUND.
IF NOISE PERSISTS, REFER TO CHART #12, "RADIO NOISE ENTERING
THROUGH HARNESS (BACKWAY NOISE) WHILE ENGINE NOT RUNNING."
RETEST FOR A DIFFERENT CAUSE :

OF NOISE, SEE CHART #10,
1
"RADIO NOISE," PAGE SA-150-20.:
IF NO OTHER NOISE IS FOUND,
SERVICE RADIO.
1
L-----------------------4
CHECKING RADIO MAST ANTENNAS
Unplug antenna lead-in at back of Radio and plug

a test antenna into Radio. Make sure test antenna
base is grounded to the vehicle chassis. Do not touch
the mast. Check Radio reception in an area away from
tall buildings, metal structures, power lines,
fluorescent lighting and power tools. Tune to high and
low ends of the dial on both AM and FM, checking
weak and strong station reception.. See "System
Performance Check," page BA-150-12. If reception is
OK, the problem exists with antenna and/or its lead-in
cable. If reception is still poor with test antenna, check
for aftermarket equipment that may be causing
complaint. If OK, service Radio.
C-METAL
CASE
A - TIP FOR RADIO
B - TIP FOR ANTENNA
D-METAL
CASE
Figure 3 Checking Lead-in Cables
CHECKING LEAD-IN CABLES
In case of continued reception or noise complaints,

always check the lead-in with a digital multimeter, see
Figure 3 and Table 1. If long jumper leads are not
available, check center conductor continuity by
jumping the antenna mast to ground and checking for
corttinuity from the center conductor at Radio to
ground.
When checking resistance, cautiously wiggle the
lead-in tip and cable. Consistent readings from
Table 1 should always be obtained. If not, some
portion of the lead-in is intermittent and lead-in
should be replaced. Also try:
1. Running a braided ground strap to the
antenna lead-in.
2. Changing the antenna lead-in.
3. Disconnecting the lead-in to check resistance.
Table 1 Lead-in Cable Resistance Values
Digital Multimeter
probes at points:
Resistance measured
in ohms
AandB
less than 3.5
CandD
less than 0.2
AandD
infinite
CandB
infinite
AandC
infinite
BandD
infinite
8A - 150- 30 ELECTRICAL DIAGNOSIS
RADIO
USE AND CONSTRUCTION OF A NOISE "SNIFFER"
The antenna sniffer can be used along with the
vehicle's Radio to locate "hot spots'' which are
generating Radio noise interference. These "hot spots"
can be found in the harnesses, in the upper part of the
dash or even between the h~od and windshield.
The sniffer can be made from an old piece of
antenna lead-in from a mast or power antenna. The
longer the lead-in the better.
Make the antenna sniffer as shown in Figure 4..
The 2" section with the black coating and braided
shield stripped back becomes the antenna when the
sniffer is plugged into the Radio's antenna socket. It
can then be used to probe and search out "hot spots."
To use the noise sniffer:
1. While listening to the complaint noise,
disconnect the antenna and plug the sniffer
i.nto the antenna socket.
2. Turn the Radio volume up.
3. Search for the noise source, keeping fingers off
the 2" probe.
When checking for noise on a wire, the best results
will be achieved when the sniffer is placed paral~el to
the wire, see Figure 5.
USE AND CONSTRUCTION OF A HAND HELD NOISE
"SNIFFER"
A noise sniffer can be built from a personal
AM/FM stereo cassette player.
EQUIPMENT
Personal AM/FM stereo cassette tape player with
headphones
Four feet of75 ohm antenna coax
One-half inch heat shrink tube the same diameter
as the coax
A drill and bit the same diameter as the coax
Book of matches or hair dryer

Soldering iron and solder
INSTRUCTION FOR THE PERSONAL TYPE RADIO

1. Strip 1/4" off both ends of the coax.
2. Place the heat shrink over one end of the bare
wire. Fasten the heat shrink to the wire by
heating it (a match or a hairdryer).
3. Disassemble the Radio and lbcate the antenna.
4. Disconnect the antenna and fasten the bare end of
the coax to the antenna mount. A soldering iron
may be needed.
5. Feed the coax to the exterior of the Radio. Drill a
feed hole if necessary.
6. Reassemble the Radio.
To use the Radio sniffer, turn the Radio on AM and
select an appropriate station.
INSTRUCTION FOR THE PERSONAL TYPE CASSETIE
1. Strip 1/4" off each end of coax.
2. Disassemble the cassette deck and locate the tape
head.
3. Remove the head and mount one end of the coax to
this point. A soldering iron may be needed.
4. Feed the coax to the exterior of the cassette deck.
Drill a feed hole if necessary.
5. Reassemble the cassette deck.
6. Feed the heat shrink tube through the other end of
the coax. DO NOT FASTEN THE HEAT
SHRINK.
7. Fasten the head to the open end of the coax. Use a
soldering iron.
8. Cover the exposed wires between the head and the
wire by positioning the heat shrink tube and
heating it.
To use the cassette sniffer, push "play." It will
work on the same idea as a metal detector.
WHITE PLASTIC INSULATOR

CENTER CONDUCTOR WIRE
2" OF COAX SHIELD
cur AWAY
Figure 4 - Antenna Sniffer
Figure 5 - Checking for Noise on a Wire
EU~CTRICAL DIAGNOSIS 8A -150 - 31
CHART #19
ONE OR MORE STEERING WHEEL RADIO CONTROLS INOPERATIVE
(SOME CONTROLS ARE OPERATIONAL)
rn
IMPORTANT:
ASSUME ALL FUNCTIONS OPERATE NORMALLY AT RADIO. IF THEY DO
NOT OPERATE NORMALLY, SERVICE RADIO. REFER TO SECTION 9A.'
IGNITION "ON."
RADIO "ON."
BACKPROBE FROM CONN C217 TERM "C" TO GROUND USING J 39200
DVM SET TO VOLTAGE.
MEASURE AND NOTE THE voLTAGE WHILE PRESSING EACH OF THE
STEERING WHEEL RADIO CONTROL BUTTONS.
COMPARE THE VOLTAGES TO THECHART ON PAGE BA-150-1.
DO THE VOLTAGES CHECK OUT OK?
r- --------------,
: SERVICE RADIO.
:
1
L----------------~
RADIO INPUT TEST

1.
2.
3.
4.
5.
DISCONNECT CONN C217.

IGNITION "ON,"
RADIO "ON."
USING SIGNAL GENERATOR 1/PTESTER J 33431-8,
SIMULATE THE RESISTANCES EQUAL TO THE VALUES IN
THE STEERING WHEEL RADIO CONTROLS THAT DO NOT
OPERATE (SEE RESISTANCE CHART).
MOMENTARILY CONNECT THE SIMULA TED RESISTANCES
FROM B + TO C217 TERM "C" (RADIO SIDE).
RESISTANCE CHART
SIMULATED
BUTTON
RESISTANCE FROM
TERM "A"TO
TERM "C" IN OHMS.
PRE-SET .
1270
VOLUME (UP)
1564
VOLUME (DOWN)
1912
PWR
2387
AM/FM
3102
SEEK (UP)
4282
SEEK(DOWN)
6652
RCL
13632
RADIO
CHART #20
HARNESS RELATED NOISE
WITH THE RADIO OFF, INTERCHANGE THE AUDIO LEADS OF A NON-COMPLAINT SPEAKER
WITH THE AUDIO LEADS OF A COMPLAINT SPEAKER AT THE RECEIVER. TURN THE RADIO ON.
DOES THE ORIGINAL COMPLAINT SPEAKER NOW PERFORM NORMALLY?
INSTALL TEMPORARY AUDIO LEADS BETWEEN

THE RECEIVER AND THE COMPLAINT SPEAKER(S).
DOES THIS ELIMINATE THE NOISE?
~-
:
I
:
:
:
I
-----------------------------------------,:
VERIFY THAT THE AUDIO LEADS WERE MAKING GOOD CONTACT

WITH THE RECEIVER, REPAIR IF NECESSARY.
IF NOISE IS RELATED TO THE ACTIVATION OR OPERATION OFA
SWITCH OR ACCESSORY, REFER TO CHART #16, "SWITCH POP OR
ACCESSORY NOISE," PAGE SA-150-26.
IF NOT, SERVICE RADIO.
:
:
:
1
L-------------------------------------------J
INSURE THAT THE AUDIO LEADS ARE MAKING

GOOD CONTACT WITH THE SPEAKER.
ALSO, VERIFY THAT THE NOISE IS NOT A SPEAKER
NOISE BY INTERCHANGING A COMPLAINT
SPEAKER WITH A NON-COMPLAINT SPEAKER.
IF THE SPEAKER IS GOOD, CALL TECHNICAL
ASSISTANCE.
INSTALL NEW AUDIO LEADS.

TRY TO ROUTE THE,NEW LEADS BY THEMSELVES SO
THAT NO INTERFERENCE CAN BE COUPLED ON TO THEM.
NOISE ENTRY
FRONTWA Y NOISE
Any noise which is brought into the Radio system

through the antenna. (Noise can be eliminated by
unplugging the antenna from the back of the Radio.)
Some Causes:
Poor grounding or missing grounds of: the

antenna base; the receiver; some electrical
components; body parts.
Defective or marginal components: relays,
solenoid, switches and electric motors.
Something near the antenna coax or corrosion at
antenna coax connections.
Solutions:
Always verify grounding first. If more than one

component interferes, a poor ground probably
exists.
Pinpoint the source: suppress, shield or replace.
Reroute noisy wires if necessary.
SIDEWAY NOISE
Any noise that enters the audio component by a

radiated field through the component case. (Noise is
reduced or eliminated when slowly removing the audio
component from its fastened location.)
Some Causes:
Noisy wires or hoses behind or on top of the Radio

or antenna coax lead-in.
Solutions:
Suppress or shield the t101Sy wire or hose or

reroute it.
Shield the Radio case.
Use aluminum or nickel tape and ground the tape
whenever shielding. (Nickel tape will also stop
magnetic interference, aluminum will not.)
BACKWA Y NOISE
Noise that enters the audio component through its

wiring harness, most commonly detected in the power
and ground circuits. (Noise that can be heard at
minimum volume and not frontway or sideway noise.)
Some Causes:
Poor grounding of the Radio or of unsuppressed

electrical components.
Poorly routed wires or
Defective suppression of electrical components.
Solutions:
Suppression (capacitors, etc.) preferably can be

installed at the noise source, then at the Radio or
both.
Switch pops are backway noise and best
suppressed using capacitors.
Squeals and buzzes are best suppressed using filter
or generator whine packages.
HARNESS RELATED NOISE
Noise induced into speaker wires or any low level

audio signal wire used as an interconnect between the
various audio components.
Some Causes:
Broken, pinched or shorted audio wires.

Screw through wire harness.
Faulty shield wires.
Solutions:
Localize problem to left, right side, front or back

speaker location. Preferably done by using the
fade and balance controls; if not, try reversing the
speaker leads at the Radio connector.
Check wiring for defects, breaks, pinches or shorts.
Check wiring near known noisy components.
SA -
150- 34
RADIO
CUSTOMER'S TIPS
HOW TO ENJOY FM STEREO
A. Select Stations Within Range - The best FM

fidelity will be obtained from stations within a
10-40 mile range. Beyond that "noise" or "flutter"
may begin to appear due to the "line of sight"
range limitations of FM signals.
SOLUTION: Reduce treble response by moving
the treble control down (or to the left) in fringe
areas. On EQ Radios, slowly slide the lOK control
down.
Finding Stereo Stations

1. Depress AM Stereo-Mono button to inward
2.
3.
position.
Consult directory, or use Seek or Scan.
Watch for stereo light to come on, indicating you
are tuned to stereo.
rn
Important:
After tuning to a stereo stati'on, there is a one or
two second delay before the stereo light
comes on.
WAYS TO REDUCE NOISE

B. Realize Tall Structures Can Interfere - Tall
buildings or hills may cause "shadows" or
cancellation of FM signals (this is similar to the
"ghost" or "flutter" effect seen on television
sometimes when airplanes are flying in the
vicinity). It will sound like a "pop" or momentary
"hiss."
SOLUTION: Reduce the treble or lOK setting to a
lower volume.
C. Interference From Another Station - Although the
circuits in Delco receivers are the most advanced
available, there are rare instances where a station
being listened to will be interfered with by another
station. This only happens when the stations are
on almost the same frequency and certain
geographical criteria are present.
SOLUTION: Select another station or switch to
tape.
HOW TO ENJOY AM
Reception Characteristics
AM stereo does not have the flutter characteristics

of FM (caused by tall buildings, hills, etc.). However,
it is subject to interference from power lines, neon
signs, atmospheric conditions, and unwanted stations.
The stereo light will only come on when tuned to a
clear, noise-free station broadcasting C-QC AM AM
Stereo.
1.
2.
3.
Press AM Stereo button to switch to mono.

Move treble control down.
Tune to a stronger station.
AM STEREO
The AM Stereo-Mono button has no effect on FM

reception.
Most AM Stereo stations broadcast in C-Quam, but
some do not. Check with your local station to
determine compatibility in your area. C-Quam is a
registered trademark of Motorola Inc.
ELECTRICAL DIAGNOSIS SA -150 - 35
\
~:IRCUIT OPERATION
rn
Important:
For Delco-Loe II Anti-theft Feature (available
only on Chevy Ul T Disk Radio option) or for
Radio Features and Controls Operation, refer to
SECTION 9A.
For Theft-Loe Anti-theft Feature (available on
all Pontiac Radio Options UT6, UP3 and UN6) or
Radio Features and Controls Operation, refer to
SECTION 9A.
The Radio receives battery voltage at all times on

CKT 40 from Fuse 8 to keep clock and preset station
memory alive when the Ignition is "OFF." With the
Ignition Switch in "ACCY'', "RUN" or "RETAINED
ACCESSORY POWER (RAP)," voltage is applied to
CKT 43 from Fuse 17 to enable Radio operation.
When the Park Lights or Headlights are turned
"ON," voltage is applied to the Radio on CKT 9 from
the Headlight Switch. When voltage is applied to
CKT 9 at the Radio, the Radio will illuminate the
display. With the Headlights or Park Lights "ON," the
Radio display may be dimmed manually using the 1/P
Dimmer Switch. The 1/P Dimmer Switch varies the
voltage on CKT 8 to the Radio to control display
dimming.
SPEAKERS: BASE (UQO OR U62)
With the Base Speaker System, the audio signals

are amplified within the Radio, and the outputs go
directly to the speakers.
SPEAKERS: DELCO-BOSE
The Delco-Bose Music System uses a relay to

control Battery voltage to three speaker/amps within
the Passenger Compartment. A shielded cable carries
the audio signals from the Radio to the speaker/amps
where the signals are then amplified to drive speakers.
SPEAKERS: UW2 (10 SPEAKER SOUND SYSTEM)
For eight of the systems ten speakers, the audio

signals are amplified within the Radio and the outputs
go directly to the speakers.
The Amplifier is used to drive two subwoofers. The
Amplifier receives all the amplified signals coming
from the Radio. These signals are used to determine
the Amplifier's output to the subwoofers. The
Amplifier has separate power and ground inputs and is
turned "ON" and "OFF" from the control output of the
Radio on CKT 314.
8A - 200- 0 ELECTRICAL DIAGNOSIS

Service Parts Catalog
Component Name Used In Section SA
Reference Name
NC Clutch Diode . . . . . . . . . . . . . . . . . . . . . . . . .
NC Compressor Clutch . . . . . . . . . . . . . . . . . . . .
NC Compressor Relay . . . . . . . . . . . . . . . . . . . . .
NC Evaporator Temperature Sensor . . . . . . . .
NC Refrigerant Pressure Sensor . . . . . . . . . . .
ABS Brake Pressure Valve Solenoid, LF . . . . .
ABS Brake Pressure Valve Solenoid, RF . . . . .
ABS Motor Pack ..........................
ABS Relay ...............................
Adjuster Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Air Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Light Sensor . . . . . . . . . . . . . . . . . . . . .
Amplifier (Part ofUW2 Speaker Option) . . . .
Antenna .................................
Arming Sensor, Dual Pole . . . . . . . . . . . . . . . . . .
Ashtray Lamp (Auto Trans) . . . . . . . . . . . . . . .
Ashtray Lamp (Manual Trans) . . . . . . . . . . . . .
ASR/TCS Relay ...........................
Audio Alarm Module . . . . . . . . . . . . . . . . . . . . . .
Backup Lamp, LH . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Lamp, RH . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Light Switch (V6 VIN S Manual) . . .
Backup Light Switch (VS VIN P Manual) . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Junction Block . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Switch (C41) . . . . . . . . . . . . . . . . . . . . . .
Blower Switch (C60) . . . . . . . . . . . . . . . . . . . . . .
Bose Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Combo Valve (ABS) . . . . . . . . . . . . . . . . .
Brake Switch Assembly (All vehicles, use
lconnonManual) .......................
Brake Transmission Shift Interrupt (BTSI)
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position Sensor (V6 VIN S) . . . . . .
Center High Mounted Stop Light (CHMSL) .
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Anticipate/Cruise Release Switch
(All V6 Manual) . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Start Switch . . . . . . . . . . . . . . . . . . . . . . .
Console Compartment Lamp . . . . . . . . . . . . . . .
Convenience Center . . . . . . . . . . . . . . . . . . . . . . .
Convertible Top Pump Assembly . . . . . . . . . . .
Convertible Top Switch . . . . . . . . . . . . . . . . . . . .
Coolant Fan, Left . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Fan, Primary . . . . . . . . . . . . . . . . . . . . .
Coolant Fan Relay #1 . . . . . . . . . . . . . . . . . . . . .
GroLp
GMSPO #12112421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.510

Not serviceable separately- Compressor, NC . . . . . . . . . . . 9.17
Relay, FWD LMP WRG HARN . . . . . . . . . . . . . . . . . . . . . . 2.485
Switch, NC MDL THERM CYCL . . . . . . . . . . . . . . . . . . . . 9.275
Sensor, NC REFRIG PRESS ..............,,........... 9.275
Valve Kit, BRK M/CYL SOL . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Valve Kit, BRK M/CYL SOL . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Motor Kit, BRK M/CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.647
Relay, ELEK BRK CONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72
Adjuster ASM, ACCEL CONT + CR CONT SERVO
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.454
Relay, FWD LMP WRG HARN . . . . . . . . . . . . . . . . . . . . . . 2.485
Sensor, Daytime Running LP AMB LGT . . . . . . . . . . . . . . 2.485
Amplifier, Low FREQ Audio . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Antenna, RDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.647
Sensor, INFL RST Arming . . . . . . . . . . . . . . . . . . . . . . . . . 14.865
Light Pipe from PRNDL Lamp (part of trim plate)
Standard Part
Relay, ELEK BRK CONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72
Alarm, ST Belt, IGN Key and LPS . . . . . . . . . . . . . . . . . . . . 9.765
Standard Part
Standard Part
Switch, B/U LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.698
Switch, B/U LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.698
Battery, STOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Block, Main WRG JUNC and Fuse . . . . . . . . . . . . . . . . . . . 2.483
Motor, Blower Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.015
Connector, BLO RES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.275
Switch, HTR CONT BLO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.852
Switch, HTR and NC CONT BLO . . . . . . . . . . . . . . . . . . . . 9.275
Relay, RDO RR SPKR WRG . . . . . . . . . . . . . . . . . . . . . . . . . 9.656
Valve, BRK COMB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.69
Switch,S/LPandTRANSCONVCLU ................
4.115
Solenoid, NTRNS SHFT LK CONT . . . . . . . . . . . . . . . . . .

Sensor, CM/SHF Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamp, High MT Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighter, CIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.054
2.383
2.679
9.709
Switch, Clutch PED POSN . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch, M/TRNS CLU Start . . . . . . . . . . . . . . . . . . . . . . . . .
Socket, FRT Console LP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not serviceable - Packard Part
Pump ASM, F/TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, F/TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Kit, ENG COOL Fan (ELEC) . . . . . . . . . . . . . . . . . .
Motor Kit, ENG COOL Fan (ELEC) . . . . . . . . . . . . . . . . . .
Relay, FWD LP WRG HARN . . . . . . . . . . . . . . . . . . . . . . . .
4.054
4.054
10.275
14.481
14.483
1.055
1.055
2.485

Reference Name
Coolant Fan Relay #2 .................... .

Coolant Fan Relay #3 .................... .
Coolant Fan Relay, Primary ............... .
Coolant Fan Relay, Secondary ............. .
Coolant Fan, Right ....................... .
Coolant Fan, Secondary ................... .
Coolant Level Latching Module ............ .
Courtesy Lamp, LR ....................... .
Courtesy Lamp, RR ...................... .
Crankshaft Position Sensor, HI Resolution
(V6 VIN S) ............................. .
Crankshaft Position Sensor, LOW Resolution
(V6 VIN S) ............................. .
Cruise Control Module .................... .
Cruise Release Brake Switch (All with K34) .
Cruise Release Clutch Switch
(VS Manual with K34, 2 pin) ............. .
Data Link Connector (DLC) ............... .
Daytime Running Lights (DRL) Module .... .
Diagnostic Energy Reserve Module (DERM) .
Discriminating Sensor, Forward ........... .
Discriminating Sensor, Passenger
Compartment .......................... .
Distributor .............................. .
Dome Lamp ............................. .
Door Illumination Lamp, LH .............. .
Door Illumination Lamp, RH .............. .
Door Jamb Switch, LH .................... .
Door Jamb Switch, RH .................... .
Door Lock Actuator, LH .................. .
Door Lock Actuator, RH .................. .
Electronic Brake Control Module (EBCM) .. .
Electronic Brake/Traction Control Module
(EBTCM) .............................. .
Engine Coolant Heater ................... .
Engine Coolant Heater Cord .............. .
Engine Coolant Level Sensor (VS VIN P) .. .
Engine Coolant Temperature (ECT) Sensor .
Engine Coolant Temperature Gage Sensor ...
Purge Solenoid Valve ................... .
Control Signal Solenoid Valve ........... .
Express Down Module .................... .
Fog Lamp, Left Front ..................... .
Fog Lamp, Right Front ................... .
Fog Light Relay .......................... .
Fog Light Switch ......................... .
I Group
Relay, FWD LP WRG HARN ....................... .

Motor Kit, ENG COOL Fan (ELEC) ................. .
Motor Kit, ENG COOL Fan (ELEC) ................. .
Module, ENG COOL LVL IND ...................... .
Standard Part
Standard Part
2.485
2.485
1.055
1.055
1.055
1.055
1.203
Sensor, CR/SHF POSN
2.383
Sensor, CR/SHF POSN . . . . . . . . . . . . . . . . . . . . . . . . .

2.383
Module, CRCONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.887
Switch, CRCONT REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.887
Switch, CRCONT REL CLU SW . . . . . . . . . . . . . . . . . . . . . 3.887
Connector, ECM Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53
Module, HDLP Auto CONT . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Module, INFL RST RESV ENGY . . . . . . . . . . . . . . . . . . . . 14.865
Sensor, INFL RST FIEND SH MET . . . . . . . . . . . . . . . . . . 14.856
Sensor, INFL RST PASS COMPT . . . . . . . . . . . . . . . . . . . 14.865
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.361
Bulb, LP DM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.991
Standard Part
Standard Part
Switch, DR Jamb (Double Pole) . . . . . . . . . . . . . . . . . . . . . . 11.95
Switch, DR Jamb (Single Pole) . . . . . . . . . . . . . . . . . . . . . . 11.95
Actuator, FRT SID LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Actuator, FRT SID LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Module, Electronic BRK CONT . . . . . . . . . . . . . . . . . . . . . . . 4.72
Module, ELEK BRAKE CONT . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Heater Cord . . . . . . . . . . . . . . . . . . . . . . . . .
Module, ENG COOL LVL IND . . . . . . . . . . . . . . . . . . . . . . .
Sensor, Coolant TEMP (ENG Unit) . . . . . . . . . . . . . . . . . . .
Sensor, ENG COOL TEMP . . . . . . . . . . . . . . . . . . . . . . . . . .
4.720
1.152
1.152
1.203
1.15
3.682
Valve, EVAP EMISCNSTRPurge SOL VLV .......... .
3.13
Valve, EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67

10.783
Module, P/W CONT . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.991
Bulb, w/Socket, Fog LP . . . . . . . . . . . . . . . . . . . . . . . .
8.991
Bulb, w/Socket, Fog LP . . . . . . . . . . . . . . . . . . . . . . . .
2.485
Relay, FWD LP WRG HARN . . . . . . . . . . . . . . . . . .
Switch, Fog LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
SA -
200 - 2


Reference Name
Forward/Back Motor (AC3 Power Seat) . . . . .

Front Height Motor (AC3 Power Seat) . . . . . .
Fuel Gage Sender .........................
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Prime Connector . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Unit ...........................
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hatch Release Actuator . . . . . . . . . . . . . . . . . . . .
Hatch Release Relay . . . . . . . . . . . . . . . . . . . . . .
Hatch Release Switch . . . . . . . . . . . . . . . . . . . . .
Hazard Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Door Motor, LH . . . . . . . . . . . . . . . . .
Headlamp Door Motor, RH .................
Headlamp, Left ...........................
Headlamp, Right ..........................
Headlight Dimmer Switch . . . . . . . . . . . . . . . . .
Headlight Doors Module . . . . . . . . . . . . . . . . . . .
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Hea,ted Oxygen Sensor, Bank #1 . . . . . . . . . . .
Heated Oxygen Sensor, Bank #2 . . . . . . . . . . .
Heater/Vent/Air Conditioning (HVAC)
Control Assembly . . . . . . . . . . . . . . . . . . . . . . . .
High Beam Headlamp, Left . . . . . . . . . . . . . . . .
High Beam Headlamp, Right . . . . . . . . . . . . . . .
High Blower Relay ........................
Horn Relay ...............................
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn #1 (A note) . . . . . . . . . . . . . . . . . . . . . . . . .
Horn #2 (F note) . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Modulator Assembly . . . . . . . . . . . . .
.1/P Compartment Lamp . . . . . . . . . . . . . . . . . . . .
I/P Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . .
1/P Fuse Block ............................
Idle Air Control ([AC) Valve . . . . . . . . . . . . . . .
Ignition Coil Module (VB VIN P) . . . . . . . . . . .
Ignition Coil (VB VIN P) . . . . . . . . . . . . . . . . . .
Ignition Control Module (ICM) (V6 VIN S) .
Ignition Key Lock Cylinder . . . . . . . . . . . . . . . .
Ignition Key Warning Switch . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inflator Module, Driver . . . . . . . . . . . . . . . . . . . .
Inflator Module, Passenger . . . . . . . . . . . . . . . . .
'Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor . . . . . . .
Isolation Diode (BTSI) . . . . . . . . . . . . . . . . . . . . .
I Grol/p
Motor, D/Seat ADJR (w/GROM and INS) . . . . . . . . . . . . . 11.556

Motor, D/Seat ADJR (w/GROM and INS) ... , . . . . . . . . . 11.556
Sender, Fuel ............................ n......... 3.107
Injector, Fuel Injection ............................. ,. . . 3.3
Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Connector, Fuel Pump ................... - . . . . . . . . . . . 3.9
Relay, F/PMP .......................... ,,, . . . . . . . . . . . . 3.9
See: Fuel Pump or Fuel Sender
Fusible Link Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.965
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.275
Actuator, Deck Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.942
Relay, R/CMPT Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243
Switch, R/CMPT Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243
Flasher, Hazard LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.575
Actuator, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76
Actuator, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76
Sealbeam, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.727
Sealbeam, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.727
Switch, DIMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.459
Modle, HDLP OPG DR ACTR CONT . . . . . . . . . . . . . . . . 2.755
Switch, Headlamp/Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Sensor, HTR OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Sensor, HTR OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Control, Heater and NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.273
Sealbeam, HDLP (High Beam) . . . . . . . . . . . . . . . . . . . . . . 2.727
Sealbeam, HDLP (High Beam) . . . . . . . . . . . . . . . . . . . . . . 2.727
Relay, BLOWER
Relay, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.815
Switch, STRG WHL Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.819
Horn, High Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.81
Horn, Low Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.81
Valve ASM, BRK PRESS MOD (Components Serviceable) 4.73
Bulb, Glove Box LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.991
Switch, 1/P LP DIMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49
Block, Main WRGJUNC and Fuse . . . . . . . . . . . . . . . . . . . 2.483
Valve Kit, TBI Idle Air CONT . . . . . . . . . . . . . . . . . . . . . . . . 3.82
Module, Ignition Coil ...'............................ 2.383
Coil, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Module, IGN Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Cylinder, STRG COL LK and IGN SW . . . . . . . . . . . . . . . . 2.188
Switch, IGN Key Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Switch, IGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.188
Module, INFL RST STRG WHL (Inflator) . . . . . . . . . . . . 14.865
Module, INFL RST I/P (Inflator) . . . . . . . . . . . . . . . . . . . . 14.865
Cluster, INST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.735
Sensor, NCL Air TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
GMSPO #12112421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.510
Component Name Used In Section 8A

Reference Name
Isolation Diode (RAP) .................... .

Isolation Diode (Wipers) .................. .
Keyless Entry Receiver ................... .
Knock Sensor ............................ .
License Lamp ............................ .
Low Beam Headlamp, Left ................ .
Low Beam Headlamp, Right ............... .
Manifold Absolute Pressure (MAP) Sensor .. .
Marker Lamp, Left Front ................. .
Marker Lamp, Left Rear .................. .
Marker Lamp, Right Front ................ .
Marker Lamp, Right Rear ................. .
Mass Air Flow (MAF) Sensor .............. .
Mirror Motor Pack ....................... .
Multi-Function Lever .................... .
Oil Level Sensor ......................... .
Oil Pressure Sensor ...................... .
Outside Mirror, LH ....................... .
Outside Mirror, RH ...................... .
Oxygen Sensor, LH ....................... .
Oxygen Sensor, RH ....................... .
Park Brake Switch ....................... .
Park/Turn Lamp, Left Front .............. .
Park/Turn Lamp, Right Front ............. .
Performance Switch ...................... .
Performance/Traction Control Switch ...... .
Power Door Lock Switch, LH .............. .
Power Door Lock Switch, RH .............. .
Power Mirror Switch ..................... .
Power Seat Actuator Assembly (AC3) ...... .
Power Seat Control Module (AQ9 Power Seat)
Power Seat Motor (AC3) .................. .
Power Seat Switch (AC3) ................. .
Power Seat Switch, Driver (AQ9) .......... .
Power Seat Switch, Passenger (AQ9) ....... .
Powertrain Control Module (PCM) ......... .
Power Window Switch, LH ................ .
Power Window Switch, RH ................ .
PRNDL Illumination Lamp (Auto Trans) .. .
Pump Assembly (AQ9 Power Seat) ......... .
Radio ................................... .
Rear Compartment Lamp ................. .
Rear Defogger Grid ....................... .
Rear Defogger Switch .................... .
Rear Defogger Switch/Timer ..... : ........ .
Rear Defogger Timer/Relay ............... .
I Group
GMSPO #12112422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.510

GMSPO #12112422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.510
Receiver, R/CON DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Sensor, Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.383
Standard Part
Sealbeam, HDLP (Low Beam) . . . . . . . . . . . . . . . . . . . . . . . 2.727
Sealbeam, HDLP (Low Beam) . . . . . . . . . . . . . . . . . . . . . . . 2.727
Sensor, MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Standard Part
Standard Part
Standard Part
Standard Part
Sensor, Mass Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Motor, 0/S RR View MIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Lever, T/SIG, HDLP D/SW, CRCONT ACTR, WSW
and WSWA ....................................... 2.897
Sensor, ENG Oil LVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.516
Sensor, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Mirror, 0/S RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Mirror, 0/S RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Sensor, OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Sensor, OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Switch, Parking BRK Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 4.589
Standard Part
Standard Part
Switch, NTRANS SHFT PRGM . . . . . . . . . . . . . . . . . . . . . . 4.056
Switch, ELEK TRACT CONT . . . . . . . . . . . . . . . . . . . . . . . . 4.710
Switch, DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Switch, DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Switch, 0/S R/CON RR View MIR SEL . . . . . . . . . . . . . . . 10.186
Actuator, 0/Seat ADJR (w/MOT and SUPT) . . . . . . . . . 11.556
Module, P/Seat PNEU CONT . . . . . . . . . . . . . . . . . . . . . . . 11.378
Motor, D/Seat AOJR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.556
Switch, D/Seat AD.JR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.558
Switch,D/SeatPNEUPumpandVLV ............... 11.378
Switch, P/Seat PNE U Pump and VLV . . . . . . . . . . . . . . . 11.378
Controller, PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
Switch, SI WDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.777
Switch, SI WDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.777
Lamp, Instrument PNL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.515
Pump, ST INFL D/Seat PNEU . . . . . . . . . . . . . . . . . . . . . . 11.378
Radio, Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Standard Part
Part of Rear Glass
9.778
Switch, R/WDO DEFG
9.778
Switch, R/WDO DEFG
9.744
Timer, R/WDO DEFG


Reference Name
Rear Dome Light Switch .................. .

Rear Height Motor (AC3 Power Seat) ...... .
Rearview Mirror ......................... .
Retained Accessory Power (RAP) Module ... .
Reverse Lockout Solenoid (VS VIN P Manual)
Seat Belt Switch ......................... .
Secondary Air Injection Pump Assembly ... .
Selector Switch (C41) .................... .
Selector Switch (C60) .................... .
SIR Coil Assembly ....................... .
Solenoid Valve Assembly (AQ9 Power Seat) .
Speaker/Amp, Left Front (BOSE) .......... .
Speaker/Amp, Rear (BOSE) ............... .
Speaker/Amp, Right Front (BOSE) ........ .
Speaker Assembly, Left Rear
(With UW2 Speakers) ................... .
Speaker Assembly, Right Rear
(With UW2 Speakers) ................... .
Speaker, Left Front Midrange
(With UW2 Speakers) ................... .
Speaker, Left Front Tweeter
(With UW2 Speakers) ................... .
Speaker, Left Front (Base - UQO) .......... .
Speaker, Left Rear Subwoofer
(With UW2 Speakers) ................... .
Speaker, Left Rear (Base - UQO) ........... .
Speaker, Right Front Midrange
(With UW2 Speakers) . . . . .
. .......... .
Speaker, Right Front Tweeter
(With UW2 Speakers) ................... .
Speaker, Right Front (Base - UQO) ........ .
Speaker, Right Rear Subwoofer
(With UW2 Speakers) ................... .
Speaker, Right Rear (Base - UQO) .......... .
Starter Motor ............................ .
Starter Solenoid ......................... .
Steering Wheel Controls, Radio (UK3) ..... .
Taillamp, LH ............................ .
Taillamp, RH ............................ .
Taillamp, LH Inboard .................... .
Taillamp, LH Outboard ................... .
Taillamp, RH Inboard .................... .
Taillamp, RH Outboard ................... .
Tail/Stop/Turn Lamp, LH ................. .
Tail/Stop/Turn Lamp, RH ................. .
Tail/Stop/Turn Lamp, LH Inboard ......... .
Tail/Stop/Turn Lamp, LH Outboard ........ .
Tail/Stop/Turn Lamp, RH Inboard ......... .
I Group
Switch, R/CMPT Lid Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243

Motor, D/Seat ADJR (w/GROM and INS) . . . . . . . . . . . . 11.556
Mirror, 1/S RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Module, Retained Accessory Power . . . . . . . . . . . . . . . . . . 10.485
Part of Transmission Exchange Program
Part of Driver's Seat Belt Buckle .......... , . . . . . . . . . 14.875
Pump, SECD Air INJN ................... ~........... 3.66
Switch, HTR CONT SEL . . . . . . . . . . . .. . . . . .. . . . . . . .. . 8.850
Switch, HTR & AIC CONT SEL . . . . . .. . . . . .. . . . . . . . . . 9.275
Coil Kit, INFL RST STRG WHL MDL . . . . . . . . . . . . . . . 14.865
Valve, D/Seat Pneumatic 3 SOL . . . . . . . . . . . . . . . . . . . . . 11.378
Amplifier, RDO FRT SPKR . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Amplifier, RDO RR SPKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Amplifier RDO FRT SPKR . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Speaker, RDO R/Q TR PNL
9.665
Speaker, RDO R/Q TR PNL
9.665
Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665

Speaker, RDO FRT SID (Tweeter) . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT S/D . . . . . . . .. . . . . .. . . .. .. . . . . . . . . . . 9.65
Speaker, RDO QTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT S/D (Tweeter) . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT S/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Speaker, RDO QTR . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 9.65
Speaker, RDO RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Motor, STRTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.041
Switch, STRTR SOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Switch, RDO CONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.649
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
200 - 5

Reference Name
Tail/Stop/Turn Lamp, RH Outboard . . . . . . . . .

Theft Deterrent Module . . . . . . . . . . . . . . . . . . . .
Theft Deterrent Relay . . . . . . . . . . . . . . . . . . . . .
Throttle Position (TP) Sensor . . . . . . . . . . . . . . .
Traction Control Motor Pack . . . . . . . . . . . . . . .
Traction Control Switch . . . . . . . . . . . . . . . . . . .
Transmission Position Switch . . . . . . . . . . . . . .
Turn Flasher ..............................
Turn/Hazard Switch Assembly . . . . . . . . . . . . .
U nderhood Electrical Center . . . . . . . . . . . . . . .
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . .
Washer Pump Motor ......................
Wheel Speed Sensor, Left Front . . . . . . . . . . . . .
Wheel Speed Sensor, Left Rear . . . . . . . . . . . . .
Wheel Speed Sensor, Rear . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor, Right Rear . . . . . . . . . . . .
Wheel Speed Sensor, Right Front . . . . . . . . . . .
Window Motor, LH ........................
Window Motor, RH . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Motor Assembly . . . . . . . . . . . . . . . . . . . .
Wiper/Washer Switch Assembly . . . . . . . . . . . .
Group
Standard Part
Module, Theft DTRNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Relay, The,ft DTRNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Sensor, Throttle Position (EFI) . . . . . . . . . . . . . . . . . . . . . . 3. 764
Motor Kit, ELEK TRACT CONT . . . . . . . . . . . . . . . . . . . . . 4.730
Switch, ELEK TRACT CONT . . . . . . . . . . . . . . . . . . . . . . . . 4.710
Switch, Park/NEU POSN . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.054
Flasher, T/SIG LP .................................. 2.892
Switch, T/SIG ...... '.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.895
Pa.rt of Harness, U/Hood LP WRG . . . . . . . . . . . . . . . . . . . . . 8.89
Sensor, VEH SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Pump, WSWA ..................................... 10.153
Sensor, WHL SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Sensor, WHL SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.710
Wheel, RR WHL SPD SEN Reluctor
Sensor, WHL SPD .................................. 4.710
Sensor, WHL SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Motor, FRT SID WOO REG . . . . . . . . . . . . . . . . . . . . . . . . . 10.783
Motor, FRT SID WOO REG . . . . . . . . . . . . . . . . . . . . . . . . . 10.783
Motor, WSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.150
Switch, WSW and WSW A . . . . . . . . . . . . . . . . . . . . . . . . . . 10.163
SA - 201
-0

BRAKE/CLUTCH
PEDAL BRACKET
CRUISE RELEASE/
BRAKE SWITCH
CLUTCH
PEDAL
I
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH
(V6 VIN S)
CRUISE RELEASE/
CLUTCH SWITCH
(VS VIN P)
CLUTCH JUMPER
HARNESS
Figure 1 - Under LH Side of 1/P
CLUTCH JUMPER
HARNESS
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH CONNECTOR
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH CONNECTOR
C270
&L32 &M49 &K34
&L32 &M49 EXC K34
FORWARD
LAMP HARNESS
[I] IMPORTANT:
LT1 &MM6 WITHOUT K34,

DOES NOT HAVE A CLUTCH
JUMPER HARNESS.
FORWARD
LAMP HARNESS
&M30 &K34
CRUISE RELEASE/
CLUTCH SWITCH
CONNECTOR
&LT1 &MM6 &K34

Figure 2 - Clutch Jumper Harness Combinations - Manual {M49 or MN6)
-1
SA -
201 - 2
INFLATOR MODULE,
DRIVER CONNECTOR
STEERING WHEEL
CONTROLS, RADIO
CONNECTOR
STEERING WHEEL
ASSEMBLY
STEERING WHEEL ..__ _ _~

CONTROLS, RADIO
Figure 3 - Steering Wheel Controls {Pontiac)

STEERING WHEEL
ASSEMBLY
INFLATOR MODULE,
DRIVER CONNECTOR
VIEWA
INFLATOR MODULE,
DRIVER
Figure 4 - Steering Wheel Controls {Chevy)
,.,,
>
_,
...1m
o:E
vw
<(
co
cr:::11'1
_11'1
v,c(
"'0~
z
c(
....
\\ ~:)
\',\ '/
\\
,-_
ii:
b
....ww
>
_,
IQ
\\'
o:E
cr:::w
\\
--v-
:::c:::c
~t:
::::>~
1-11'1
Cl
;:;
er:
w
Z
>c
E
::::,
0
v
C'I
;:
I
\
'
\\
'
11'1
~\'
\\ \ " "
.
,\A > '"it 'd/
'
'I\
')
ffi1!111'1
:::c
~~
1=:c
~11'1
, \, ,I
'\
,J
w>-:av
~
,..,,
',
cu
....cu
2v
z:::c
11'1
... t:t:
z::
in
...cu::::,
....C'I
~11'1
~t . ,.\~,'\
rl,
>\
;::;:~'
\
.
:
'
~~~
~
~
~
~:,
~g -
I
\\.
\
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Wz
Ov
>
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&
c(ll'I
Nll'I
c(c(
/,/"/
"'
c...
....cu
SA - 2.01 - 4 ELECTRICAL DIAGNOSIS
DOME LAMP
CONNECTOR
ROOF
PANEL
Figure 6 Center Rear on Roof Panel (Coupe)
REAR DEFOGGER
GRID CONNECTOR
(LEFT SIDE)
C420
Figure 7 Bottom Side of Hatch, Shown Upside Down (Coupe)
SPEAKER. LEFT REAR

CON.N (WITH BASE UQO)
SPEAKER. LEFT REAR
SUBWOOFER CONN
(WITH UW2)
SPEAKER ASSEMBLY,
LEFT REAR CONNECTOR
(WITH UW2)
.
SPEAKER/AMP. REAR
CONNECTOR (WITH U82)
Figure 8 - LH Rear Quarter Panel
1/PWIRING
HARNESS
FUEL TANK
UNIT JUMPER
Figure 9 - Forward of LH Side of Rear Axle
-5
8A-
5301
Figure 10 -.RH Rocker Panel
#2 FLOOR
PAN RAIL
Figure 11 LH Rocker Panel
DAYTIME RUNNING
LIGHTS (DRL) MODULE
1/PWIRING
HARNESS
HVACDUCT
Figure 12 - Under Center of 1/P
HINGE
PILLAR
Figure 13- Behind LH Dash Mat
201 7
8A
201 8
ELECTRONIC..BRAKE
OR
ELECTRONIC BRAKE/
TRACTION CONTROL
MODULE (EBCTM)
LH HINGE
PILLAR
Figure 14 Under LH Side of 1/P
DAYTIME RUNNING
LIGHTS (DRL)
MODULE
/:'L>
THEFT DETERRENT
MODULE
Q~O.
l,,.'TO
~~:.i,)'
DIAGNOSTIC
ENERGY RESERVE
MODULE (DERM)
Figure 15 Rear View of 1/P Carrier
ELECTRICAL DIAGNOSIS SA 201
G201
G200
1/PWIRING
HARNESS
1/PWIRING
HARNESS
CROSS CAR HARNESS
Figure 16 1/P Grounds (Chevy shown Pontiac similar)
.............
(FOR A MORE GENERAL
VIEW OF THIS AREA
REFER TO FIG. 84
PAGE 8A20145)
RETAINED ACCESSORY
POWER (RAP) MODULE
Figure 17. Center of Dash Mat Above Floor Tunnel
SA -
201 10
WIPER MOTOR
BRACKET
~.......-WIPER MOTOR
ASSEMBLY
,___r~~
VIEWA
Figure 18 - Inside LH Side of Cowl
FORWARD
LAMP
HARNESS
FUSIBLE
LINKS
Figure 19 RH Wheelhouse
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _JE}L~EC~T~RlllCCAL DIAGNOSIS 8
OIL PRESSURE
SENSOR
OIL LEVEL
SENSOR
LEFT FRONT
FRAME RAIL
SECONDARY
AIR INJECTION
PUMP ASSEMBL y
G109
A-201
- 11
.
SA - 201
- 12
_;___
nF.
AIR PIPE
S107
Figure 22 - Rear of Engine (V6 VIN S)
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
EXHAUST GAS
RECIRCULATION (EGR)
SOLENOID VALVE
VACCUM CONTROL
SIGNAL SOLENOID
VALVE
OXYGEN
SENSOR, RH
Figure 23 - Top Rear RH Side of Engine (V6 VIN S)
CAMSHAFT POSITION
SENSOR CONNECTOR
(HARNESS SIDE)
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
CAMSHAFT POSITION
SENSOR PIGTAI.L
OXYGEN
SENSOR, LH
Figure 24- LH Side of Engine (V6 VIN S)
Figure 25 - Lower Front of Engine (V6 VIN S)
SA-
201 14

GENERATOR
GENERATOR
CONNECTOR
A/C COMPRESSOR
CLUTCH CONNECTOR
Figure 26 Front RH Side of Engine (VS VIN P)
Figure 27 Top Front RH Side of Engine (VS VIN P)
PCM BRACKET
VIEWA
Figure 28 - Right Rear of Engine Compartment

ENGINE COOLANT
TEMPERATURE
GAGE SENSOR
MODULE
G102
. e of Engine
. cva VINP)
Figure 29 Font
r . LHS1d
POWER DOOR
LOCK SWITCH, LH
CONNECTOR
POWER MIRROR
SWITCH CONNECTOR
OUTSIDE
MIRROR, LH
CONNECTOR
DOOR LOCK
ACTUATOR, LH
CONNECTOR
SPEAKER,
LEFT FRONT
TWEETER (UW2)
CONNECTOR
Figure 31 - Behind LH Door Trim (RH Door Similar)
FORWARD LAMP
HARNESS
Figure 32 RH Side of Front Fascia (LH Similar)

POWER DOOR
LOCK SWITCH. LH
FRONT Of.
VEHICLE
Figure 33 - LH Door Armrest (Chevy)

POWER DOOR
LOCK SWITCH. LH
Figure 34 - LH Door Armrest (Pontiac)
ELECTRICAL DIAGNOSIS 8A- 201 - 19
A/C REFRIGERANT
PRESSURE SENSOR
ENGINE COOLANT
HEATER CORD
(V6 VIN S)
ENGINE COOLANT
LEVEL SENSOR
FORWARD
LAMP
HARNESS
HORN #2
(F NOTE)
Figure 35 - Engine Compartment
ENGINE COOLANT
HEATER CORD
(VS VIN P)
CRUISE
CONTROL
MODULE
Figure 36 - Engine Compartment
SA -
201 - 20
A/C EVAPORATOR
TEMPERA TU RE
SENSOR AND PROBE
C240
Figure 37 Behind Lower RH Side of 1/P
DISCRIMINATING
SENSOR,PASSENGER
COMPARTMENT
WHEEL SPEED
SENSOR, REAR
Figure 38 - General Harness Routing View
HEATER/VENT/AIR
CONDITIONING (HVAC)
CONTROL ASSEMBLY
Figure 39 - Center of 1/P {Pontiac)
HEATER/VENT/AIR
CONDITIONING {HVAC)
CONTROL ASSEMBLY
Figure 40 - Center of 1/P (Chevy)
- 21
BA -

THEFT DETERRENT RELAY AND
HATCH RELEASE RELAY
BOSE RELAY
Figure 41 - Behind RH Side of 1/P
BRAKE
TRANSMISSION
SHIFT INTERRUPT
(BTSI) SOLENOID
PARK BRAKE
SWITCH
CONNECTOR
TRANSMISSION
POSITION
SWITCH
Figure 42 - Rear Side Under Console - Automatic (M30)
201 - 23
VIEWS
HEADLAMP
MOUNTING
PANEL
VIEWA
C165
Figure 43 - Headlamp Area (Pontiac)
SA - 201
- 24

S127
HEATED
OXYGEN
SENSOR,
BANK 1
Figure 44 - LH Side of Engine (VS VIN P)
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR
Figure 45 - Front of Engine (VS VIN P)
ELECTRICAL DIAGNOSIS SA 201
- 25
kANTENNA
~~
-f:q9,~,.~
v~/.11ctlt:
;: :-. . ._
ANTENNA
CONNECTOR
FROM HARNESS
WASHER
BO TILE
Figure 46 Front of Vehicle. Forward of Tie Bar
Figure 48 ~ight Rear Quarter Panel
C200C
WHEEL SPEED SENSOR

LEFT FRONT (ABS)
Figure 47 - Inward Side of Steering Knuckle

(Right Side Similar)
CROSS CAR
HARNESS
Figure 49 Between LH Kick Panel and Steering

Column
SA - 201
- 26

EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
INJECTOR#4
INJECTOR #2
MANIFOLD
ABSOLUTE
PRESSURE
(MAP} SENSOR
OIL
PRESSURE
SENSOR
Figure 50- RH Side of Engine (VS VIN P)
TO BACKUP
LIGHT SWITCH
REVERSE LOCKOUT
SOLENOID
Figure 52-Top Front LH Side of Engine (V6 VIN S)
STEERING COLUMN.'
MULTl-FUNCTION
LEVER
Figure 53 - Steering Column
8A - 201
- 28

CRANKSHAFT
POSITION
SENSOR
(LOW RES)
KNOCK
A/C COMPRESSOR
CLUTCH
CONNECTOR
I
,_I
STARTER
MOTOR
0
Figure 54 - RH Side of Engine (V6 VIN S)
WHEEL SPEED
SENSOR. RIGHT REAR
REAR AXLE
RIGHT REAR WHEEL

SPEED SENSOR
CONNECTOR
IDLE AIR CONTROL

(IAC) VALVE
/.
THROTTLE
POSITION (TP) /
SENSOR
"
l /
INTAKE AIR
TEMPERATURE
(IA T) SENSOR
CONNECTOR
Figure 56 - Top Front RH Side of Engine (V6 VIN S)
8A -
201 - 30
5405
5402
5401
C400
--
Figure 57 LH Rear Cargo Compartment
Figure SS LH Rear Cargo Compartment (Convertible)
S440
REAR FASCIA
LICENSE LAMP
MARKER LAMP,
LEFT REAR
Figure 59 - Rear Fascia
1/PCARRIER
HATCH RELEASE
SWITCH
1/P HARNESS
Figure 60 Behind 1/P Compartment Door (Chevy)
8A - 201
- 32

TAIL/STOP/TURN
LAMP, RH
BACKUP LAMP, LH
TAILLAMP,
LHOUTBOARD
P400
C430
RR FASCIA HARNESS
REAR FASCIA
Figure 61 - Rear of Vehicle (Chevy)
BACKUP LAMP, LH
TAIUSTOP/TURN
LAMP, RH INBOARD
TAIL/STOP/TURN
LAMP, LH INBOARD
BACKUP
LAMP, RH
TAILLAMP, LH
TAIL/STOP/TURN
LAMP, LH OUTBOARD
P400
RR FASCIA HARNESS
REAR FASCIA
Figure 62 - Rear of Vehicle (Pontiac)
- 33
TAIUSTOP/TURN
LAMP, RH OUTBOARD
SA - 201
34
1/PWIRING
HARNESS
SIR COIL
ASSEMBLY
CONNECTOR
Figure 63 - Bottom of Steering Column
ELECTRICAL DIAGNOSIS SA-201-35
IGNITION SWITCH
Figure 64- Bottom o f Steering Column
C2
8A -
201 36
C4
Figure 65 - Center of 1/P (Chevy similar)
1/PWIRING
HARNESS
HEADLIGHT
SWITCH
1/PDIMMER
SWITCH
VIEWB
1/PWIRING
HARNESS
REAR DEFOGGER
SWITCH/TIMER
1/P KNEE
BOLSTER
VIEWA
Figure 66 - LH Side of 1/P (Chevy)
BA_
201 _38
1/P KNEE
BOLSTER
VIEWB
1/PWIRING
HARNESS
VIEWA
FOG LIGHT
SWITCH
Figure 67. LH Side of 1/P (Pontiac)
ELECTRICAL DIAGNOSIS SA- 201 - 39
ABS BRAKE PRESSURE

VALVE SOLENOID, RF
S190
S175
Figure 68 - Front LH Side of Engine Compartment
Figure 69 - Lower RH Side of Engine (VS VIN P)
Figure 70 - Inside Left Front Frame Rail
. RH HINGE PILLAR
Figure 71 - Behind RH Kick Panel
KNOCK SENSOR
Figure 72 - Lower RH Side of Engine (VB VIN P)
ADJUSTER ASSEMBL V
AUTOMATIC
TRANSMISSION
CONNECTOR
Figure 73 - RH Side of Automatic

Transmission (M30)
DISTRIBUTOR
Figure 75 - LH Side of Engine (VS VIN P)
C310
'-...:
POWERS~
ACTUATOR
ASSEMBLY
,~
FRONT
HEIGHT
MOTOR
POWER SEAT
SWITCH
Figure 74 - Front of Engine (VS VIN P)
Figure 76 - Bottom of Driver Seat (AC3)
- 41
SA -
201 - 42

HIGH
BLOWER
RELAY
PERFORMANCE/
TRACTION CONTROL
SWITCH
HVAC DUCT
Figure 77 Above Left Side of Floor Tunnel
Figure 79 Center Console (Pontiac)
CIGAR LIGHTER
CONNECTOR
TRACTION
CONTROL
SWITCH
CONNECTOR
TRACTION
CONTROL
SWITCH
CONVERT! BLE
TOP,SWITCH
Figure 78 - Left Side of Upper Console (Chevy)
CONVERTIBLE TOP
SWITCH
CONSOLE
Figure 80 Left Side of Lower Console (Pontiac)
CONVERTIBLE TOP
SWITCH CONNECTOR
(CHEVY)
CIGAR LIGHTER CONNECTOR
ARMING SENSOR,
DUAL POLE
CONNECTOR
TRACTION CONTROL
SWITCH CONNECTOR PONT
Figure 81 LH Side, under Console Automatic (M30)
CONVERT! BLE TOP

SWITCH CONNECTOR
(CHEVY)
CIGAR LIGHTER CONNECTOR

TRACTION CONTROL
SWITCH CONNECTOR (CHEVY)
CREOHIVT OF
ICLE
ARMING SENSOR,
DUAL POLE
CONNECTOR
CONVERTIBLE TOP
SWITCH CONNECTOR
(PONT)
CONSOLE
COMPARTMENT
LAMP
Figure 82 LH Side, under Console Manual (M49 or MM6)
RH REAR
QUARTER
PANEL
SPEAKER, RIGHT REAR

CONNECTOR (WITH
BASE UQO)
SPEAKER, RIGHT REAR
SUBWOOFER
CONNECTOR
(WITH UW2)
AMPLIFIER
(WITH UW2)
SPEAKER ASSEMBLY,
RIGHT REAR CONNECTOR
(WITH UW2)
Figure 83. RH Rear Quarter Panel
ISOLATION
DIODE (RAP)
CROSS CAR
HARNESS
DOOR JAMB
SWI.TCH,LH
CONNECTORS
5264
5261
"""
EXPRESS.
DOWN
MODULE
RETAINED ACCESSORY
POWER (RAP) MODULE (WITH AU3)
COOLANT LEVEL LATCHING
MODULE (WITHOUT
AU3 AND VS VIN P)
(FOR A CLOSE UP VIEW OF

THESE 2 MODULES
SEE FIG. 17
PAGE SA-201-9)
Figure 84 - Dash Panel with Cross Car Harness
L-~~~
~ l-~"~
I
I
L-1
(305
Figure 85 -Under Passenger Seat (AQ9)
- 47
PUMP ASSEMBLY
SOLENOID VALVE
ASSEMBLY
POWER SEAT
SWITCH,.DRIVER
(PASSENGER SWITCH
SIMILAR)
Figure 86 - Under Driver's Seat {AQ9)
C100
ENGINE HARNESS TO
FORWARD LAMP
HARNESS
12065425
10-WAY F METRlPACK 150 SERIES
BLK
CAVITY
WIRE COLOR
CKT
PNK
639
POWER FEED FROM INJECTOR FUSE 9
8A-203,(V6 VIN S),

SA-21-3 (VS VIN P)
459
A/C COMPRESSOR RELAY CONTROL
SA-64-0, 1
A/C COMPRESSOR CLUTCH SOLENOID FEED
SA-64"0, 1
DESCRIPTION
PAGE
..
DKGRN/WHT .
DKGRN
59
LTBLU
832
TRACTION CONTROL ACTIVE
SA,44-3
BRN
436
AIR PUMP RELAY CONTROL
SA-20-5 (V6 VIN S),

BA-21-3 (VS VIN P)
BRN
541
POWER FEED FROM FANS/ACTR FUSE 6
SA-11-12
PNK
239
POWER FEED FROM IGNITION FUSE 11
BA-11-15
DKBLU
473
SA-31-1,2
DKGRN
335
SA-31-0, 1,2
PNK
839
SA-20-3 (V6 VIN S),

BA-21-3 (VS VIN P)
C110
ENGINE HARNESS (V6 VIN S)
TO INJECTOR JUMPER
HARNESS
12065425
10-WAY F METRI-PACK 1 SO SERIES
BLK
CAVITY
WIRE COLOR
CKT
BLK
1744
FUEL INJECTOR #1 OUTPUT
8A-20-3
LTGRN/BLK
1745
8A-20-3
PNK/BLK
1746
8A-20-3
LTBLU/BLK
844
8A-20-3
BLK/WHT
845
8A-20-3
YEL/BLK
846
8A-20-3
PNK
639
8A-20-3
PNK
839
8A-20-3
BLK
470
SENSOR REFERENCE GROUND
8A-20-4
YEL
410
COOLANT TEMPERATURE SENSOR SIGNAL
8A-20-4
DESCRIPTION
PAGE

1/P HARNESS TO FORWARD
C200D
E13
DDDDDDDDDDDDDEl
:: _:_::__::
~
~:
.
I
:~
==:::
1_1_.....I
::
:=:
.._I___.I I II I
II
mDDDDDDDDDDDD DODD DA,
B6
12077822
Bl
M CONNECTOR
F TERMINAL
48-WAY M METRI-PACK MIXED SERIES
BLK
(200A

1/PHARNESS
c1mDDDDDDDDDDDD DODD DA,I

\
12047842
BLK

.1/P HARNESS
C200B
Bl
cil
DI
__11__
1_1__1_1__
11
1_1__
11
1_1__
11
__1_1__H
__1_1_ ...II
86
I
I
C6
06
12084183
BLK

1/P HARNESS
C200C
IAlDDDDDD DODD DDDA13l

\
12047840
GRY
202 - 3

CAVITY
WIRE COLOR
CKT
A1
DKGRN/WHT
817
VEHICLE SPEED SIGNAL TO CRUISE CONTROL MODULE
SA-33-0
A2
ORN/BLK
463
t~ACTION CONTROL SYSTEM SPARK RETARD
SA-44;-3
A~
LTGRN
8fi7
ABS FAILURE FEED TO 1/P SOLID STATE
SA-81-1
A4
.YEL
820
CENTER HIGH MOUNTED STOPLAMP FEED
SA-34-1
AS
TAN/WHT
33
BRAKE INDICATOR WARNING SIGNAL
A7
DKGRN
29
HORN FEED
8A-4Q-O
AS
TAN/BLK
464
TRACTION CONTRQL SYSTEM THROTTLE PO,SITiON
SA-44-3
A9
DKBLU
1537
"LOW TRAC" INDICATOR CONTROL
8A-81-3
A10
BLK
884
LEFT REAR, WH.EEL SPEEQ SENSOR SIGNAL
8A-44-4
A11
RED
885
LEFT REAR, WHEEL SPEED SENSOR RETURN ..
DESCRIPTION
PAGE
SA-44-0
'
SA-44-4
'
A12
TAN
800
SERIAL DATA SIG,NAL
A13
BRN/WHT
1571
TRACTION CONTROL S.YSTEM SWITCH SIGNAL
SA-44-4
A14
WHT
883
REAR WHEEL SPEED SfNSOR RETURf)I

{WITH NW9) RIGHT REAR WHEEL SPEEDS.ENSOR RETURN
SA-44-1
SA-44-4
A15
BRN
882
REAR WHEEL SPEED SENSOR SIGNAL

{WITH NW9) RIGHT REAR WHEEL SPEED SENSOR SIGNAL
SA-44-1
SA-44-4
A16
YEL
317
FOG LIGHTS ON RELAY FEED
SA-100-1, 3
A17
YEL/BLK
68
LOW COOLANT INDICATOR - LATCHED GROUND
SA-81-3
81
PNK
SA-50~0
.,
SA-10-3
..
IGNITION SWITCH OUTAUT- HOT IN RUN AND CRANK
..
82
ORN
300
IGNITION SWITCH OUTPUT - HOT IN RUN
SA-10-3
83
PPL
34
FOG LIGHTS ON INDICATOR FEED {PONT)
SA-100-3
84
RED
202
BATTERY FEED FROM FUSIBLE LINKA
SA-63-0
85
YEL
10
HEADLIGHTS ON OUTPUT
SA-100-0,2
86
RED
702
BATTERY FEED FROM FUSIBLE LINK Z
SA-10-1
C1
RED
102
BATTERY FEED FROM FUSIBLE LINKE (DOUBLE WIRE)
SA-10-2
C2
RED
1002
13ATTERY FEED FROM FUSIBLE LINK F (DOUBLE WIRE)
SA-10-1
C3
LTGRN
11
HI BEAM HEADLAMP POWER FEED
SA-100-0, 2
C4
PPL/WHT
1572
"ASR" (CHEVY) OR "TCS OFF" {PONT) INDICATOR CONTROL (DOUBLE WIRE ON PONT),
SA-44-2
cs
YEL
IGNITION SWITCH OUTJ>UT- CRANK
SA-10-3
C6
BRN
IGNITION SWITCH OUTPUT- ACCESSORY {DOUBLE WIRE)
SA-10-2
01
BLKIWHT
1751
SUPPLEMENTAL INFLATABLE RESTRAINTS GR(,)UND {DOUBLE WIRE)
SA-47-1
02
OK GRN
348
SUPPLEMENTAL INFLATABLE RESTRAINTSJNFLATQR OUTPUT (DOUBLE WIRE)
SA-47-1
03
YEL
143
WIPER/WASH FUSE 14 OUTPUT
BA-11-9
04
BRN
PARK LAMPS FEED
SA-110-2, 3
05
LTBLU
14
LEFT FRONT TURN SIGNAL LAMP FEED
SA-110-2, 3
06
DKBLU
15..
RIGHT FRONT TlJRN SIGNAL LAMP FEED
SA-110-2, 3
E1
WHT
156
COURTESY LAMP OUTPUT (SWITCHED GROUND)
BA-114-0, 1
..
SA -
202 - 4

CAVITY
WIRE COLOR
CKT
E2
BRN
E3
ORN
E4
ES
DESCRIPTION
PAGE
IGNITION SWITCH OUTPUT- ACCESSORY AND RUN
SA-10-2
40
COURTESY FUSE 8 OUTPUT
BA-11-8
RED
102
BATTERY FEED FROM FUSIBLE LINKE
BA-10:2
TAN
159
KEY-IN-IGNITION SWITCH OUTPUT
BA-76-0
DKBLU
75
RETAINED ACCESSORY POWER RELAY OUTPUT COMMON CONTACT ACCESSORY
SA-15-0
E7
GRY
1/P DIMMER FUSE 13 OUTPUTTO LH AND RH DOOR ILLUMINATION LAMPS
BA-117-1
EB
YEUBLK
68
E9
ORN
640
POWER ACCESSORY FUSE 7 OUTPUT
BA-11-8
E10
PNK
39
GAGES FUSE 9 OUTPUT FOR KEYLESS ENTRY MODULE
SA-11-5
E11
BRN
341
WINDOWS CIRCUIT BREAKER OUTPUT
SA-120-0
E12
PNK
70
RETAINED ACCESSORY POWER COMMON CONTACT IGN 3
BA-15-0
E13
BLK
1576
HATCH RELEASE FEED TO KEVLESS ENTRY MODULE
SA-132-1,3
E6
.,
.LOW COOLANT INDICATOR CONTROL (DOUBLE WIRE)
SA-81-3
C215
fr
~P INIMIL IKI
~ FORWARD LAMP
0 IH IGIF IE IDPJ
~~~~~SJ J~iJ:~:ING
06294509
11 WAY F PACK-CON I
BLK

CAVITY
WIRE COLOR
CKT
DESCRIPTION
VEL
143
A/B
POWER FROM WIPER/WASH FUSE 14/POWER TO WINDSHIELD WIPER MOTOR MODULE

(DOUBLE WIRE)
BA-91-0
DKGRN
113
WINDSHIELD WIPER SWITCH SIGNAL - ON
SA-91-0
GRV
112
WINDSHIELD WIPER SWITCH SIGNAL- LOW/PULSE/MIST
BA-91-0
PPL
92
WINDSHIELD WIPER SWITCH SIGNAL - HIGH
BA-91-0
PNK
94
WINDSHIELD WASHER SWITCH SIGNAL
SA-91-0
GRV/BLK
87
CRUISE CONTROL SWITCH SIGNAL~ RESUME/ACCEL
BA-34-0
DKBLU
84
CRUISE CONTROL SWITCH SIGNAL - SET/COAST
BA-34-0
GRV
397
CRUISE CONTROL SWITCH SIGNAL - ON
SA-34-0
PNK
139
Elf
POWER .F.ROM A/C COMPRESSOR RELAY/POWER TO CRUISE RELEASE SWITCHES

(DOUBLE WIRE), (SINGLE WIRE WITH NW9 AND K34)
SA-34-0
PAGE
202 - 5
(216
1/P HARNESS TO
STEERING COLUMN
HARNESS
12004147
11-WAY F PACK-CON I
BLK

CAVITY
WIRE COLOR
CKT
TAN
159
LTGRN
G
H
H
J
J
DESCRIPTION
PAGE
KEY-IN-IGNITION SWITCH OUTPUT
BA 0 76-0
80
KEY-IN-IGNITION SWITCH TO AUDIO ALARM MODULE
8A-76-0
BLK
28
HORN RELAY FEED (SWITCHED GROUND)
8A-40-0
LTBLU
LTBLU/WHT
14
1414
LEFT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE WIRE)
(WITH T61) LEFT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE
WIRE)
BA-110-0
DKBLU
DKBLU/WHT
15
1415
SA-.110-0
RIGHT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE. WIRE)
(WITH T61) RIGHT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE
WIRE)
8A-110-0
8A-110-0
BRN
27
HAZARD FLASHER OUTPUT
BA-110-0
PPL
16
TURN SIGNAL FLASHER OUTPUT
SA-110-0
YEL
18
LEFT REAR TURN SIGNAL
BA-110-1
DKGRN
19
RIGHT REAR TURN SIGNAL
8A-110-1
LTBLU
20
STOPLAMP FEED
BA-110-0
SA -
202 - 6.
C220
ENGINE HARNESS
TO 1/P HARNESS
12064769
WHT
**CAVITIES NOT LISTEOARE NOT USED

CAVITY
WIRE COLOR
CKT
DESCRIPTION
RED
225
TAN
31
BRN
1174
ORN/BLK
463
TAN/BLK
464
THROTTLE POSITION SENSOR SIGNAL (EBTCM)
SA-44-4
TAN
800
SERIAL DATA SIGNAL
SA-50-0
DKGRN/WHT
817
SA-330
DKBLU/WHT
1493
375
(AUTOMATIC)PERFORMANCE SWITCH SIGNAL

(MANUAL) SKIP SHIFT INDICATOR CONTROL (V8 VIN P ONLY)
SA-39-0
SA-81-3
DKGRN/WHT
465
FUEL PUMP RELAY CONTROL
SA-20-2 (V6 VIN S),

SA-21-2 (VS VIN P) .
DKGRN
135
COOLANT TEMPERATURE FEED TO INSTRUMENT CLUSTER
SA-81-1
PAGE
GENERA TOR FEED TO INSTRUMENT CLUSTER
8A 0 30-1
OIL PRESSURE FEED TO INSTRUMENT CLUSTER
SA-81-0
OIL LEVEL FEED TO INSTRUMENT CLUSTER
8A-8M
SPARK RETARD REQUEST
SA-44-4
ct?~ [i3l. q;J G5l

~ 6J ca 11J cZ:i
ENGINE HARNESS TO
1/P HARNESS
12064871
BLU

CAVITY
WIRE COLOR
CKT
PAGE
LTBLU
553
48
(AUTOMATIC) PERFORMANCE SWITCH INDICATOR CONTROL

(MANUAL) CLUTCH ANTICIPATE SIGNAL (V6 VIN SONLY)
BA-20-7,
BA-39-0
BRN/WHT
419
SERVICE ENGINE SOON INDICATOR FEED
BA-81-3
WHT/BLK
448
DIAGNOSTIC REQUEST SIGNAL
BA-50-0
WHT
121
TACHOMETER SIGNAL TO INSTRUMENT CLUSTER
BA-81-0
DKBLU
229
THEFT DETERRENT- FUEL ENABLE FEED
BA-133-1
DKGRN/WHT
762
A/C REQUEST SIGNAL
BA-64-0, 1
PNK
439
BA-11-5
LT BLU/BLK
583
(AUTOMATIC) TCC SWITCHED POWER FEED
BRN
141
(MANUAL) POWER FROM TURN B/U FUSE #2 TO BACKUP SWITCH
BA-20-6 (V6 VIN S),

BA-21-6 (VB VIN P)
BA-112-0
ORN/BLK
434
LTGRN
24
(AUTOMATIC) PARK/NEUTRAL FEED FROM TRANSMISSION

POSITION SWITCH (VB VIN P ONLY)
(MANUAL) BACKUP LAMP FEED
SA-20-6 (V6 VIN S),

BA-21-6 (VB VIN P)
SA-112-0
TAN/BLK
422
(AUTOMATIC) TORQUE CONVERTER CLUTCH CONTROL
BA-20-6 (V6 VIN S),

BA-21-6 (VB VIN P)
DESCRIPTION

C405B
1/P HARNESS TO FUEL
SENDER/REAR WHEEL
SPEED SENSOR HARNESS
12092789
10-WAY M METRI-PACK 150, 280 SERIES
BLK
C405A
C405C
FUEL TANK UNIT
HARNESS TO
1/P HARNESS
REAR WHEEL
SPEED SENSOR
HARNESS TO
1/P HARNESS
12092859
12092800
4-WA Y F METRI-PACK MIXED SERIES
WHT
BLK

CAVITY
WIRE COLOR
CKT
DESCRIPTION
PAGE
A1
GRY
120
FUEL PUMP MOTOR FEED
SA-20-2 (V6 VIN S),

SA-21-2 (VS VIN P)
A2
PPL
30
FUEL GAGE SENSOR SIGNAL
SA-20-2 (V6 VIN S),

SA-21-2 (VS VIN P)
A3
BLK
1050
GROUND
SA-20-2 (V6 VIN S),

SA-21-2 (VS VIN P)

CAVITY
WIRE COLOR
CKT
DESCRIPTION
PAGE
C2
WHT
883
WHE El SPEED SENSOR RETURN

(WITH NW9) RIGHT REAR WHEEL SPEED SENSOR RETURN
8A-44-1
8A-44-4
C3
BRN
882
WHEEL SPEED SENSOR SIGNAL

(WITH NW9) RIGHT REAR WHEEL SPEED SENSOR SIGNAL
8A-44-1
8A-44-4
01
RED
885
(WITH NW9) LEFT REAR WHEEL SPEED SENSOR RETURN
8A-44-4
02
BLK
884
(WITH NW9) LEFT REAR WHEEL SPEED SENSOR SIGNAL
8A-44-4
12110088
24-WA Y F MICRO-PACK 100 SERI ES
LTGRY
AMPLIFIER (PONT)
DESCRIPTION
PAGE
CAVITY
WIRE COLOR
CKT
ORN
40
POWER FEED FROM COURTESY FUSE 8
8A-11-8
BLK
650
GROUND
8A-14-9
PNK
314
RADIO SIGNAL - ON
8A-150-5
DKBLU
46
RIGHT REAR SPEAKER FEED (POS)
SA-150-5
10
BRN
199
LEFT REAR SPEAKER FEED (POS)
8A-150-5
11
LTGRN
200
8A-150-5
12
TAN
201
8A-150-5
13
LT BLU/BLK
315
RIGHT SUBWOOFER SPEAKER RETURN (NEG)
8A-150-5
14
DKGRN
1795
RIGHT SUBWOOFER SPEAKER FEED (POS)
8A-150-5
15
LTGRN/BLK
1794
LEFT SUBWOOFER SPEAKER RETURf':' (NEG)
8A-150-5
16
DKBLU/WHT
346
LEFT SUBWOOFER SPEAKER FEED (POS)
SA-150-5
21
LTBLU
115
RIGHT REAR SPEAKER RETURN (NEG)
8A-1505
22
YEL
116
LEFT REAR SPEAKER RETURN (NEG)
8A-150-5
23
DKGRN
117
SA-150-5
24
GRY
118
SA-150-5
l c
l c
l c
E_.9_0_0_ Q_ 0
(
12129829
12-WAY F MICRO-PACK 100W
GRY
AUTO MA TIC TRANSMISSION

DESCRIPTION
CAVITY
WIRE COLOR
CKT
PAGE
LTGRN
1222
SA-39-0
YEUBLK
1223
SA-39-0
RED/BLK
1228
PRESSURE CONTROL SOLENOID FEED
SA-39-0
LTBLU/WHT
1229
PRESSURE CONTROL SOLENOID RETURN
SA-39-0
PNK
239
POWER FEED FROM IGNITION FUSE 11
SA-11-15
YEUBLK
1227
TRANSMISSION TEMPERATURE SENSOR SIGNAL
SA-39-0
BLK
470
SENSOR RETURN - PCM
8A-39-0
PNK
1224
TRANSMISSION'PRESSURE SWITCH SIGNAL- RANGE A
SA-39-0
RED
1226
TRANSMISSION PRESSURE swrfc;;H SIGNAL - RANGE c
SA-39-0
DKBLU
1225
TRANSMISSION PRESSURE SWITCH SIGNAL- RANGE B
SA-39-0
WHT
687
3-2 SHIFT SOLENOID CON.TROL
SA-39-0
TAN/BLK
422
TORQUE CONVERTER CLUTCH SOLENOID CONTROL
SA-39-0
12065425
10-WAY F METRI-PACK 150 S.ERIES
BLK

CAVITY
WIRE COLOR
CKT
GRY
397
CRUISE CONTROL SWITCH - ON
8A-34-0
DKBLU
84
CRUISE CONTROL SWITCH.- SET/COAST
8A-34-0
GRY/BLK
87
CRUISE CONTROL SWITCH - RESUMEfACCEL
8A-34-0
BRN
86
CRUISE RELEASEfBRAKE SWITCH OUTPUT
8A-34-0
BLK
1650
GROUND
8A-14-0, 2
PNK
139
POWER FEED FROM A/C-CRUISE FUSE #12
8A-34-0
YEL
820
8A-34-1
DKGRN/WHT
817
8A-34-1
DESCRIPTION
PAGE
Ci~;:n;!rn~ Ct,) ft? liil O

~ ~ c2l ~ t2:J c2J db ......._..,
12020043
12-WA V F METRI-PACK 280 SERIES
B(K
DATA LINK CONNECTOR {DLC)

DESCRIPTION
PAGE
CAVITY
WIRE COLOR
CKT
BLK/WHT
451
GROUND
8A-14;1,2,3
's
WHT/BLK
448
DIAGNOSTIC REQUEST, PCM
8A-20-0,
8A-21-0
BLK/WHT
1455
PROGRAM INPUT, KEYLESS ENTRY MODULE
8A132-1
TAN
800
SERIAL DATA LINE, DIAGNOSTIC ENERGY RESERVE MODULE (DERM), ELECTRONIC

BRAKE CONTROL MODULE (EBCM) AND PCM
8A-50-0
SA -
202 12
12092689
YEL
DIAGNOSTIC ENERGY RESERVE MODULE (DERM)

DESCRIPTION
WIRE COLOR
CKT
A1
BLK/WHT
1751
GROUND
A2
BLK
650
GROUND
CAVITY
PAGE
8A-14-4
SA-14-8,9
..
A3
PNK
1401
DUAL ARMING SENSOR FEED- PASSENGER- 36 VOLT
A4
YELJBLK
236
DUAL ARMING SENSOR FEED - DRIVER - 36 VOLT
SA-47-1
AS
LTGRN
1400
DUAL ARMING SENSOR SIGNAL - DRIVER
SA-47-1
A6
LTGRN/WHT
1837
DUAL ARMING SENSOR SIGNAL- PASSENGER
SA-47-1
A7
WHT/BLK
1403
INFLATOR FEED - PASSENGER
SA-47-1
A9
YEL
1139
SA-47-0, 1
A10
YEL
1139
SA-47-0, 1
A12
BLK/WHT
1751
GROUND
SA-14-4
81
BRN
358
AIR BAG INDICATOR LAMP FEED
SA-47-0
82
PNK
39
SA-11-5
BS
BLK/WHT
238
SEATBELT SWITCH SIGNAL
SA-47-0
87
DKGRN
348
SIR INFLATOR OUTPUT
8A-47-1
88
DKGRN
348
SIR INFLATOR OUTPUT
8A-47-1
89
WHT
347
INFLATOR FEED- DRIVER
8A-47-1
810
PPL
806
POWER FEED FROM CRANK FUSE #16
8A-11-9
B11
TAN
800
SERIAL DATA SIGNAL
8A-50-0
SA-47-1
C1
C2
12110626
12110113
8-WAY F METRI-PACK 280 FLX LK
LTGRY
DK RED
ELECTRONIC BRAKE CONTROL MODULE {EBCM)

OR
CONTROL MODULE {EBTCM)
ELECTRONIC BRAKE CONTROL MODULE {EBCM)

OR
C3 (WITH NW9)
12129088
8-WA Y F METRI-PACK 280 SERIES FLX LK
BLK

CAVITY
WIRE COLOR
CKT
DESCRIPTION
BLK
1280
LEFT FRONT ABS MOTOR FEED
SA-44-1. 2
PNK
1281
LEFT FRONT ABS MOTOR RETURN
SA-44-1,2
DKGRN
1284
REAR ABS MOTOR FEED
SA-44-1,2
RED
1633
ABS RELAY OUTPUT- SWITCHED TO BATTERY
BA-44-1, 3
BLK/WHT
651
GROUND
8A-44-0, 2
ORN
1285
REAR ABS MOTOR RETURN
SA-44-1, 2
PPL
1282
RIGHT FRONT ABS MOTOR FEED
SA-44-1,2
BLK
1283
RIGHT FRONT ABS MOTOR RETURN
SA-44-1,2
PAGE
C1
BA- 202-14 ELECTRICAL DIAGNOSIS

CAVITY
DESCRIPTION
WIRE COLOR
CKT
A1
BLK
884
LEFT REAR. WHEEL SPEED SEN$0R SIGNAL (WITH NW9)
SA-44-4
A2
RED
885
LEFT REAR WHEH SPEED SENSOR RETURN (WITH NW9)
SA-44-4
A3
TAN
833
RIGHT FRONT WHEEL SPEED SENSOR RETURN
SA-44-1,4
A4
DKGRN
872
RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
8A-44-1,4
AS
AS
WHT
WHT
883
883
REAR WHEEL SPEED SENSOR RETURN

RIGHT REAR WHEEL SPEED SENSOR RETURN (WITH NW9)
8A-44-1
8A-44-4
A6
A6
BRN
BRN
882
882
REAR WHEEL SPEED .SENSOR SIGNAL

RIGHT REAR WHEEL SPEED SENSOR SIGNAL (WITH NW9)
BA-44-1
8A-44-4
A7
YEL
873
LEFT FRONT WHEEL SPEED SENSOR RETURN
8A-44-1,4
AB
LTBLU
830
LEFT FRONT WHEEL SPEED SENSOR SIGNAL
SA-44-1.4
A9
LTBLU
1289
RIGHT FRONT SOLENOID FEED
SA-44-0,2
A11
TAN
800
SERIAL DATA SIGNAL
BA-50-0
A14
TAN/BLK
464
THROTTLE POSITION SENSOR SIGNAL (WITH NW9)
SA-44-3
A15
BRN/WHT
1571
TRACTION CONTROL SYSTEM SWITCH SIGNAL (WITH NW9)
SA-44-4
A16
LTBLU
832
TRACTION CONTROL ACTIVE (WITH NW9)
SA-44-3
81
DKGRN
1288
LEFT FRONT SOLENOID FEED
SA-44-0,2
82
LTGRN
867
ABS FAILURE INPUT TO INSTRUMENT CLUSTER (SOLID STA TE)
SA-44-0,2
83
PNK
1632
ABS ENABLE FEED TO RELAY
BA-44-1,3
84
TAN/WHT
33
"BRAKE" INDICATOR LAMP (SWITCHED GROUND)
SA-44-0,2
BS
DKBLU
1537
"LOW TRAC" INOICATOR LAMP CONTROL
BA-44-0,2
810
ORN
440
POWER FEED FROM ABS BAT FUSE #1
BA-44-1, 3
811
BRN
641
POWER FEED FROM ABS IGN FUSE #5
BA-44-1,3
812
YEL
820
BA-44-0,2
814
ORN/BLK
463
SPARK RETARD REQUEST (WITH NW9)
8A-44-3
815
PPL/WHT
1572
"ASR" (CHEVY) OR "TCS OFF" (PONT) INDICATOR CONTROL (WITH NW9)
BA-44-2,4
(2
PAGE
C3 (WITH NW9)
A
LTGRN
566
RIGHT REAR TCS MOTOR FEED
BA-44-3
PPL
562
TCS ENABLE FEED TO RELAY
BA-44-3
RED/BLK
563
TCS RELAY OUTPUT - SWITCHED TO BATTERY
BA-44-3
GRY
561
THROTTLE RELAXER MOTOR RETURN
BA-44-3
WHT
560
THROTTLE RELAXER MOTOR FEED
BA-44-3
LTBLU
564
LEFT REAR TCS MOTOR FEED
SA-44-3
DKBLU
565
LEFT REAR TCS MOTOR RETURN
BA-44-3
DKGRN
567
RIGHT REAR TCS MOTOR RETURN
BA-44-3
12129077
BLK
HEADLIGHT SWltCH
CAVITY
WIRE COLOR
CKT
BRN
BLK
650
VEL
DESCRIPTION
PAGE
PARK LAMP FEED
SA-100-0
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-100-0
GRV
SA-100-0
ORN
240
SA-100-0
RED
702
SA-100-0
C3
17
20
12047531
12047530
10-WAY F MICRO-PACK
BLK
4-WA Y F MICRO-PACK
BLU
EJDDDDDm
[] []] []] [] [] [] []
12065873
BLK
RADIO
(PONTIAC)
DESCRIPTION
WIRE COLOR
CKT
GRY
118
8A-150-0,4
TAN
201
SA-150-0,4
DKGRN
117
8A-150-0, 4
LTGRN
200
SA-150-0,4
BLK
650
GROUND
SA-14-7, 8, 9
BRN
PARK LAMP FEED
8A-150-0,4
GRY
8A-150-0,4
PNK
314
(WITH UW2) RADIO SIGNAL- ON
8A-150-4
YEL
43
8A-150-0,4
10
ORN
40
8A-11-8
17
LTBLU
115
8A-150-0, 5
18
DKBLU
46
8A-1SO-O, 5
19
YEL
116
8A-150-0, 5
20
BRN
199
8A-150-0, 5
STEERING WHEEL RADIO CONTROL SIGNAL
8A-150-1, 5
CAVITY
PAGE
C1
C3
C4 (WITH UK3)
6
DKBLU
1796

CAVITY
(CHEVY)
DESCRIPTION
PAGE
WIRE COLOR
CKT
GRY
118
8A-1S0-0
TAN
201
SA-150-0
DKGRN
117
SA-150-0
LTGRN
200
SA-150-0
BLK
650
GROUND
SA-14-7, 8, 9
C1 (BASE)
C1 (DELCO-BOSE)
1
BARE
514
DRAIN WIRE
SA-150-3
TAN
511
SPEAKER SIGNAL LEFT FRONT
BA-150-3
WHT
513
SPEAKER RETURN LEFT AND RIGHT
BA-150-3
LTGRN
512
SPEAKER SIGNAL RIGHT FRONT
BA-150-3
BLK
1051
GROUND
BA-14-10
C1 (ALL RADIOS)
6
BRN
PARK LAMP FEED
BA-150-0, 2
GRY
8A-150-0,2
PNK
314
(WITH U82 ONLY) RADIO SIGNAL - ON
8A-150-2
YEL
43
8A-150-0, 2
10
ORN
40
8A-11-8
17
LTBLU
115
~GHTREARSPEAKERRETURN
8A-150-0
18
DKBLU
46
8A-150-0
19
YEL
116
BA-150-0
20
BRN
199
BA-150-0
C3 (BASE)
C3 (DELCO-BOSE)
17
BARE
514
DRAIN WIRE
BA-150-2
18
DKBLU
546
REAR PRE AMP FEED (RIGHT SIGNAL)
BA-150-2
19
DKGRN/WHT
689
REAR PRE AMP RETURN
BA-150-2
20
BRN
599
REAR PRE AMP FEED (LEFT SIGNAL)
BA-150-2
8A - 202 18 ELECTRICAL DIAGNOSIS
12110259
GRN
THEFT DETERRENT MODULE

DESCRIPTION
CAVITY
WIRE COLOR
CKT
A1
ORN
340
POWER FEED FROM PCM BAT FUSE #4
8A-11-7
A2
PNK
439
8A-11-5
A3
DKBLU
229
FUEL ENABLE SIGNAL
8A-1331
A4
YEUBLK
625
THEFT DETERRENT RELAY CONTROL
8A-133-0, 1
AS
GRY
728
"SECURITY'" INDICATOR LAMP CONTROL
8A-133-1
BS
BLK/WHT
451
GROUND
SA-14-1, 2, 3
87
PPUWHT
1074
IGNITION KEY RESISTOR RETURN
8A-133-1
88
WHT/BLK
1073
IGNITION KEY RESISTOR FEED
8A-1331
PAGE
[!][!]~
12047950
BLK
ENGINE HARNESS TO
DISTRIBUTOR JUMPER (VS VIN P)
000
12064762
GRV
REAR BODY HARNESS TO 1/P HARNESS
12015664
BLK
ENGINE HARNESS T0.1/P HARNESS
C217ldJc2JrlJ~r
CJ
12092162
12110295
GRV
ABS MOTOR PACK
BLK
SIR COIL ASSEMBLY HARNESS TO 1/P HARNESS
.
STEERING WHEEL CONTROLS, RADIO
12064752
BLK
CROSS CAR HARNESS TO 1/P HARNESS
SEAT'JUMPER HARNESS TO DRIVER SEAT HARNESS
SEAT JUMPER HARNESS TO PASSENGER SEAT HARNESS
BLOWER RESISTOR
SPEAKER/AMP, REAR (CHEVY BOSE)
12092761
VEL
ARMING SENSOR, DUAL POLE

C2
C1
BLOWER RESISTOR
SEE C240
BOSE RELAY (CHEVY)
SEE FUEL PUMP RELAY
12033704
BLK
~511;:rut? ct?
dJt2llfJL1J
12064766
12064998
8-WA Y F METRI-PACK
150 SERIES
BLU
8-WAY F METRI-PACK
280 SERIES
BLK
DAYTIME RUNNING LIG.HTS (DRL) MODULE
CLUTCH ANTICIPATE/CRUISE RELEASE SWITCH

(V6 WITH MANUAL)
CONVENIENCE CENTER
REFER TO PAGE SA-76-1
12059401
4-WAY F METRI-PACK 150.1 SERIES
PULL-TO-SEAT
GRY
12052856
DISTRIBUTOR (VS VIN P)

BLK
CONVERTIBLE TOP SWITCH (CHEVY OR PONT)
12065292
4-WA Y F METRI-PACK 150 PULL-TO-SEAT
BLK
12015308
8-WA Y PC EDGEBOARD - STD
BLK
COOLANT LEVEL LATCHING MODULE
EXHAUST GAS RECIRCULATION (EGR) VACUUM

CONTROL SIGNAL SOLENOID VALVE (V6 VIN S)
12015356
5-WAY F METRI-PACK 150 480 SERIES
BLK
EXPRESS DOWN MODULE
12129068
BLK
GENERATOR
FOG LIGHT SWITCH (CHEVY)

SEEC400
HATCH RELEASE RELAY
SEE FUEL PUMP RELAY
I I Ic I I
I I I I t
A
12045688
8-WAY M METRlPACK 150 SERIES
BLK
C1
FOG LIGHT SWITCH (PONT)
15300030
BLK
E1 B El
BBB
12110541
6-WA Y F METRlPACK 280 FLX LK
BLK
FUEL PUMP RELAY
HATCH RELEASE RELAY
THEFT DETERRENT RELAY
HIGH BLOWER RELAY
BOSE RELAY (CHEVY)
C2
15300029
BLK
HEADLIGHT DOORS MODULE (PONT ONLY)
8A - 202 22 ELECTRICAL DIAGNOSIS
12059870
12110188
BLIC

PULL-TO-SEAT
BLK
HEATED OXYGEN SENSOR BANK #1 AND

BANK#2

(VS VIN P AND V6 VIN S)
12040754
PULL-TO-SEAT
BLK
12020813
IGNITION COIL MODULE (VS VIN P)

BLK
C1
A
c
D
12015664
BLK
12124045
HEATER/VENT/AIR CONDITIONING (HVAC)

CONTROL ASSEMBLY

BLK
IGNITION CONTROL MODULE (V6 VIN S)
ELECTRICAL DIAGNOSIS BA 202 - 23
. 12034060
4-WA Y F M~TRlPACK 480 SERIES
~'.NAT.(WHT)
1/P DIMMER SWITCH
06294641
1/P FUSE BLOCK

REFER TO PAGE 8A-11-0 (CHEVY)
8A 11 1 (PONT)
4-WAY FMIXED SERIES

BLK
C2
12010966
5-WAY F 56 SERIES
BLU
12064766
IGNITION SWITCH

BLU
(16
O
01
cbcacf:JdJ
016
12045575
BLK
INSTRUMENT CLUSTER (CHEVY)
~lt? lt?ct?
12064998
BLK
KEYLESS ENTRY RECEIVER
POWER SEAT CONTROL MODULE (AQ9)
~~-r-1
BLOCKED
CAVITY
12065803
12065401

BLK
INSTRUMENT CLUSTER (PONT)
OIL PRESSURE SENSOR
GRY
12066498
BLK
OUTSIDE MIRROR
LHAND RH
PERFORMANC SWITCH
PERFORMANCE/TRACTION CONTROL SWITCH
SEE SOLENOID VAVLE ASSEMBLY (AQ9)
12064862
8-WA Y F METRlPACK 1 SO SERIES
BLK
POWER MIRROR SWITCH (PONT)
POWER SEAT CONTROL MODULE

(AQ9 POWER SEAT)
SEE KEYLESS ENTRY RECEIVER (C2)
12004680
NAT
POWER DOOR LOCK SWITCH
LHAND RH
__
ao[]
.__
Eo
co
[Joo
FODO
12085013
BLK
POWER SEAT SWITCH (AC3)
I A I8 I c ID 1
IHIGIFIEI
12045688
BLK
POWER MIRROR SWITCH (CHEVY)
12033944
BLK
POWER SEAT SWITCH (AQ9)
DRIVER AND PASSENGER
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129022 (CLRI
12146093
12129030
12129025
GGGGGGGGGGGGGGGG
0008088808808888
12129025
32-WAY F MICRO-PACK 100 SERIE$
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
1212~21 (BLK)
12146093
12129030
12129025
GGGGGGGGGGGGGGGG
0008088808808888
12129025
NAT
POWERTRAIN CONTROL MODULE (PCM) (V6 VI.NS)

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129023 (BLU)
12146093
12129028
12129025
SA -
202 - 26

A
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
- 12129024 (RED)
- 12146093
12129028
- 12129025
GG8G0G000GGGGGG0
888808C088G8888GG
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129021 (BLK)
12146093
12129028
12129025
8G8G0G000GGGGG80
8888088800888888
12129025
32-WAY F MICRO~PACK 100 SERIES
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
12129022 ((LR)
12146093
12129030
12129025
GGGGGGGGGGGGGGGG
888800880G8GGGGG
12129025
NAT

TPA
SEAL
STRAIN RELIEF
CONNECTOR
- 12129023 (BLU)
12146093
- 12129030
- 12129025
0
12048027
12052854
GRV
BLK
POWER WINDOW SWITCH, LH
RETAINED ACCESSO.RY POWER (RAP) MODULE
AQ QB
CJ
cQ Qo
CJ
12064769
eQ
12033945
NAT
BLK
POWER WINDOW SWITCH, RH
SOLENOID VALVE ASSEMBLY (AQ9)

PERFORMANCE SWITCH
PERFORMANCE/TRACTION CONTROL SWITCH
I I Ic I I I
A
12059296
RED
REAR DEFOGGER SWITCH/TIMER (CHEVY)
12052848
BLK
SPEAKER/AMP, LEFT AND
RIGHT FRONT (CHEVY BOSE)
SPEAKER/AMP, REAR (CHEVY BOSE)
SEE C240
12047785
BLK
REARVIEW MIRROR
STEERING WHEEL CONTROLS, RADIO

SEE C217
THEFT DETERRENT RELAY

SEE FUEL PUMP RELAY

12129565

REFER TO PAGE SA-113
GRY
TRACTION CONTROL MOTOR PACK
~I InIF 'h
~,A,uclole
_
lJ_
II
Li
12015307
12129126

BLK

BLK
WIPER MOTOR ASSEMBLY
BLANK
202 - 29
SA -
203 - 0

C160
C165
C120
C100
P100
C200A, B, C, D
PSOO
0
C240
C285
(IN THIS
C300
C305
AREA)
ELECTRICAL DIAGNOSIS SA 203 1
HARNESS LEGEND
Forward Lamp Harness
CHMSL Jumper Harness
Engine Harness/
10
Distributor Jumper Harness (VB VIN P)
1/P Harness
11
Wheel Speed Sensor Jumper Harness
Cross Car Harness
12
RR Wheel Speed Sensor Jumper Harness
Rear Body Harness
13
Fuel Tank Unit Pigtail
Hatch Harness
14
Steering Column Harness
RR Fascia Harness
15
Headlamp jumper Harness (Pontiac only)
Injector Harness (VG VIN S)
16
Seat Jumper Harness (with AQ9) or Driver Seat

Harness (with AC3)
CONNECTOR LEGEND
PAGE
FIGURE
CONNECTOR
C100 (10 cavities)
Engine Harn to Forward Lamp Harn, behind LH

wheelhouse attached to PCIYI Bracket
201-15
28
202-0
C110 (10cavities)
(VG VIN S)
Engine Harn to Injector Harn, top center of Intake

Manifold
201-12
22
202-1
C120 (2cavities)
Forward Lamp Harn to Wheel SpE\ed Sensor Jumper

Harn, mounted t.o LH Frame Rail
C130 (2 cavities)
Forward Lamp Harn to Wheel Speed Sensor Jumper

Harn, mounted to RH Frame Rail
C140 (4 cavities)
(VB VIN P)
Engine Harn to Distributor Jumper Harn, right side of

Intake Plenum, attached to EVAP Solenoid Valve
201-26
50
202-19
C160 (3 cavities)
(Pontiac)
Forward Lamp Harn to Headlamp Jumper Harn,

behind LH Headlamp Door Bracket
201-23
43
C165 (3 cavities)
(Pontiac)
Forward Lamp Harn to Headlamp Jumper Harn,

behind RH Headlamp Door Bracket
:
201-23
43
C200A
(17 cavities)
Forward Lamp Harn to 1/P Harn, between LH kick

panel and Steering Column
201-25
49
202-2
C200B
(18cavities)
Forward Lamp Harn to 1/P Harn, between LH kick

panel and Steering Column
201-25
49
202-2
C200C
( 13 cavities)
Cross Car Harn to 1/P Harn, between LH kick panel

and Steering Column
201-25
49
202-2
C200D
(48 cavities)
1/P Harn side, between LH kick panel and Steering

Column
201-25
49
202-2
C210 (4 cavities)
1/P Harn to Engine Harn, under RH side of 1/P behind

RH kick panel
201-20
37
202-19
C215 ( 11 cavities)
Forward Lamp Harn to Steering Column Harn, near

base of Steering Column
201-35
64
202-4
8A -
203 2

CONNECTOR LEGEND
PAGE
FIGURE
CONNECTOR
C216 ( 11 cavities)
1/P Harn to Steering Column Harn, attached to base

of Steering Column
201-34
63
202-5
C217 (4 cavities)
(Pontiac)
1/P Harn to SIR Coil Assembly Harn, near base of

Steering Column
\
201-34
63
202-19
C220 (10 cavities)

kick panel
201-20
37
202-6
C230 (10 cavities)

kick panel
201-20
37
202-7
C240 (6 cavities)
Cross Car Harn to 1/P Harn, under RH side of 1/P

behind kick panel
201-20
37
202-19
C250 (2 cavities)
Forward Lamp' Harn to Clutch Jumper Harn, near

Brake/Clutch Pedal Bracket
201-1
C270 (2 cavities)
1/P Harn to Clutch Jumper Harn, near Brake/Clutch

Pedal Bracket
201-1
C285 ( 1 cavity)
(Chevy AUD and
U82)
Cross Car Harn to 1/P Harn, under RH side of 1/P

behind kick panel
201-20
37
C300 (6 cavities)
(Pontiac AQ9)
Seat Jumper Harn to Driver Seat Harn, under Driver

Seat Assembly
201-47
86
202-19
C305 (6 cavities)
(Pontiac AQ9)
Seat Jumper Harn to Passenger Seat Harn, under

Passenger Seat Assembl'y
201-46
85
202-19
C310 (2 cavities)
(with AC3 or
AQ9)
1/P Harn to Driver Seat Harn (with AC3) or Seat

Jumper Harn (with AQ9), betwee'n rear mounting
bolts of driver seat
201-6
11
C320 ( 1 cavity)
(Convertible)
1/P Harness to Convertible Rear Defogger Jumper,

under left Interior Garnish Molding above left rear
wheelhouse
C330 (3 cavities)
1/P Harn to Hatch Harn, center of roof near Dome

Lamp (Coupe only)
201-4
C4.00 (6 cavities)
1/P Harn to Rear Body Harn, LH rear Cargo

Compartment
201-30
57
202-19
C405A
(4 cavities)
Fuel Tank Unit Pigtail to 1/P Harn, part of Pass Thru

Connector forward of rear axle
201-5
202-8
C405B
( 10 cavities)
1/P Harn side, part of Pass Thru Connector forward of

rear axle
201-5
202-8
C405C
(4 cavities)
Rear Wheel Speed Sensor Jumper Harn to 1/P Harn,

part of Pass Thru Connector forward of rear axle
201-5
202-8
C420 (2 cavities)
Hatch Harn to CHMSL Jumper Harn, LH side of hatch

between hatch frame and plastic panel (Coupe) or
1/P Harn to CHMSL Jumper Harn, located on LH
underside of Deck Lid (Convertible).
201-4
C430 (2 cavities)
Rear Body Harn to Rear Fascia Harn, between. rear

fascia and rear end panel on LH side
201-32,
201-33
61, 62
BLANK
INDEX 1
A
~bbreviations . . . . . . . . . . . . .. . . . . . . . . . . .. OA-16 & 7A-14A-2
Ahlbreviations, Transmission Definitions and ........ 7A-14A-1
"ABS INOP" Indicator Lamp .......................... 8C-5
Accelerate Switch, Off-On-Resume/ . . . . . . . . . . . . . . . . . . . 98-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Accessory Switch Opening Cover Assembly,
Accessory Switch panel Assembly and . . . . . . . . . . . . 10-6-7
Accessory Switch Panel Assembly and
Accessory Switch Opening Cover Assembly . . . . . . . 10-6-7
Accident Damage, SIR Tilt Steering Column
Floor Shift .................................... 3F5B-18
Accumulator Assembly Automatic Transmission
On-Vehicle Service .............................. 7A-18
Accumulator Hose Assembly Replacement
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-26
A/C Replacement Procedures, Heater,
Ventilation and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
A/C System (Engine Off), Charging the ................ 1B-14
Actuator Cylinder Assembly, Clutch Master and ......... 7C-7
Actuator Lever Knob, Front Seat Adjuster . . . . . . . . . . 10-10-20
Actuators, Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-19
Adapt Function, Transmission .................... 7A-14A-3
Adapter Plate, Transmission, (T56)
Repair and Inspection, ....................... 78-108-21
Adhesive Caulking Kit, Stationary Windows . . . . . . . . . . . 10-2-1
Adhesive Molding Assemblies . . . . . . . . . . . . . . . . . . . . . . 10-1-3
Adhesive Nameplate/Emblem Assemblies . . . . . . . . . . . . 10-1-3
Adjustment and Alignment, Body Panel . . . . . . . . . . . . . 10-5-27
Adjustment, Downstop, Folding Top . . . . . . . . . . . . . . . . 10-9-36
Adjustment, Front Side Door Lock Striker . . . . . . . . . . . . 10-6-30
Adjustment, Front Side Door Window . . . . . . . . . . . . . . . 10-6-36
Adjustment, Hood Panel Assembly . . . . . . . . . . . . . . . . . 10-5-27
Adjustment, Roof Lift-Off Window Assembly . . . . . . . . . 10-9-37
Adjustment, Upstop, Folding Top . . . . . . . . . . . . . . . . . . . 10-9-36
Adjustments Affecting Tooth Contact Rear Axle .......... 48-9
Adjustments, Folding Top . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-36
Aiming After a Collision, Headlamp ................... 88-11
Aiming Alternate Procedure, Headlamp ............... 88-10
Aiming by Screen Method, Headlamp .................. 88-8
Aiming Procedure, Front Fog Lamp,
On-Vehicle Service ............................... 88-5
"AIR BAG" Indicator Lamp ........................... 8C-5
Air Baffle Assemblies and Deflectors, Radiator . . . . . . . . . . 68-3
Air Baffle Assemblies and Deflectors,
Radiator, On-Vehicle Service ...................... 68-21
Air Bleed Pipe Assembly, Coolant,
On-Vehicle Service .............................. 68-22
Air Check, Clutch .............................. 7A-148-35
Air Cleaner and Crankcase Ventilation
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-5
Air Conditioning Compressor and Condenser
Hose Assembly Replacement
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-15 & 18-24
Air Conditioning Compressor and Power
Steering Pump Bracket Assembly
(5.7L LT1 Engine) Replacement
Procedures, Generator and . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Air Conditioning Compressor Assembly . . . . . . . . . . . . . . . . 18-4
Air Conditioning Compressor Assembly Replacement
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
Air Conditioning Compressor Bracket

Assembly (3.4L L32 Engine) Replacement
Procedures, Generator and . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Air Conditioning Compressor Relay . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning Compressor Relay, Manual Control .... 181-15
Air Conditioning Compressor Service or Unit
Repair R-134a, HD6/HR6-He ..................... 102-1
Air Conditioning Condenser Assembly . . . . . . . . . . . . . . . . . 1B-4
Air Conditioning Condenser Assembly
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Air Conditioning Control Assembly, Heater and . . . . . . . . . . 8C-9
Air Conditioning Control Lamp, Heater and . . . . . . . . . . . . . 88-4
Air Conditioning Control Lamp, Heater and,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-16
Air Conditioning Ducts, f-:leat, Ventilation and ........... 8C-18
Air Conditioning Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4
Air Conditioning Evaporator and Blower
Module Assembly, Heater and .................... 8C-20
Air Conditioning Evaporator, Manual Control .......... 181 -15
Air Conditioning Evaporator Temperature
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning Evaporator Temperature
Sensor Assembly, Manual Control ................ 181 -15
Air Conditioning Evaporator Tube Assembly
Air Conditioning Evaporator Tube Replacement
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Air Conditioning, Heater, Ventilation and ................ 1B-1
Air Conditioning, Heating and . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Air Conditioning, Manual Control ..................... 181 -1
Air Conditioning Odor, Eliminating ..................... 1B-7
Air Conditioning Overview, Manual Control ............. 181 -1
Air Conditioning Performance Test, Manual Control . . . . 1B1-15
Air Conditioning Receiver and Dehydrator Assembly . . . . . 1B-4
Air Conditioning Receiver and Dehydrator Assembly
Air Conditioning Receiver Dehydrator Tube
Replacement Procedures ........................ 1B-16
Air Conditioning Refrigerant Pressure
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning Refrigerant Pressure Sensor
Assembly, Manual Control ....................... 181 -15
Air Conditioning Refrigerant Service Valve
Air Conditioning System Operation, Heater,
Ventilation and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Air Conditioning Thermostatic Expansion Valve
Assembly Replacement Procedures ............... 1B-18
Air Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-19
Air Delivery, Improper, Manual Control A/C . . . . . . . . . . . 181 -11
Air Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Air Distribution System, Manual Control A/C ........... 181 -4
Air Distributor Assembly ............................ 8C-18
Air Extractors, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19
Air Hose Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Air Inlet Screen Assemblies . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
Air Inlet Valve, Manual Control A/C ................... 181 -5
Air Lower Baffle Assembly and Deflector,
Radiator, On-Vehicle Service ...................... 68-21
Air Lower Deflector, Radiator . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Air Outlet Duct Assemblies, Center ................... 8C-18
Air Outlet Duct Assemblies, Outer .................... 8C-20
2 INDEX
Air Outlet Duct Assembly, Floor ...................... 8C-18
Air Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Air Upper Baffle Assembly, Radiator,
Alarm Assembly, On-Vehicle Service .................. 8C-32
Alignment Angles, Measuring Rear, Wheel Alignment .... 3A-5
Alignment, Body Panel Adjustment and . . . . . . . . . . . . . 10-5-27
Alignment Checking, Body Dimensions
and Underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1
Alignment, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
All Season Tires .................................... 3E-2
Aluminum Radiator Service, On-Vehicle Service ......... 68-9
Aluminum Wheel Assemblies ........................ 3E-12
Aluminum Wheel Assembly Hub Cap ................. 3E-12
Aluminum Wheel Assembly Porosity Repair ........... 3E-12
Aluminum Wheel Assembly Refinishing ............... 3E-12
AM/FM Stereo and Clock Radio Assembly .............. BC- 7
AMAX Stereo Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
AMAX Stereo Certification (U1 C) ..................... 9A-1 o
AMAX Stereo Certification (UN6) ...................... 9A-8
AMAX Stereo Certification (UP3) ..................... 9A-11
AMAX Stereo Certification {UT6) . . . . . . . . . . . . . . . . . . . . . . 9A-9
Ambient Light Sensor (Canadian Only),
Daytime Running Lamp (DRL) ..................... 8C-4
Ambient Light Sensor Assembly, Daytime
Running Lamp, On-Vehicle Service ................ 8C-11
Ambient Light Sensor Module Assembly,
Daytime Running Lamp .......................... 8C-11
Amplifier Assembly, Low Frequency Audio . . . . . . . . . . . . 10-7-9
Anchor Bracket, Child Seat Top-Tether ............... 10-11-7
Anchor Plate, Front Side Door Lock Striker . . . . . . . . . . 10-6-30
Angle Adjustment, Rear Thrust, Wheel Alignment . . . . . . . . 3A-6
Angle, Trust, Wheel ~lignment ........................ 3A-1
Antenna Assembly Diagnosis, Radio Fixed . . . . . . . . . . . . 9A-14
Antenna Assembly, Radio Fixed ...................... 9A-2
Antenna Assembly, Radio Fixed, On-Vehicle Service .... 9A-15
Anti-Theft Feature, Setting Radio ..................... 9A-12
Anticipate Switch Assembly, Clutch .................... 7C-7
Anticorrosion Protection, Body Front End . . . . . . . . . . . . . 10-5-3
Anticorrosion Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-7
Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E1 -1
Antilock Brake System with Traction Control System .... 5E2-1
Antilock Warning/Indicator Lamp Operation . . . . . . . . . . . . . . 5-4
Applique Assembly, Outside Rearview Mirror . . . . . . . . . 10-6-22
Arm Replacement, Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
Arm Tip Pressure Check, Wiper . . . . . . . . . . . . . . . . . . . . . 8E-16
Arm, Torque, Rear Suspension On-Vehicle Service ...... 30-6
Armrest and Map Pocket and Radio Front
Side Door Speaker Grilles, Front Side Door . . . . . . . . 10-6-3
Armrest and Radio Front Side Door Speaker
Grille, Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-3
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Ashtray Lamp, On-Vehicle Service ................... 88-15
"ASR" Indicator Lamp ............................... 8C-6
Assembly Removal and Installation
Automatic Transmission On-Vehicle Service ......... 7A-25
Assist Rod Assembly, Hood Open . . . . . . . . . . . . . . . . . . 10-5-18
Assist Rod Bracket Assembly, Hood Open . . . . . . . . . . . 10-5-19
Audio Amplifier Assembly, Low Frequency ............ 10-7-9
Audio System (UQO), Base ........................... 9A-1
Audio System, Optional .............................. 9A-2
Audio Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Automatic and Manual Transmission .................... 7-1
Automatic Transmission Control Assembly Automatic

Transmission On-Vehicle Service .................. 7A-1 O
Automatic Transmission Diagnosis (RPO M30)
Description, HYDRA-MATIC 4L60-E ................. 71
Automatic Transmission Indicator Lamp ................ 88-3
1
Automatic Transmission Indicator Lamp,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88'-15
Automatic Transmission On-Vehicle Service,
2-4 Band Servo Assembly . . . . . . . . . . . . . . . . . . . . . . . . TA-19
Accumulator Assembly ........................... 7A-18
Assembly Removal and Installation ................ 7A-25
Automatic Transmission Control Assembly .......... 7A-10
Automatic Transmission Park Lock Cable Assembly .. 7A-10
Automatic Transmission Range Selector
Lever Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-9
Case Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7A-18
Automatic Transmission On-Vehicle Service, Case
Extension Oil Seal Assembly . . . . . . . . . . . . . . . . . . . . . 7A-25
Changing Transmission Fluid and Automatic
Transmission Oil Filter Assembly .................. 7A-13
Control and Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . 7A-22
Control Lever Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-12
Control Valve Body and Pressure Switch . . . . . . . . . . . 7A-21
Automatic Transmission On-Vehicle
Service Description ................................ 7~1
Electrical Connector and Seal ..................... 7A-25

Fluid Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6
Automatic Transmission On-Vehicle Service, Flywheel
Assembly/Torque Converter Clutch Vibration
Test Procedure .................................. 7A-6
General Service Procedures . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Methods for Locating Leak . . . . . . . . . . . . . . . . . . . . . . . . 7A-6
No Air Tool Recommendation ...................... 7A-4
Noise and Vibration Analysis ....................... 7A-3
Noise Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Oil Cooler Flushing Procedures ................... 7A-15
Oil Cooler Upper Pipe and Upper and Lower Hose
Assemblies . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. 7A-14
Park/Neutral Position Switch Assembly .......... , .. 7 A-12
Park/Neutral Position Switch Assembly
Adjustment Using Old Switch Assembly . . . . . . . . . . . . 7A-12
INDEX 3
\ . Adjustment Using New Switch Assembly ........... 7A-1.3
Parts Cleaning, Inspection and Replacement ......... 7A-4
Possible Points of Fluid Leak . . . . . . . . . . . . . . . . . . . . . . 7A-8
Automatic Transmission On-Vehicle Service, Preliminary
Checking Procedure .............................. 7A-3
Pressure Regulator Valve ........................ 7A-20
Repairing the Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6
Shift Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2
TCC Solenoid and Wiring Harness Replacement ..... 7A-22
Throttle Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2
Torque Converter Clutch Diagnosis . . . . . . . . . . . . . . . . . 7A-9
Torque Converter Clutch Electrical Controls .......... 7A-8
Transmission Assembly Definitions . . . . . . . . . . . . . . . . . 7A-2
Transmission Assembly Identification Information ..... 7A~2
Transmission Case Porosity Repair . . . . . . . . . . . . . . . . . 7A-8
Transmission Converter Cover . . . . . . . . . . . . . . . . . . . . 7A-20
Transmission Fluid Checking and
Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Transmission Fluid Filler Tube Assembly . . . . . . . . . . . . 7A-16
Vehicle Speed Sensor (VSS) ..................... 7A-17
Automatic Transmission Park Lock Cable
Assembly Automatic Transmission
Automatic Transmission Range Selector
Lever Cable Assembly Automatic Transmission
On-Vehicle Service ............................... 7A-9
Automatic Transmission Unit Repair (RPO M30)
Description, HYDRA-Matic 4L60-E ................... 7-1
Auxiliary (Booster) Battery Assembly, Jump
Starting in Case of Emergency with ................ 601 -8
Auxiliary Fuse Block .. . . . .. .. . . .. . . .. . . . .. . . . . . . . .. . 8C-2
Auxiliary Fuse Block, On-Vehicle Service .............. 8C-26
Auxiliary Sealing Strip, Front Side Door Bottom . . . . . . . 10-6-16
Axle Assembly Identification, Rear ..................... 48-5
Axle Assembly, Rearr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-15
Axle Assembly with Disc Brakes, Rear ................ 48-27
Axle Noises, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-6
Axle Operation, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-3
Axle, Rear ......................................... 48-1
Axle, Rear, Inspection and Diagnosis .................. 48-8
B
Backing Plate, Duo-Servo Drum Brakes ............... 5C2-6
Backing Plate Selection, Reverse Input Clutch ..... 7A-14B-39
Backlash Clunk, Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-7
Backup Lamp Switch Assembly, Manual Trans ......... 78-10

Backup Lamps ..................................... 88-2
Backup Lamps, On-Vehicle Service ............. , ...... 88-4
Baffle Assemblies and Deflectors, Radiator Air . . . . . . . . . . 68-3
Baffle Assemblies and Deflectors, Radiator Air,
Baffle Assembly and Deflector, Radiator Air Lower,
Baffle Assembly, Radiator Air Upper,
Balance Check, Propeller Shaft Assembly . . . . . . . . . . . . . . 4A-7
Balance Duo-Servo Drum Brakes .................... 5C2-2
Balance Duo-Servo Drum Brakes .................... 5C2-8
Balance Precautions, General, Tires and Wheels ....... 3E-10
Balance, Tire and Wheel Assembly . . . . . . . . . . . . . . . . . . . . 3-22
Balancer Assembly, Crankshaft, 3.4L V6 Engine
On-Vehicle Service ............................ 6A2A-14
Balancing, Off-Vehicle, Tires and Wheels .............. 3E-1 O
Balancing, On-Vehicle, Tires and Wheels .............. 3E-1 O
Balancing, Propeller Shaft Assembly ................... 4A-7
Balancing Tire and Wheel Assembly . . . . . . . . . . . . . . . . . . 3E-1 O
Ball Assembly - Replacement Procedures,
Check Valve Retainer and .................... 7A-148-26
Ball Stud Assembly Inspection, Control Arm ............ 3C-3
Ball Stud Assembly, Lower Control Arm . . . . . . . . . . . . . . . . 3C-3
Ball Stud Assembly Replacement, Control Arm .......... 3C-4
Ball Stud Assembly Replacement, Lower Control Arm . . . . 3C-4
Ball Stud Assembly Replacement, Upper Control Arm .... 3C-5
Ball Stud Assembly, Upper Control Arm ................ 3C-4
Band Assembly, 2-4 ............................. 7A-148-41
Band, Reverse Input Clutch, Input Clutch
and Input Gear Set, 2-4 ...................... 7A-14B-10
Base Audio System (UQO) ........................... 9A-1
Basecoat Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-9
Basecoat/Clearcoat, Metal Part Refinishing . . . . . . . . . . . 10-1-9
Basecoat/Clearcoat Preparation . . . . . . . . . . . . . . . . . . . . . 10-1-9
Battery ........................................... 601-1
Battery Assembly .................................. 601 -1
Battery Assembly Charging ......................... 601 -6
Battery Assembly Electrical Drain .................... 601 -4
Battery Assembly Protection During Vehicle Storage .... 601 -3
Battery Assembly Ratings ........................... 601 -2
Battery Assembly Replacement ...................... 601 -8
Battery Assembly Testing ........................... 601 -3
Battery Assembly Usage ........................... 601 -13
Battery Cable Assembly Replacement and Routing ..... 601 -9
Battery, Common Causes of Failure .................. 601 -2
Battery Diagnosis .................................. 601 -3
Battery Negative Cable Assembly, Disconnecting the . . . . . OA-1
Battery On-Vehicle Service .......................... 601-6
Battery Replacement, Remote Keyless Entry ............ 9K-1
Battery Tray and Coolant Recovery
Reservoir Assembly ............................. 68-19
Battery Tray Assembly and Hold-Down Retainer ........ 601-2
Battery Tray Assembly Replacement .................. 601 -8
Bearing and Rod Bearing Selection,
Main, 3.4L VIN S .............................. 6A28-29
Bearing Annulus Assembly, Pinion Seal,
Dust Seal and ................................. 381 A-6
Bearing Assembly, Wheel ........................... 3C-19
Bearing, Clutch Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2
Bearing, Clutch Pilot, On-Vehicle Service .............. 7C-13
Bearing, Front Countershaft, Borg-Warner (TS) ...... 78-68-12
Bearing Locations, Seal and, Transmission ........ 7A-14B-71
4 INDEX
Bearing Noise, Connecting Rod, Engine
Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bearing Noise, Main, Engine Noise Diagnosis . . . . . . . . . . . . 6-4
Bearing Noise, Rear Axle ............................ 48-7
Bearing Preload, Rack, Power Steering Gear ......... 381 A-4
Bearing Retainer Oil Seal, Drive Gear,
Borg-Warner (TS) ............................ 78-68-1 o
Bearing Rollers and Spacers, Borg-Warner (TS) ...... 78-68-8
Bearings, Camshaft, 3.4L VIN S Assembly .......... 6A2B-41
Bearings, Camshaft, 3.4L VIN S Disassembly ........ 6A28-22
Bearings, Crankshaft, 3.4L V6 Engine
Bearings, Front and Rear, Borg-Warner (TS) ......... 78-68-8
Belt (Serpentine Belt), Power Steering Pump ............ 38-5
Belt Assemblies, Center ........................... 10-11-5
Belt Seals, Front Side Door Front and Rear . . . . . . . . . . 10-6-15
Belts Operational and Functional Checks, Seat ........ 10-11-1
Belts, Seat ....................................... 10-11-1
Belts Service Precautions, Seat ..................... 10-11-2
Bench Bleeding, Master Cylinder Assembly . . . . . . . . . . . . . 5A-4
Bench-Check Procedures, Compressor . . . . . . . . . . . . . . 102-11
Bezel, Front Side Door Inside Handle . . . . . . . . . . . . . . . . 10-6-9
Bi-Level Valve, Manual Control A/C ................... 181-5
Bladders, Lumbar and Lateral Support . . . . . . . . . . . . . 10-10-10
Blade Assembly Replacement, Wiper ................. 8E-11
Blade Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
Blade Element Replacement, Wiper . . . . . . . . . . . . . . . . . . 8E-13
Blade Element Set Check, Wiper ..................... 8E-17
Bleed Pipe Assembly, Coolant Air,
Bleeding Procedure, Hydraulic System, Folding Top . . . 10-9-26
Blocker Rings, First/Second, Borg-Warner (TS) ....... 78-68-9
Blocker Rings, Synchronizer, Borg-Warner (TS) ...... 78-68-9
Blocker Rings, Third/Fourth, Borg-Warner (TS) ....... 78-68-9
Blower Module Assembly, Heater
and Air Conditioning Evaporator and ............... 8C-20
Blower Motor Assembly and Blower Motor Fan . . . . . . . . . 1A-17
Blower Motor Assembly and Evaporator,
Manual Control AIC ............................. 181-5
Blower Motor Assembly Noise . . . . . . . . . . . . . . . . . . . . . . . . 1A-9
Blower Motor Assembly Relay . . . . . . . . . . . . . . . . . . . . . . . . 18-5
Blower Motor Assembly Relay, Manual Control AIC . . . . 1B1-15
Blower Motor Assembly Speed Control Knob . . . . . . . . . . . 1A-5
Blower Motor Assembly Switch, Control
Assembly and Vacuum Selector Valve and/or . . . . . . . . . 1A-9
Blower Motor Fan, Blower Motor Assembly and ........ 1A-17
Blower Motor Resistor Assembly . . . . . . . . . . . . . . . . . . . . . 1A-17
Blower Motor Speed Control, Manual Control AIC ....... 181-4
Blower with Impeller Motor Assembly
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . 18-27
Body (Assemble), Oil Pump ..................... 7A-148-44
Body and Chassis, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Body Construction, General ........................ 10-3-1
Body Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
Body Dimensions and Underbody . . . . . . . . . . . . . . . . . . . 10-3-1
Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Body Hinge Pillar Inner Panel Sound Barriers . . . . . . . . 10-5-22
Body Hinge Pillar Trim Panel Assembly . . . . . . . . . . . . . 10-5-22
Body Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-2
Body, Oil Pump ................................ 7A-148-41
Body Panel Adjustment and Alignment . . . . . . . . . . . . . . 10-5-27
Body Panel Assembly Adjustment and Alignment . . . . . 10-1-19
Body Rear End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Body Repair and Dimensions, Structural . . . . . . . . . . . . . . . 11-1
Body Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Body Service, General ....... : . . . . . . . . . . . . . . . . . . . . . 10-1-1
Booster System, Vacuum ........................... 501 -1
Borg-Warner (TS) 5-Speed Manual Transmission
Unit Repair (RPO M49) Description .................. 7-1
Borg-Warner (TS) Unit Repair ...................... 78-6fl-1
Borg-Warner (T56) 6-Speed Manual Transmission
(
Unit Repair (RPO MM6) Description ................. 17-2
Borg-Warner (T56) Unit Disassembly .............. 78-108-1
Borg-Warner (T56) Unit Repair .................... 78-108~1
Borg-Warner (T56) Unit Subassembly Repair
and Inspection ............................... 78-1 OB-9
Bow Assemblies, Folding Top ....................... 10-9-7
Bow Finish Molding Assembly, Roof Panel
Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-39
Bow Links, Folding Top Number One
and Number Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-16
Bracket and Link Assembly, Stabilizer Shaft ............. 30-9
Bracket, Front License Plate . . . . . . . . . . . . . . . . . . . . . . . . 10-4-3
Brackets, Engine Mount Assemblies and,
3.4L V6 Engine On-Vehicle Service .............. 6A2A-4
Braided Lead Wire Repair, Rear Window Defogger . . . . 10-2-9
Brake (Center) Hose Assembly, Rear ......... : ........ 5-22
Brake Adjustment, Parking ........................... SF-7
Brake Booster Assembly, Power ..................... 501-1
Brake Booster Assembly, Power, On-Vehicle Service .... 501-2
Brake Booster Vacuum Hose and Routing, Power ...... 501-4
Brake Caliper Anchor Bracket and
Mounting Plate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-8
Brake Caliper Assembly, Front ....................... 581-1
Brake Caliper Assembly, Front, On-Vehicle Service ..... 581-4
Brake Caliper Assembly Inspection, Front .............. 581-4
Brake Caliper Assembly Inspection, Rear .............. 582-3
Brake Caliper Assembly, Rear, On-Vehicle Service ...... 582-3
Brake Caliper Assembly, Rear, Unit Repair ........... 582-11
Brake Fluid and Fluid Handling . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Brake Fluid and Fluid Handling . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Fluid, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Brake Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Fluid, Substandard or Contaminated . . . . . . . . . . . . . . 5-2
Brake Fluid, Substandard or Contaminated . . . . . . . . . . . . . 5A-2
Brake Free-Travel Adjustment, Parking ................ 582-9
Brake Hose and Pipe Assembly Inspection . . . . . . . . . . . . . . 5-5
Brake Hose Assembly, Front .................... , . . . . 5-21
Brake Hose Assembly, On-Vehicle Service . . . . . . . . . . . . . 5-21
Brake Hose Assembly, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Brake Hydraulic System, Flushing . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Hydraulic System, Flushing, On-Vehicle Service ... 5-24
"BRAKE" Indicator Lamp ...................... 5F-1 & 8C-5
Brake Lever Assembly, Parking . . . . . . . . . . . . . . . . . . . . .. . 5F-1
Brake Lever Assembly, Parking, On-Vehicle Service ..... 5F-3
Brake, Parking ..................................... 5F-1
Brake Pedal Assembly, On-Vehicle Service .............. 5-8
Brake Pedal Assembly Travel . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Pedal Assembly with Bracket, On-Vehicle Service ... 5-5
Brake Performance, External Conditions That Affect . . . . . . 5-4
Brake Pipe Assembly, On-Vehicle Service .............. 5-11
Brake Pressure Differential Warning Switch . . . . . . . . . . . . . . 5-2
Brake Proportion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Rotor Assemblies, Burnishing Front .......... "... 581-8
Brake Rotor Assemblies, Burnishing Rear ............ 582-11
Brake Rotor Assemblies Non-Directional
Finishing, Front ............................ , .... 581 -8
INDEX 5
. Brake Rotor Assemblies Non-Directional
\r;i;i~~~~ ~::mbii~~
att~v~i,i~1~ ..................
582 11
-
\ Procedure, Front ................................ 581-7

Brake Rotor Assemblies Off-Vehicle, Rear ............ 582-1 o
Brake Rotor Assemblies On-Vehicle
Procedure, Front ................................ 581 -7
Brake Rotor Assemblies On-Vehicle, Rear ............ 582-10
Brake Rotor Assemblies, Refinishing Front ............ 581-7
Brake Rotor Assemblies, Refinishing Rear ............. 582-9
Brake Rotor Assembly, Front ........................ 581-1
Brake Rotor Assembly, Front, On-Vehicle Service ....... 581-7
Brake Rotor Assembly Inspection, Front ............... 581 -2
Brake Rotor Assembly Inspection, Rear ............... 582-2
Brake Rotor Assembly, Rear, On-Vehicle Service ....... 582-8
Brake Rotor Assembly Tolerance and Surface
Finish, Front .................................... 581 -2
Brake Rotor Assembly Tolerance and Surface
Finish, Rear .................................... 582-2
Brake System, Antilock ............................. 5E1-1
Brake System, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake System, Parking .............................. 5F-1
Brake System Testing, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake System with Traction Control System, Antilock . . . . 5E2-1
Brake Transmission Shift Interlock (BTSI),
Steering Wheel and Column On-Vehicle Service ...... 3F-2
Brakes ............................................. 5-1
Brakes, Drum Assembly Inspection Duo Servo Drum .... 5C2-1
Brakes, Duo-Servo Drum ........................... 5C2-1
Brakes, Duo-Servo Drum, Primary and
Secondary Shoes Inspection ...................... 5C2-1
Brakes, Front Disc ................................. 581-1
Brakes, Rear Disc ................................. 582-1
Buckle-Side Belt Assemblies, Front Driver and
Passenger Seat ................................ 10-11-2
Built-In Hydrometer, Battery ......................... 601 -3
Bulb Replacement, Courtesy Lamp . . . . . . . . . . . . . . . . . . 10-2-6
Bulb Usage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-18
Bulbs, Halogen ..................................... 88-2
Bumper Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumper Assembly, Jounce, Rear Suspension ........... 30-1
Bumper Assembly, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-8
Bumper Energy Absorber, Front . . . . . . . . . . . . . . . . . . . . . 10-4-3
Bumper Energy Absorber, Rear . . . . . . . . . . . . . . . . . . . . 10-4-10
Bumper Fascia Emblem Assemblies, Front . . . . . . . . . . . 10-4-6
Bumper Fascia Lower Deflectors, Front . . . . . . . . . . . . . . 10-4-7
Bumper, Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-31
Bumper Impact Bar Assembly, Front . . . . . . . . . . . . . . . . . 10-4-5
Bumper Impact Bar, Rear . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-10
Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumpers Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumpers, Front Side Door Window Front and Rear . . . 10-6-40
Bushing Assembly, Lower Control Arm ................. 30-1
c
Cable Assemblies, Parking Brake . . . . . . . . . . . . . . . . . . . . . 5F-1
Cable Assembly (Disc Brakes), Rear, Parking
Brake, On-Vehicle Service ......................... 5F-6
Cable Assembly (Drum Brakes), Rear, Parking Brake,
On-Vehicle Service ............................... 5F-5
Cable Assembly Adjustment (Optional),
Cable Assembly Adjustment (Standard),

Cable Assembly, Cruise Control, On-Vehicle Service . . . . 98-16
Cable Assembly, Front, Parking Brake,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-3
Cable Assembly, Negative .......................... 601-9
Cable Assembly, Positive .......................... 601-10
Cable Assembly Replacement (Optional),
Cable Assembly Replacement (Standard),
Cable Assembly Replacement and Routing, Battery ..... 601 -9
Cables Assemblies, Parking Brake,
Caliper Anchor Bracket and Mounting
Plate, Rear Brake ............................... 582-8
Caliper Assembly, Front Brake ....................... 581-1
Caliper Assembly, Front Brake, On-Vehicle Service ..... 581-4
Caliper Assembly Inspection, Front Brake ............. 581 -4
Caliper Assembly Inspection, Rear Brake .............. 582-3
Caliper Assembly, Rear Brake, On-Vehicle Service ...... 582-3
Caliper Assembly, Rear Brake, Unit Repair ............ 582-11
Camber and Caster Adjustment, Front,
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4
Camber, Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Camshaft, 3.4L VIN S Assembly ................... 6A2B-46
Camshaft, 3.4L VIN S Disassembly ................. 6A2B-18
Camshaft Assembly, 3.4L V6 Engine
Camshaft Assembly 5. 7 Liter V8 Engine ............. 6A3A-15
Camshaft Assembly 5.7 Liter V8 Engine
Unit Repair ................ 6A3B-14, 6A3B-29 & 6A3B-34
Camshaft Bearings, 3.4L VIN S Assembly ........... 6A2B-41
Camshaft Bearings, 3.4L VIN S Disassembly ........ 6A2B-22
Camshaft Bearings 5.7 Liter V8 Engine
Unit Repair ......................... 6A3B-20 & 6A3B-31
Camshaft Inspection, 3.4L VIN S ................... 6A2B-38
Camshaft Position Sensor Assembly
(3.4L L32 Engine) ............................... 604-2
Camshaft Position Sensor Assembly
(3.4L L32 Engine), On-Vehicle Service ............. 604-9
Camshaft Sprockets, Timing Chain Assembly,
and Crankshaft and, 3.4L V6 Engine
Cap and Lines Inspection, Fuel Tank, .................. 08-5
Care, Cleanliness and, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Carpet Assembly, Floor ..................... , . . . . . 10-10-1
Carpet Assembly, Floor, On-Vehicle Service . . . . . . . . 10-10-26
Carpet Insert Reattachment . . . . . . . . . . . . . . . . . . . . . . . 10-1-19
Carpet, Seats and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Case Assembly, Auto Trans Unit Repair ........... 7A-14B-14
Case, Auto Trans Unit Repair .................... 7A-14B-14
Case Extension Automatic Transmission
Case Extension Oil Seal Assembly Automatic
Transmission On-Vehicle Service .................. 7A-25
Case Extension, Speed Sensor and ............... 7A-148-5
Case Extension, Speed Sensor and,
Trans Reassembly .......................... 7A-14B-58
Cassette Care, Tape Player and, On-Vehicle Service .... 9A-14
Cassette Tape Player (UN6) . . . . . . . . . . . . . . . . . . . 9A-4 & 9A-8
Cassette Tape Player (UT6) ......................... 9A-10
Cassette Tape Player (UU8) .......................... 9A-5
6 INDEX
Caster Adjustment, Camber and, Wheel Alignment . . . . . . 3A-4
Caster, Wheel Alignment ............................. 3A-1
Catalytic Converter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Catalytic Converter Assembly, On-Vehicle Service ....... 6F-4
Catalytic Converter Hanger Assembly .................. 6F-7
Catalytic Converter Heat Shield . . . . . . . . . . . . . . . . . . . . . . 6F-11
Caulking Kit, Adhesive, Stationary Windows . . . . . . . . . . 10-2-1
Center Air Outlet Duct Assemblies ................... 8C-18
Center Belt Assemblies ............................ 10-11-5
Center Molding Assembly, Front Side Door . . . . . . . . . . 10-6-10
Center Support Bearing, Propeller Shaft . . . . . . . . . . . . . . . . 4A-1
Center Support Bearing Replacement ................. 4A-12
Chain and Sprocket Noises, Timing Gear or,
Engine Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Chain and Sprockets, Timing, 3.4L VIN S ............ 6A28-38
Chain and Sprockets, Timing,
3.4L VIN S Assembly .......................... 6A28-46
Chain and Sprockets, Timing,
3.4L VIN S Disassembly ....................... 6A28-18
Chain Usage, Tire .................................. 3E-2
Chamber, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
Changing Transmission Fluid and
Automatic Transmission Oil Filter
Assembly Automatic Transmission
Charging a Very Low or Completely
Discharged Battery Assembly ..................... 601 -7
Charging, Battery Assembly ......................... 601 -6
Charging Equipment, Battery ....................... 601-1 O
Charging Procedure, Battery ........................ 601 -7
Charging System .................................. 603-1
Charging the A/C System (Engine Off) ................ 18-14
Charging Time Required, Battery ..................... 601 -7
Chassis, Electrical Body and . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-4
"CHECK GAUGES" Indicator Lamp .................... 8C-6
Check Valve Retainer and Ball Assembly Replacement Procedures .................... 7A-148-26
Check Valve, Vacuum .............................. 501 -4
Checking Limited Slip Operation, Rear Axle ............. 48-7
Chemical Stability in the Refrigeration
System, Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-9
Child Seat ....................................... 10-11-6
Child Seat Top-Tether Anchor Bracket ............... 10-11-7
Chimes, Warning/Reminder .......................... 8C-6
Chimes, Warning/Reminder, On-Vehicle Service ........ 8C-32
Cigarette Lighter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-15
Circuit, Cranking ................................... 602-1
Circuit Descriptions, Fluid Flow and ............... 7 A-14A-52
Circuit Operation, Windshield
Wiper/Washer System (Pulse) ..................... 8E-1
Clamps and Welded Connections, Exhaust System . . . . . . 6F-2
Clamps Inspection, Hose Assemblies and .............. 684
Cleaning and Inspection, Borg-Warner (T5) .......... 78-68-8
Cleaning, Inspection and Repair, 3.4L VIN S ......... 6A28-22
Cleaning, Inspection and Repair
5.7 Liter V8 Engine Unit Repair .................. 6A3B-21
Cleaning, Inspection and Testing
(PG-250 and SD210 Starter Motor Assemblies) ..... 602-10
Cleanliness and Care, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Clearance Dimensions, Exhaust System . . . . . . . . . . . . . . 6F-13
Clearcoat Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 O
Clearcoat Repair without Repainting . . . . . . . . . . . . . . . . . 10-1-9
Clearcoat Thickness .............................. 10-1-11
Clock Radio Assembly, AM/FM Stereo and ............. 8C-7

Closeout Filler, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13
Closeout Filler, Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Closeout Panel Assembly, Rear Compartment . . . . . . . 10-8-1 O
Closeout Panel Assembly, Rear
Compartment Lift Window . . . . . . . . . . . . . . . . . . . . . . . 10-9
~~r_n_i~~~l~~'.~~t~~ .~~~:~.
g:~:~~r.
: : : : : : : : : : : : : : : : : : : : : : 8 :~
Clutch Air Check .............................. 7A-14 -35
Clutch Anticipate Switch Assembly .................... T/C-7
Clutch Assembly, 3-4 ........................... 7A-14B-35
Clutch Assembly, Input ......................... 7A-14825
Clutch Coil, Compressor ............................ 102-7
Clutch Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Clutch Driven Plate Assembly (5-Speed) ............... 7C-8
Clutch Driven Plate Assembly (6-Speed) ............... 7C-9
Clutch Fluid, Hydraulic ............................... 7C-2
Clutch Fork Assembly and Clutch Release
Bearing Assembly (5-Speed) ...................... 7C-12
Clutch Fork Assembly and Clutch Release
Bearing Assembly (6-Speed) ...................... 7C-12
Clutch, Hydraulic ................................... 7C-1
Clutch Master and Actuator Cylinder Assembly .......... 7C-7
Clutch On-Vehicle Service ........................... 7C-4
Clutch Pedal Assembly .............................. 7C-7
Clutch Pedal Position Switch Assembly (Clutch
Start Switch Assembly) ........................... 7C-8
Clutch Pilot Bearing ................................. 7C-2
Clutch Pilot Bearing, On-Vehicle Service .............. 7C-13
Clutch Piston Travel Check, 3-4 .................. 7A14B-35
Clutch Plate and Hub Assembly, Compressor . . . . . . . . . . 102-3
Clutch Preliminary Checks ........................... 7C-2
Clutch Principle Components ......................... 7C-1
Clutch Release Bearing Assembly (5-Speed),
Clutch Fork Assembly and ........................ 70-12
Clutch Release Bearing Assembly (6-Speed),
Clutch Fork Assembly and ........................ 7C-12
Clutch Rotor and/or Bearing ......................... 102-4
Clutch Spacer Plate Selection, Lo and Reverse .... 7A-14B-18
Clutch Sprag Assembly, Forward ................. 7A 148-32
Clutch Support Assembly, Lo and Reverse ........ 7 A-148-21
Clutch System Diagnosis ............................ 7C-2
Coast Button Switch, Seti ............................ 98-2
Coast Test, Propeller Shaft Diagnosis . . . . . . . . . . . . . . . . . . 4A-3
Coil Assembly (3.4L L32 Engine), Ignition .... 604-8 & 604-10
Coil Assembly (5.7L LT1 Engine), Ignition ............. 604-7
Cold Cranking Amps, Battery ........................ 601 -2
Column Assembly Removal, Steering ................. 3F-14
Column Assembly, Steering ..................... 3-8 & 3F-2
Column Lock and Ignition Cylinder Assembly,
Steering, Theft Deterrent .......................... 90-2
Column, Lower, SIR Tilt Steering Column
Floor Shift .................................... 3F5B-15
Column, Mid, SIR Tilt Steering Column Floor Shift .... 3F58-11
Column-Mounted Dimmer Switch, Steering
Column Diagnosis ................................ 3-14
Column On-Vehicle Service, Steering Wheel and ........ 3F-1
Column, Upper, SIR Tilt Steering Column Floor Shift ... 3F5B-4
Combination Valve Assembly, Brakes . . . . . . . . . . . . . . . . . . . 5-2
Combination Valve Assembly, Brakes On-Vehicle Service ............................... 5-20
Comfort Controls, Pneumatic . . . . . . . . . . . . . . . . . . . . . . 10-10-2
Compact Disc (U1 T), Delco -GM/Bose Music System/ .... 9A-6
Compact Disc Care, On-Vehicle Service .............. 9A-15
INDEX 7
pact Disc Player (U1 C) ................... 9A-7 & 9A-11
mpact D!sc Player (UH) .......................... 9A-6
pact Disc Player (UP3) ......................... 9A-12
pact Spare Tire Assembly ........................ 3E-9
partment, Instrument Panel, On-Vehicle Service .... 8C-30
Compartment Lamp, Instrument Panel ................. 88-4
Compartment Lamp, Instrument Panel,
Compartment Lamp, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-4
Compartment Lamp Switch .......................... 8C-16
Compartment Lock System, Rear . . . . . . . . . . . . . . . . . . . 10-8-1
Compartments, Trim Panel Cluster Bezel
Assembly, Upper Trim Panel Assembly and ......... 8C-29
Component and System Descriptions,
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14A~3
Component Location View, Electronic . . . . . . . . . . . . . . 7A-14A-5
Component Locations, Windshield
Wiper/Washer System (Pulse) ..................... 8E-3
Component Repair and Transmission
Reassembly ................................ 7A-148-14
Component Replacement, Exhaust System
Component Resistance Chart .................... 7A-14A-36
Components (Canadian Only), Daytime
Running Lamp (DRL) .. . . . . . .. . . . . . . . . . . . . .. .. . .. 8C-11
Components, Other, Manual Control NC .............. 181 -5
Compression Test, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Compressor and Condenser Hose Assembly
Replacement Procedures,
Air Conditioning .. . . . . . . . . . .. . . . . . . . . . . . . 18-15 & 1B-24
Compressor Assembly, Air Conditioning . . . . . . . . . . . . . . . . 1B-4
Compressor Assembly, Manual Control NC ........... 181-1 O
Compressor Assembly Replacement
Procedures, Air Conditioning . . . . . . . . . . . . . . . . . . . . . . 1B-20
Compressor Clutch Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102-7
Compressor Clutch Plate and Hub Assembly . . . . . . . . . . 102-3
Compressor Clutch Rotor and/or Bearing . . . . . . . . . . . . . . 102-4
Compressor Leak Testing .......................... 102-11
Compressor Pressure Relief Valve .................. 102-10
Compressor Relay, Air Conditioning . . . . . . . . . . . . . . . . . . . 1B-5
Compressor Relay, Manual Control NC .............. 181-15
Compressor Repair Procedures, Major . . . . . . . . . . . . . . . . 102-8
Compressor Repair Procedures, Minor . . . . . . . . . . . . . . . . 102-3
Compressor Service or Unit Repair
R-134a, HD6/HR6-HE Air Conditioning ............. 102-1
Compressor Shaft Seal Replacement . . . . . . . . . . . . . . . . . 102-8
Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-14
Condenser Assembly, Air Conditioning . . . . . . . . . . . . . . . . . 1B-4
Condenser Assembly, Manual Control NC ............ 181-10
Condenser Assembly Replacement Procedures, Air
Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Condenser Hose Assembly Replacement
Procedures, Air Conditioning Compressor and . . . . . . . 1B-15
Condenser Hose Assembly Replacement
Procedures, Air Conditioning Compressor and . . . . . . . 1B-24
Connecting Rod Assemblies, Piston and,
Connecting Rod Bearing Noise, Engine
Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Connecting Rod Bearings, 3.4L V6 Engine
Connecting Rod Bearings 5.7 Liter V8 Engine ........ 6A3A-23
Connecting Rod Bearings 5.7 Liter
VB Engine Unit Repair ............... 6A3B-25 & 6A3B-33
Connecting Rod, Piston and, 3.4L

VIN S Disassembly ............................ 6A2B-21
Connecting Rods, Pistons and, 3.4L VIN S .......... 6A2B-26
Connecting Rods, Pistons and, 3.4L
VIN S Assembly .............................. 6A2B-44
Connector (DLC), Data Link ......................... 8C-10
Console, Instrument Panel, Gages and ................. 8C-1
Console Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Console Lamp, On-Vehicle Service ................... 88-15
Console Service Precautions, Instrument
Panel, Gages and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC-7
Construction 5.7 Liter VS Engine Unit Repair .......... 6A3B-6
Contact Plate Assembly, Steering Wheel Horn Switch ... 3F-1 O
Contamination Repair, Surface Level . . . . . . . . . . . . . . . 10-1-1 O
Control and Shift Solenoids Automatic
Control Arm Assembly, Lower . . . . . . . . . . . . . . . . . 3C-8 & 30-5
Control Arm Assembly, Upper ....................... 3C-17
Control Arm Ball Stud Assembly Inspection ............. 3C-3
Control Arm Ball Stud Assembly, Lower ................ 3C-3
Control Arm Ball Stud Assembly Replacement . . . . . . . . . . 3C-4
Control Arm Ball Stud Assembly Replacement, Lower . . . . 3C-4
Control Arm Ball Stud Assembly Replacement, Upper . . . . 3C-5
Control Arm Ball Stud Assembly, Upper ................ 3C-4
Control Arm Bushing Assembly, Lower . . . . . . . . . . 3C-9 & 30-1
Control Arm Busing Assembly, Upper ................. 3C-18
Control Assembly and Vacuum Selector Valve
and/or Blower Motor Assembly Switch . . . . . . . . . . . . . . . 1A-9
Control Assembly, Heater and Ventilation . . . . . . . . . . . . . . . 1A-2
Control Assembly Lamp Bulb ........................ 1A-15
Control Assembly, Manual Control NC ................ 181 -3
Control Cable Assembly, Temperature . . . . . . . . . . . . . . . . 1A-16
Control Knob, Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Control Knob, Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Control Lamp, Heater and Air Conditioning ............. 88-4
Control Lamp, Heater and Air Conditioning,
Control Lever Boot Assembly, Manual Transmission ...... 78-6
Control Lever Handle Assembly (6-Speed), Manual
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-8
Control Lever Solenoid Automatic Transmission
Control Module Assembly, Headlamp Opening
Door Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-8
Control Switch Assembly, Radio . . . . . . . . . . . . . . . . . . . . . 3F-11
Control Switches, Compressor . . . . . . . . . . . . . . . . . . . . . . 102-11
Control Switches, Functional, Cruise Control . . . . . . . . . . . . 98-2
Control Switches, Traction .......................... BC-17
Control Valve Assembly, Auto Trans Unit Repair .... 7A-14B-50
Control Valve Assembly, Power Steering Pump ........ 381 B-6
Control Valve Body and Pressure Switch Automatic
Control Valve, Hydraulic Pump Flow ................... 38-8
Controls, Instrument Panel, Gages and Console ......... 8C-7
Controls, Radio Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
Controls, Steering Wheel Assembly . . . . . . . . . . . . . . . . . . . 3F-2
Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Convenience Center, On-Vehicle Service .............. 8C-26
Converter Assembly, Catalytic ........................ 6F-1
Converter Assembly, Catalytic, On-Vehicle Service ....... 6F-4
Converter Assembly, Torque .................... 7A-14B-59
Converter Evaluation, Torque .................... 7A-14A-20
Convertible Top Switch ............................. 8C-16
Coolant Air Bleed Pipe Assembly, On-Vehicle Service ... 68-22
8 INDEX
Coolant, Checking Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Coolant Concentration, Engine ........................ 68-4
Coolant Drain Hole Plug, Engine Block ................. 68-3
Coolant Fan Assembly, Electric Engine ................ 68-3
Coolant Fan Assembly, Electric Engine,
Coolant Heater Assembly Replacement, Engine ......... 9E-1
Coolant Heater Cord Assembly
Replacement, Engine ............................. 9E-2
Coolant Heater, Engine .............................. 9E-1
Coolant Hose Assemblies, Engine,
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-20
Coolant Pump, 3.4L VIN S ........................ 6A2B-39
Coolant Pump, 3.4L VIN S Assembly ............... 6A2B-48
Coolant Pump, 3.4L VIN S Disassembly ............. 6A2B-17
Coolant Recovery Reservoir Assembly,
Battery Tray and ................................ 68-19
Coolant Recovery System ........................... 68-3
Coolant Thermostat Assembly, Engine,
Coolant Thermostat Assembly Test, Engine ............. 68-4
Coolant Weepage, Water Pump Assembly .............. 68-4
Cooler Gasket, Transmission Oil ..................... 68-14
Cooler Inlet and Outlet Hose Assemblies, Engine Oil .... 68-20
Cooler, Transmission Oil ............................ 68-15
Cooling and Radiator ........................... 6-2 & 68-1
Cooling and Radiator Maintenance
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Cooling Check, Insufficient, Manual Control A/C ....... 1BH 1
Cooling Fin Removal, On-Vehicle Service ............. 68-11
Cooling System Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . 68-6
Cooling System, Draining and Refilling ................. 68-7
Cooling System Overheating . . . . . . . . . . . . . . . . . . . . . . . . . 68-4
Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-4
Cord Assembly Replacement, Engine Coolant Heater . . . . 9E-2
Core, Heater ...................................... 1A-20
Core Repair, General, On-Vehicle Service ............. 68-12
Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1-9
Counter Extension, (T56) Assembly .............. 78-108-28
Counterbalance Arm Channel
Assembly, Front Side Door Window Regulator . . . . . 10-6-17
Countershaft, (T56) Repair and Inspection ......... 78-108-13
Countershaft Bearing, Front, Borg-Warner (T5) ...... 78-68-12
Countershaft Extension, (T56) ................... 78-108-32
Countershaft Extension Assembly,
(T56) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-1 OB-7
Countershaft Extension Assembly,
(T56) Repair and Inspection .................. 78-108-13
Countershaft, Input Shafl/Mainshaft and, (T56) ..... 78-108-32
Coupling Shaft Assembly, Steering Gear .............. 3F-12
Courtesy Lamp Assembly, Quarter .................. 10-7-5
Courtesy Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . 10-2-6
Courtesy Lamps, Front Side Door ..................... 88-3
Courtesy Lamps, Front Side Door,
Courtesy Lamps, Rear Quarter ....................... 88-4
Cover (Assemble), Oil Pump .................... 7A-14B-44
Cover (Disassemble), Oil Pump ............... ?A-14842
Cover and Body, Oil Pump ...................... 7A-14B-45
Cover Assembly, Engine Front, 3.4L
V6 Engine On-Vehicle Service .................. 6A2A-14
Cover Assembly, Folding Top . . . . . . . . . . . . . . . . . . . . . . 10-9-33
Cover Assembly Replacement, Wiper Motor . . . . . . . . . . . 8E-15
Cover, Front Fog Lamp Opening . . . . . . . . . . . . . . . . . . . . 10-4-6

Cover, Housing, SIR Tilt Steering
Column Floor Shift ............................. 3F58-9
Cover Retention Cable Assembly, Folding Top . . . . . . . 10-9-31
Cover, Transmission, Borg-Warner (T5) ............ 78-68-~ 1
Covers, R~ar Trim and .......................... 10-1i'23
Covers, Trim, Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . 10- -5
Cracked, Scored or Grooved Duo-Servo
Drum Brakes ................................... 5 2-7
Cradle-to-Body Fastener Repair ..................... 1 -3-1
Crankcase Ventilation Filter Replacement,
Air Cleaner and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-5
Cranking Amps, Cold, Battery ....................... 601 -2
Cranking Circuit ............................. , ..... 602-1
Cranking System .................................. 602-1
Cranking System Diagnosis ......................... 602-1
Cranking System On-Vehicle Service ................. 602-2
Cranking System Unit Repair ........................ 602-5
Crankshaft, 3.4L VIN S ........................... 6A2B-25
Crankshaft, 3.4L VIN S Assembly .................. 6A2B-42
Crankshaft, 3.4L VIN S Disassembly ................ 6A2B-21
Crankshaft and Camshaft Sprockets,
Timing Chain Assembly, and 3.4L V6
Engine On-Vehicle Service ..................... 6A2A-15
Crankshaft Assembly 5.7 Liter V8 Engine
Unit Repair ......................... 6A3B-23 & 6A38-32
Crankshaft Balancer Assembly, 3.4L
Crankshaft Balancer Assembly and Hub,
5. 7 Liter V8 Engine ................... , ........ 6A3A-12
Crankshaft Balancer Assembly and Hub
5.7 Liter V8 Engine Unit Repair .................. 6A3B-35
Crankshaft Balancer Assembly and Hub
5. 7 Liter V8 Engine Unit Repair .................. tlA3B-11
Crankshaft Bearing Fitting 5.7 Liter
V8 Engine Unit Repair ......................... 6A3B-22
Crankshaft Bearings, 3.4L V6 Engine
Crankshaft Bearings 5.7 Liter V8 Engine ............ 6A3A-25
Crankshaft Position Sensor Assembly
(3.4L L32 Engine), 24X Signal .................... 604-2
(3.4L L32 Engine), 24X Signal, On-Vehicle Service ... 604-8
(3.4L L32 Engine), 3X Signal ...................... 604-2
(3.4L L32 Engine), 3X Signal, On-Vehicle Service .... 604-8
Crankshaft Rear Oil Seal 5.7 Liter
VB Engine Unit Repair ......................... 6A3B-33
Crankshaft Rear Oil Seal Assembly,
Crankshaft Rear Oil Seal Assembly 5.7 Liter
V8 Engine ................................... 6A3A-28
Crankshaft Rear Oil Seal Housing 5.7
Liter V8 Engine Unit Repair ..................... 6A3B-32
Crankshaft rear Oil Seal Housing and
Crankshaft Assembly 5.7 Liter VB
Engine Unit Repair ............................ 6A3B-19
Crankshaft Rear Oil Seal Housing
Assembly and Gasket 5.7 Liter VB Engine ........ 6A3A-29
Cross Section, Auto Trans Unit Repair ............ 7A-148-61
Cross-Flow Radiator Core and Outlet
and Inlet Tanks .................................. 68-2
Crossmember Assembly ............................ 3C-19
INDEX 9
Crossover Pipe Assembly, Exhaust ............ , ....... 6F-1
Crossover Pipe Assembly, Exhaust,
ruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-1
C uise Control Cable Assembly, On-Vehicle Service ..... 98-16
Cruise Control Module Assembly . . . . . . . . . . . . . . . . . . . . . . 98-1
Cruise Control Module Assembly, On-Vehicle Service ... 98-14
Cruise Control Switch Assemblies ..................... 98-1
Cruise Control Switch Assemblies,
Cr,uise Control Switch Assemblies, Stoplamp and . . . . . . . . . 5-9
C~ Generator Assembly Bench Check ................ 603-2
C Generator Assembly On-Vehicle Check ............ 603-2
CS, 130 105-Amp Generator Assembly
(3.4L L32 Engine, On-Vehicle Service .............. 603-3
CS-130 105-Amp Generator Assembly
(3.4L L32 Engine), Unit Repair .................... 603-6
CS-130 and CS-144 Generator Assemblies ............ 603-1
CS-144 124-Amp or 140 Amp Generator
Assembly (5.7L LT1 Engine), On-Vehicle Service .... 603-6
CS-144 124-Amp or 140-Amp Generator
Disassembly, Test and Reassembly
(5.7L LT1 Engine), Unit Repair .................... 603-7
CS-144 Generator Assemblies, CS-130 and ........... 603-1
Cushion Assemblies, Front Seat . . . . . . . . . . . . . . . . . . . 10-10-9
Cushion Assembly, Rear Seat . . . . . . . . . . . . . . . . . . . . 10-10-21
Cushion Assembly, Rear Seatback . . . . . . . . . . . . . . . . 10-10-21
Cutting Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-8
Cylinder Assembly Check, Master . . . . . . . . . . . . . . . . . . . . . 5A-2
Cylinder Assembly, Clutch Master and Actuator ......... 7C-7
Cylinder Assembly, Folding Top . . . . . . . . . . . . . . . . . . . . 10-9-25
Cylinder Assembly, Master . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Cylinder Assembly, Master, On-Vehicle Service .......... 5A-3
Cylinder Assembly, Master, Unit Repair ................ 5A-4
Cylinder Block, 3.4L VIN S ........................ 6A2B-22
Cylinder Block, 3.4L VIN S Assembly ..... 6A28-41 & 6A2B-45
Cylinder Head, 3.4L VIN S Disassembly ............. 6A28-20
Cylinder Head Assembly 5.7 Liter
V8 Engine Unit Repair ...... 6A3B-14, 6A3B-27 & 6A3B-34
Cylinder Head Assembly and Gasket,
Cylinder Head Assembly and Gasket
5.7 Liter V8 Engine ............................ 6A3A-17
Cylinder Head Reconditioning, 3.4L VIN S ........... 6A2B-33
Cylinder Line Assembly and 0-Ring Seals ............ 381 A-5
Cylinder Lower Hose Assembly (Right-Hand
Cylinder), Folding Top . . . . . . . .. . . . .. .. . . . . . . . . . . 10-9-24
Cylinder, Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A 1
Cylinder Unit, Lock, On-Vehicle Service ............. 10-6-33
Cylinder Upper Hose Assembly (Left-Hand
Cylinder), Folding Top . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-23
D
Damper, Torsional, 3.4L VIN S Assembly ............ 6A2B-49
Damper, Torsional, 3.4L VIN S Disassembly ......... 6A2B-17
Dash Sound Barrier Assembly . . . . . . . . . . . . . . . . . . . . . 10-5-22
Data Link Connector (DLC) .......................... 8C-10
Daytime Running Lamp (DRL) Ambient Light
Sensor (Canadian Only) ........................... 8C-4
Daytime Running Lamp (DRL) Components
(Canadian Only) ................................ 8C-11
Daytime Running Lamp Ambient Light
Sensor Assembly, On-Vehicle Service .............. SC-11
Daytime Running Lamp Ambient Light

Sensor Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . SC-11
Daytime Running Lamps (Canadian Only) .............. 88-2
Daytime Running Lamps (DRL) (Canadian Only) ........ SC-2
Decal, Exterior Moldings and . . . . . . . . . . . . . . . . . . . . . . 10-5-24
Decal, Headlamp Opening Door . . . . . . . . . . . . . . . . . . . 10-5-26
Decals, Stripes and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-2
Decimal and Metric Equivalents ...................... OA-11
Definitions and Abbreviations, Transmission ........ 7A-14A-1
Deflector, Driver Knee Bolster Assembly and ........... SC-13
Deflector, Radiator Air Lower . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Deflector, Radiator Air Lower Baffle Assembly
and, On-Vehicle Service .......................... 68-21
Deflectors, Front Bumper Fascia Lower .............. 10-4-7
Deflectors, Radiator Air Baffle Assemblies and . . . . . . . . . . 68-3
Deflectors, Radiator Air Baffle Assemblies
and, On-Vehicle Service .......................... 68-21
Defogger Outlet Duct Assembly ...................... 8C-18
Defogger, Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-8
Defogger Relay Replacement Procedures, Rear . . . . . . . . 18-27
Defrost Valve, Heater and, Manual Control NC ......... 181 -6
Defrosting, Insufficient Heating or . . . . . . . . . . . . . . . . . . . . . 1A-8
Dehydrator Assembly, Air Conditioning Receiver and . . . . . 1B-4
Dehydrator Assembly, Receiver,
Manual Control NC ............................ 181 -11
Delco-GM/BOSE Music System/Cassette (UU8) ......... 9A-5
Delco-GM/Bose Music System/Compact Disc (U1 T) ..... 9A-6
Delco-GM/Bose Music Systems . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Deployed Inflatable Restraint Steering
Wheel Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-4
Deterrent Systems, Theft ............................ 90-1
Differential Bearing Assembly Preload
Adjustment Rear Axle ............................ 48-21
Differential Case (Limited Slip) Rear Axle .............. 48-26
Differential Case Rear Axle .......................... 48-18
Differential Drive Pinion Gear Depth Rear Axle . . . . . . . . . 48-24
Differential Drive Pinion Gear Inner Bearing
Assembly Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-23
Differential Drive Pinion Gear Outer Bearing
Assembly Rear Axle ............................. 48-23
Differential drive Pinion Gear Rear Axle ............... 48-22
Differential Drive Pinion Gear Yoke
and Seal Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-14
Differential Drive Pinion Gear Yoke
Runout Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Differential Ratios and Tire Information ................. OA-5
Differential Ring Gear Tooth Nomenclature,
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-9
Differential Ring Gear-to-Differential Drive
Pinion Gear Backlash Rear Axle . . . . . . . . . . . . . . . . . . . 48-20
Dimensions and Underbody, Body . . . . . . . . . . . . . . . . . . . 10-3-1
Dimmer Switch Assembly, Headlamp and
Instrument Panel Lamp ........................... SC-4
Dimmer Switch Assembly, Headlamp and
Instrument Panel Lamp, On-Vehicle Service ......... 8C-24
Dimmer Switch Assembly, Ignition Switch and . . . . . . . . . . . 3F-5
Dimmer Switch, Column-Mounted, Steering
Column Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Disabling the SIR System, Steering Wheel and
Column On-Vehicle Service ........................ 3F-4
Disassembly 5.7 Liter VS Engine Unit Repair .......... 6A3B-6
Disc Brake Inner and Outer Pad Assemblies,
Front, On-Vehicle Service ........................ 581 -5
10 INDEX
Disc Brake Inner and Outer Pad Assemblies
Inspection, Front ................................ 581-2
Disc Brake Inner and Outer Pad Assemblies
Inspection, Rear ................................ 582-2
Disc Brake Inner and Outer Pad Assemblies,
Rear, On-Vehicle Service ......................... 582-6
Disc Brakes, Front ................................. 581-1
Disc Brakes, Rear ................................. 582-1
Disc Care, Compact, On-Vehicle Service .............. 9A-15
Disc Player (U1 C), Compact ................... 9A-7 & 9A-11
Disc Player (U1 C), ETR AM/FM
Stereo/Compact . . . . . . . . . . . . . . . . . . . . . . . . . 9A-7 & 9A-1 O
Disc Player (U1 T), Compact .......................... 9A-6
Disc Player (UP3), Compact ......................... 9A-12
Disc Player with Graphic Equalizer (UP3),
ETR AM/FM Stereo/Compact ..................... 9A-11
Disconnecting the Battery Negative Cable Assembly ..... OA-1
Distributor (5.7L LT1 Engine) ........................ 604-6
Distributor Assembly 5. 7 Liter VB Engine ............ 6A3A-12
Distributor Assembly 5. 7 Liter VB Engine
Unit Repair ......................... 6A3B-12 & 6A3B-35
Distributor Assembly, Air ............................ BC-18
Dome and Reading Lamp ............................ 88-3
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-2
Dome Lamp, On-Vehicle Service ..................... 88-15
Door Actuator Control Module Assembly,
Headlamp Opening ............................... 88-8
Door Assembly, Front Side, On-Vehicle Service . . . . . . 10-6-35
Door Decal, Headlamp Opening . . . . . . . . . . . . . . . . . . . 10-5-26
Door Edge Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Door Jamb Switch Assemblies, Front . . . . . . . . . . . . . . . 10-5-23
Door Lock Switches, Side Window, Outside
Remote Control Rearview Mirror Selector and . . . . . 10-6-19
Door Outer Panel Replacement, Structural
Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Door Service, Structural Body Repair . . . . . . . . . . . . . . . . . 11-21
Door Sill Trim Plate, Front Side, On-Vehicle Service .... 10-3-2
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1
Double Lap Flare, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Downstop Adjustment, Folding Top . . . . . . . . . . . . . . . . . 10-9-36
Drain Cock Assembly, Radiator . . . . . . . . . . . . . . . . . . . . . . . 68-2
Drain Cock Assembly, Radiator, On-Vehicle Service ..... 68-15
Drain Hole Plug, Engine Block Coolant ................. 68-3
Draining and Refilling Cooling System ................. 68-7
Draining Engine Assembly 5.7 Liter VB
Engine Unit Repair ............................ 6A3B-10
Drive Belt and Tensioner Assembly, Serpentine,
3.4L V6 Engine On-Vehicle Service ............... 6A2A-2
Drive Belt Inspection, Serpentine ...................... OB-4
Drive Belt, Serpentine ............................... 68-3
Drive Belt, Serpentine, Diagnosis ...................... 68-5
Drive Gear Assembly, Borg-Warner (T5) ............ 78-68-12
Drive Gear Bearing Retainer Oil Seal,
Borg-Warner (T5) ............................ 78-68-10
Drive Gear Disassembly, Borg-Warner (T5) .......... 78-68-8
Drive Motor Assemblies, Driver Seat Adjuster and ... 10-10-15
Drive Shaft Seal, Power Steering Pump .............. 3818-6
Drive Shaft Seal Replacement, Power
Steering Pump ................................. 381 B-3
Driveability and Emissions - Fuel Injection
(Port) (3.4L) .............................. 6E3 (3.4L)-1
Driveability and Emissions - General
Information ................................. 6-2 & 6E-1
Driveability and Emissions - Sequential

Multiport Fuel Injection (SFI) (5.7L) .......... 6E3 (5.7L)-1
Driven Gear, 5th/6th, (T56) Assembly ............. 78-108-29
Driven Gear, 5th/6th, (T56) Disassembly ........... 78-108-6
Driven Member, Clutch .............................. 7C;1
Driven Plate Assembly (5-Speed), Clutch ............... 7,8
Dnven Plate Assembly (6-Speed), Clutch ............... 7 -9
Driver and Passenger Seat Buckle-Side Belt
Assemblies, Front .............................. 10- 1-2
Driver and Passenger Seat Retractor-Side
Belt Assemblies, Front .......................... 10-11-2
Driver Knee Bolster Assembly and Deflector ........... BC-13
Driver Seat Adjuster and Drive Motor Assemblies . . . . 10-10-15
Driving Members, Clutch ............................. 7C-1
Drum Assembly Duo-Servo Drum Brakes ..... 5C2-2 & 5C2-7
Drum Assembly Inspection Duo-Servo
Drum Brakes ................................... 5C2-1
Duct Assemblies, Center Air Outlet ................... BC-18
Duct Assemblies, Outer Air Outlet .................... 8C-20
Duct Assembly, Defogger Outlet ..................... 8C-18
Duct Assembly, Floor Air Outlet ...................... BC-18
Ducts and Outlets, Manual Control NC ............... 181-6
Ducts, Heat, Ventilation and Air Conditioning ........... BC-18
Duo-Servo Drum Brakes ............................ 5C2-1
Duo-Servo Drum Brakes, Backing Plate ............... 5C2-6
Duo-Servo Drum Brakes, Balance . . . . . . . . . . . . 5C2-2 & 5C2-8
Duo-Servo Drum Brakes, Cracked,
Scored or Grooved .............................. 5C2-7
Duo-Servo Drum Brakes, Drum Assembly ..... 5C2-2 & 5C2-7
Duo-Servo Drum Brakes, Inside Diameter Check ....... 5C2-2
Duo-Servo Drum Brakes, Out-of-Round or Tapered ..... 5C2-7
Duo-Servo Drum Brakes, Primary
and Secondary Shoes ........................... 5C2-4
Duo-Servo Drum Brakes, Rear
Drum Brake Adjustment .......................... 5C2-7
Duo-Servo Drum Brakes, Refinishing ................. 5C2-7
Duo-Servo Drum Brakes, Runout Check .............. 5C2-2
Duo-Servo Drum Brakes, Surface Finish .............. 5C2-2
Duo-Servo Drum Brakes, Wheel Cylinder . . . . . . 5C2-5 & 5C2-8
Dust Damage Repair, Rail .......................... 10-1-11
Dust Seal and Bearing Annulus Assembly,
Pinion Seal, ................................... 381 A-6
E
Edge Protector, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Effects of Differential Drive Pinion Gear
Position on Tooth Pattern Rear Axle . . . . . . . . . . . . . . . . 48-11
Effects of Increasing Load on Tooth Contact
Pattern Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-9
Electric Engine Coolant Fan Assembly . . . . . . . . . . 18-4 & 68-3
Electric Engine Coolant Fan Assembly,
Electric Halogen Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 18-5
Electrical Body and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical Connector and Seal Automatic
Electrical Connector, Transmission ................ 7A-14A-9
Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
Electrical Drain, Battery Assembly .................... 601 -4
Electrical/Electronic Components and Systems,
Standard Nomenclature for . . . . . . . . . . . . . . . . . . . . . . . OA-11
Electrical, Engine .............................. 6-2 & 60-1
INDEX 11
\
\iElectrical/Garage Shift Test ...................... 7 A-14A-18
Electrohydraulic Diagnosis, Folding Top . . . . . . . . . . . . . . 10-9-6
Electrol~te Freezing, Battery_ .... .' ................. : ... 601-2
lectron1c Component Location Views ............. 7A-14A-5
ctronic Ignition Module, 3.4L VIN S Assembly ..... 6A2B-49
(:l~ctronic Ignition Module,
' 3.4L VIN S Disassembly ....................... 6A28-16

Electronic Speed Sensor (6-Speed),
. Manual Trans ................................... 78-11
Electrostatic Discharge (ESD) Sensitive
Parts, Handling ........................... OA-1 & 8C-7
El~ment Set Check, Wiper Blade . . . . . . . . . . . . . . . . . . . . . SE-17
Emblem Assemblies, Front Bumper Fascia . . . . . . . . . . . 10-4-6
Emblem Assembly, Front Fender .................... 10-5-11
Emplem Assembly, Front Side Door ................ 10-6-12
Emblem Assembly, Rear End Finish Panel . . . . . . . . . . . 10-8-6
Emissions - Fuel Injection (Port) (3.4L),
.
Driveability and ........................... 6E3 (3.4L)-1
Emissions - General Information,
Driveability and ............................. 6-2 & 6E-1
Emissions - Sequential Multiport
Fuel Injection (SFI) (5.7L), Driveability and .... 6E3 (5.7L)-1
Enabling the SIR System, Steering Wheel
and Column On-Vehicle Service ........ : ........... 3F-4
End Panels, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
End Plate and Rotating Group Replacement,
Power Steering Pump .......................... 381 B-4
End Play Check, Transmission Disassembly ........ 7A-14B-9
End Play Check, Transmission Reassembly ........ 7 A-148-46
Endgate Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-3
Energy Absorber, Front Bumper . . . . . . . . . . . . . . . . . . . . . 10-4-3
Energy Absorber, Rear Bumper ........... ., . . . . . . . . . 10-4-10
Energy Absorbing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Engagement Switch, On-Vehicle Service .............. 98-14
Erigine .............................................. 6-1
Engine Assembly, 3.4L V6 Engine
Engine Assembly 5. 7 Liter VS Engine ............... 6A3A-29
Engine Block 5.7 Liter VS Engine Unit Rep;:i.ir ...... 6A3B-21 &
6A3B-31
.Engine Block Coolant Drain Hole Plug ................. 68-3
Engine Compartment Front Outer Side Rail,
Structural Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Engine Construction, 3.4L VIN S .................... 6A2B-6
Engine Control Module (ECM), Theft Deterrent .......... 90~3
Engine Coolant, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Engine Coolant Concentration . . . . . . . . . . . . . . . . . . . . . . . . 68-4
Engine Coolant Fan Assembly, Electric . . . . . . . . . . 18-4 & 68-3
Engine Coolant Fan Assembly, Electric,
On.Vehicle Service .............................. 68-15
Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
Engine Coolant Heater Assembly Replacement . . . . . . . . . 9E-1
Engine Coolant Heater Cord Assembly Replacement ..... 9E-2
Engine Coolant Hose Assemblies,
Engine _Coolant Temperature (ECT) Sensor ............. 68-3
Engine Coolant TemperaturEl Gage Sensor ............. 68-3
Engine Coolant Testing, On-Vehicle Service ........... 68-23
Engine Coolant Thermostat Assembly . . . . . . . . . . . . . . . . . 68-3
Engine Coolant Thermostat Assembly,
Engine Coolant Thermostat Assembly Test ............. 68-4
Engine, Draining the, 3.4L VIN S Disassembly ........ 6A2B-6
Engine Electrical ............................... 6-2 & 60-1

Engine Front Cover, 3.4L. VIN S .................... 6A2B-38
Engine Front Cover, 3.4L VIN S Assembly ........... 6A2B-48
Engine Front Cover, 3.4L VIN S Disassembly ........ 6A28-18
Engine Front Cover Assembly, 3.4L
V6 Engine On-Venicle Service .................. 6A2A-14
Engine Front Cover Assembly 5.7 Liter V8 Engine .... 6A3A-13
Engine Front Cover Assembly 5.7 Liter
VS Engine Unit Repair ...... 6A3B-12, 6A3B-30 & 6A3B-35
Engine Fro.nt Cover Oil Seals 5.7 Liter
VS Engine Unit Repair ......................... 6A3B-30
Engine Fuel ................................... 6-2 & 6C-1
Engine Identification ................................. OA-5
Engine Knock Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Lubrication, 3.4L VIN S ..................... 6A2B-6
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Engine Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Mount Assemblies and Brackets,
Engine Mount Assemblies and Brackets 5.7
Liter VS Engine ................................ 6A3A-3
Engine Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . 08-1
Engine Oil Cooler and Hose Assembly 5.7
Liter VS Engine ............................... 6A3A-20
Engine Oil Cooler Assembly .......................... 68-2
Engine Oil Cooler Inlet and Outlet Hose Assemblies .... 68-20
Engine On-Vehicle Service, 3.4 Liter V6 .............. 6A2A-1
Engine Performance Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Service, General Information on . . . . . . . . . . . . . . . . . 6-2
Engine Wiring ..................................... 605-1
Engine Wiring Harness Assembly (3.4L L32),
Left-Hand Side ................................. 605-3
Engine Wiring Harness Assembly
(3.4L L32), Rear View ........................... 605-4
Engine Wiring Harness Assembly (3.4L L32),
Right-Hand Side ................................ 605-2
Engine Wiring Harness Assembly (5.7L LT1 ),
Left-Hand Side ................................. 605-6
Engine Wiring Harness Assembly (5.7L LT1 ),
Right-Hand Side ................................ 605-5
Engine Wiring Harness Assembly
(All), Transmission .............................. 605-7
English-Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . OA-11
ETA AM/FM Stereo/Cassette (UN6) ................... 9A-4
ETA AM/FM Stereo/Cassette Tape Player (UN6) ........ 9A-8
ETA AM/FM Stereo/Cassette Tape Player
with Graphic Equalizer (UT6) ...................... 9A-9
ETA AM/FM Stereo/Compact Disc
Player (U1C) ............................ 9A-7 & 9A-10
ETA AM/FM Stereo/Compact Disc Player
with Graphic Equalizer (UP3) ..................... 9A-11
Evacuating and Recharging Procedures,
Refrigerant Recovery and Recycling, Adding Oil, . . . . . . 1 B-9
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B-12
Evaporator, Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B-4
Evaporator Assembly Replacement Procedures . . . . . . . . 1 B-26
Evaporator, Blower Motor Assembly and,
Manual Control A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 81 -5
Evaporator, Manual Control A/C ............ 181-11 & 1B1-l5
Evaporator Temperature Sensor Assembly,
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-5
Evaporator Temperature Sensor Assembly,
Manual Control A/C ............................ 181-15
12 INDEX
Evaporator Tube Assembly Replacement
Procedures, Air Conditioning ...................... 18-24
Evaporator Tube Replacement Procedures,
Air Conditioning, ................................ 18-18
Excessive Oil Loss, Engine Mechanical Diagnosis . . . . . . . . 6-3
Exhaust Crossover Pipe Assembly .................... 6F-1
Exhaust Crossover Pipe Assembly,
Exhaust Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Exhaust Manifold, 3.4L VIN S Assembly ............. 6A2B-50
Exhaust Manifold, 3.4L VIN S Disassembly .......... 6A2B-14
Exhaust Manifold Assemblies, 3.4L V6
Exhaust Manifold Assemblies 5. 7 Liter V8 Engine ...... 6A3A-7
Exhaust Manifold Assemblies 5.7 Liter
V8 Engine Unit Repair ............... 6A38-1 O & 6A38-39
Exhaust Muffler Assembly ............................ 6F-2
Exhaust Muffler Assembly, On-Vehicle Service .......... 6F-6
Exhaust Muffler Hanger Assemblies . . . . . . . . . . . . . . . . . . . 6F-9
Exhaust Muffler Heat Shield, Exhaust Pipe
Heat Shield Assembly and . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Exhaust Muffler Interior Bracket Assembly ............. 6F-10
Exhaust Pipe Assembly, On-Vehicle Service ............ 6F-5
Exhaust Pipe Heat Shield Assembly and
Exhaust Muffler Heat Shield ...................... 6F-12
Exhaust System ............................... 6-2 & 6F-1
Exhaust System Clearance Dimensions . . . . . . . . . . . . . . . 6F-13
Exhaust System Diagnosis ........................... 6F-2
Exhaust System On-Vehicle Service ................... 6F-3
Exhaust Tailpipe Extension Assembly
(5.7L LT1 Engine) ................................ 6F-6
Expansion Valve Assembly, Thermostatic . . . . . . . . . . . . . . . 18-4
Expansion Valve Assembly, Thermostatic,
Manual Control NC ............................ 181-10
Express Down, Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-2
Extended Method, Windshield Assembly
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-4
Extension (With Lift-Off Roof Assemblies),
Quarter Trim Finishing Panel ..................... 10-7-4
Extension Assembly (5.7L LT1 Engine),
Exhaust Tailpipe ................................. 6F-6
Extension Assembly, (T56) Repair and
Inspection, Countershaft ..................... 78-108-13
Extension Assembly, Countershaft,
(T56) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-1 OB-7
Extension, Counter, (T56) Assembly .............. 78-108-28
Extension Housing, (T56) Assembly .............. 78-108-30
Extension Housing, (T56) Disassembly ............. 78-108-4
Extension Housing, (T56) Repair and Inspection .... 78-108-23
Extension Housing Bushing, Borg-Warner (T5) ...... 78-68-10
Extension Housing Oil Seal, Borg-Warner (T5) ...... 78-68-10
Exterior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Exterior Lighting, On-Vehicle Service .................. 88-4
Exterior Moldings and Decal . . . . . . . . . . . . . . . . . . . . . . . 10-5-24
Exterior Radiator Assembly Cleaning . . . . . . . . . . . . . . . . . . 68-4
Exterior Trim, Front Side Door . . . . . . . . . . . . . . . . . . . . . 10-6-10
Exterior Trim, Rear Compartment . . . . . . . . . . . . . . . . . . . 10-8-6
Exterior Trim, Rear Quarters ....................... 10-7-10
External Leakage Check, Power Steering
Gear and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . 3-15
F
Fabricating a Patch Panel . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-12
Factory Backup Unlocking Code for

Secured Radio Assembly, Determining ............. 9A-14
Fallout (Acid Rain), Industrial . . . . . . . . . . . . . . . . . . . . . . 10-1-1 O
Fallout Damage, Preventing Industrial . . . . . . . . . . . . . . . 10-1-12
Fan, Blower Motor Assembly and Blower Motor ........ 1A-t7
Fascia Emblem Assemblies, Front Bumper . . . . . . . . . . . 1Q.45
Fasc!a, Front Bumper ............................. 10~-1
Fascia Lower Deflectors, Front Bumper .............. 10- -7
Fascia, Rear Bumper ............................. 10- -10
"FASTEN SAFETY BELTS" Indicator Lamp . . . . . . . . . . . . . C-4
Fasten Seat Belt Assembly Warning ................... SC-6
Fastener Repair, Cradle-to-Body . . . . . . . . . . . . . . . . . . . . 10-3-1
Fastener Strength Identification . . . . . . . . . . . . . . . . . . . . . . . OA-9
Fasteners, Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Fasteners, Body On-Vehicle Service . . . . . . . . . . . . . . . . . 10-1-1
Fasteners, Locking Thread, Doors . . . . . . . . . . . . . . . . . . . 10-6-2
Federal Vehicle Theft Prevention Standard . . . . . . . . . . . . . OA-2
Fender Assembly and Brackets, Front ............... 10-5-7
Fender Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-6
Fender Center Rear Molding Assembly, Front . . . . . . . . 10-5-24
Fender Emblem Assembly, Front .................... 10-5-11
Filler Cap Assembly, Radiator . . . . . . . . . . . . . . . . . 68-2 & 68-5
Filler Door Assembly, Fuel Tank ..................... 10-7-11
Filler Plug Torque, Rear Axle ......................... 08-9
Filler Pocket Assembly, Fuel Tank ................... 10-7-11
Filter Assembly, Pan and . . . . . . . . . . . . . . . . . . . . . . . . . 7 A-148-6
Filter Replacement, Air Cleaner and
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-5
Fin Removal, Cooling, On-Vehicle Service ............. 68-11
Finesse Polishing, Slight Clearcoat Damage Wet Sanding, .................................. 10-1-11
Finish Lace, Liftgate Window Opening . . . . . . . . . . . . . . 10-8-16
Finish Molding Assembly, Roof Panel
Longitudinal Bow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-39
Finish Panel Assembly, Rear End ................... 10-8-7
Finish Panel Emblem Assembly, Rear End . . . . . . . . . . . 10-8-6
First/Second Blocker Rings, Borg-Warner (T5) ....... 78-68-9
Fixed Antenna Assembly Diagnosis, Radio ............ 9A-14
Fixed Antenna Assembly, Radio . . . . . . . . . . . . . . . . . . . . .. 9A-2
Fixed Antenna Assembly, Radio, On-Vehicle Service .... 9A-15
Flare, Double Lap, Brakes ........................... 5-13
Flare, ISO, Brakes . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. 5-19
Flasher Assembly, Hazard Lamp . . . . . . . . . . . . . . . . . . . . . . 88-2
Flasher Assembly, Hazard Lamp, On-Vehicle Service .... 88-5
Flasher Assembly, Turn Signal Lamp .................. 88-3
Flasher Assembly, Turn Signal Lamp,
Flexible Plastic Part Refinishing . . . . . . . . . . . . . . . . . . . . 10-1-17
Flexible Plastic Part Repair . . . . . . . . . . . . . . . . . . . . . . . . 10-1-16
Flexible Plastic Part Repair and Refinishing . . . . . . . . . . 10-1-12
Flexplaten-orque Converter Vibration
Test Procedure ............................. 7 A-14A-22
Floor Air Outlet Duct Assembly ...................... 8C-18
Floor Carpet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Floor Carpet Assembly, On-Vehicle Service . . . . . . . . . 1D-10-26
Floor Console Assembly, Front ....................... 8C-2
Floor Console Assembly, Front, On-Vehicle Service ..... 8C-14
Floor Shift Unit Repair, Supplemental
Inflatable Restraint (SIR) Tilt Steering Column ...... 3F5B-1
Fluid, Adding, Folding Top Hydraulic System . . . . . . . . . 10-9-26
Fluid and Fluid Handling, Brake .................. 5-2 & 5A-1
Fluid, Brake, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fluid Capacities, Approximate . . . . . . . . . . . . . . . . . . . . . . . . 08-9
Fluid, Checking and Adding Power Steering . . . . . . . . . . . . 38-4
INDEX 13
uid Checking Procedure, Transmission .......... 7A-14A-16
uid Flow and Circuit Descriptions ............... 7A-14A-52
u!d, Hydra~lic Clu:ch ................................ 7C-2
1d Leak D1agnos1s ........................... 7A-14A-50
id Leak Diagnosis Automatic Transmission
Fluid Leaks, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fluid Level, Checking Manual
Transmission Assembly ........................... 78-4
Fluid Passage Identification ..................... 7A-14A-76
Fluid Replacement, Power Steering . . . . . . . . . . . . . . . . . . . 38-4
Fluid Reservoir Assembly, Power Steering . . . . . . . . . . . . . 38-12
Fluid Reservoir Hose Assembly, Power Steering . . . . . . . . 38-12
Fluid, Substandard or Contaminated Brake ............. SA-2
Fluids and Lubricants, Recommended ................. 08-8
Fluorescent Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-6
Flush, Underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2
Flushing Brake Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 5-2
Flushing Brake Hydraulic System, On-Vehicle Service .... 5-24
Flywheel, 3.4L VIN S Assembly .................... 6A28-52
Flywheel, 3.4L VIN S Disassembly .................. 6A2B-6
Flywheel Assembly, 3.4L V6 Engine
Flywheel Assembly 5.7 Liter V8 Engine ............. 6A3A-27
Flywheel Assembly 5.7 Liter V8 Engine
Unit Repair ......................... 6A38-10 & 6A3B-40
Flywheel Assemblyrrorque Converter
Clutch Vibration Test Procedure Automatic
Transmission On-Vehicle Service ................... 7A-6
Flywheel Noises (Automatic Transmission),
FM Stereo ................. . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
Fog Lamp Aiming Procedure, Front,
Fog Lamp Assemblies, Front ............ : ............ 88-2
Fog Lamp Assemblies, Front, On-Vehicle Service ........ 88-4
Fog Lamp Opening Cover, Front . . . . . . . . . . . . . . . . . . . . 10-4-6
Folcling Top (Convertible), On-Vehicle Service . . . . . . . . . 10-9-5
Folding Top Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-36
Folding Top Assembly Complete Replacement . . . . . . . 10-9-35
folding Top Assembly Hydraulic System . . . . . . . . . . . . 10-9-23
Folding Top Assembly, Wep.therstrips
and Garnishes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-27
Folding Top Bow Assemblies . . . . . . . . . . . . . . . . . . . . . . . 10-9-7
Folding Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . 10-9-33
Folding Top Cover Retention Cable Assembly . . . . . . . . 10-9-31
Folding Top Cylinder Lower Hose Assembly
(Right-Hand Cylinder) .............. , . . . . . . . . . . . 10-9-24
Folding Top Cylinder Upper Hose Assembly
(Leit-Hand Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-23
Folding Top Front Latch Assembly . . . . . . . . . . . . . . . . . . 10-9-15
Folding Top Front Weatherstrip Assembly . . . . . . . . . . . 10-9-28
Folding Top Front Weatherstrip Retainers . . . . . . . . . . . . 10-9-29
Folding Top Number Five Bow Assembly . : . . . . . . . . . . 10-9-14
Folding Top Number Four Bow Assembly ............. 10-9-11
Folding Top Number One and Number
Two Bow Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-16
Folding Top Number One Bow Assembly . . . . . . . . . . . . . 10-9-7
Folding Top Number Three Bow Assembly ............ 10-9-11
Folding Top Number Two Bow Assembly . . . . . . . . . . . . . 10-9-9
Folding Top Operation, On-Vehicle Service . . . . . . . . . . . 10-9-5
Folding Top Outer Arm Assemblies ................. 10-9-19
Folding Top Outer Arm Weatherstrip Assemblies . . . . . 10-9-27
Folding Top Outer Arm Weatherstrip Retainers . . . . . . . 10-9-28
Folding Top Pivot Bracket Assembly . . . . . . . . . . . . . . . . 10-9-23

Folding Top Pump Assembly with Motor . . . . . . . . . . . . . 10-9-26
Folding Top Rail Assemblies . . . . . . . . . . . . . . . . . . . . . . . 10-9-16
Folding Top, Roof and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-1
Folding Top Side Door Lower
Weatherstrip Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10-9-30
Folding Top Side Rail Assemblies . . . . . . . . . . . . . . . . . . 10-9-17
Folding Top Side Rail Garnish Molding . . . . . . . . . . . . . . 10-9-31
Folding Top Side Rail Link Assembly . . . . . . . . . . . . . . . . 10-9-21
Folding Top Side Rail Weatherstrip Assemblies . . . . . . . 10-9-27
Folding Top Side Rail Weatherstrip Retainers . . . . . . . . 10-9-27
Fork Assemblies, Shift Rail and, (T56)
Repair and Inspection ....................... 78-1 OB-19
Fork Assembly and Clutch Release Bearing
Assembly (5-Speed), Clutch ...................... 7C-12
Fork Assembly and Clutch Release Bearing
Assembly (6-Speed), Clutch ...................... 7C-12
Forward Clutch Piston Travel Check .............. 7A-148-34
Forward Clutch Sprag Assembly ................. 7A-148-32
Frame ....................................... , . . 10-3-2
Frame and Underbody, On-Vehicle Service ........... 10-3-1
Frame Replacement, Side Door Opening,
Structural Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Frame Sectioning, Side Door Opening,
Frame, Side Door Opening, Structural Body Repair ..... 11-16
Free-Travel Adjustment, Parking Brake ................ 582-9
Front Alignment Angles, Measuring .................... 3A-3
Front and Rear Bearings, Borg-Warner (TS) ......... 78-68-8
Front and Rear Belt Seals, Front Side Door . . . . . . . . . . 10-6-15
Front Brake Caliper Assembly ....................... 581-1
Front Brake Caliper Assembly Inspection ... : .......... 581 -4
Front Brake Caliper Assembly, On-Vehicle Service ...... 581-4
Front Brake Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Front Brake Rotor Assemblies, Burnishing ............. 581 -8
Front Brake Rotor Assemblies
Non-Directional Finishing ......................... 581-8
Front Brake Rotor Assemblies Off-Vehicle Procedure .... 581-7
Front Brake Rotor Assemblies On-Vehicle Procedure .... 581-7
Front Brake Rotor Assemblies, Refinishing ............ 581-7
Front Brake Rotor Assembly ......................... 581 -1
Front Brake Rotor Assembly Inspection ............... 581 -2
Front Brake Rotor Assembly, On-Vehicle Service ....... 581-7
Front Brake Rotor Assembly Tolerance
and Surface Finish ....................... ....... 581 -2
Front Bumper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Front Bumper Energy Absorber . . . . . . . . . . . . . . . . . . . . . 10-4-3
Front Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Front Bumper Fascia Emblem Assemblies . . . . . . . . . . . . 10-4-6
Front Bumper Fascia Lower Deflectors . . . . . . . . . . . . . . . 10-4-7
Front Bumper, Hood Adjust ........................ 10-5-19
Front Bumper Impact Bar Assembly . . . . . . . . . . . . . . . . . 10-4-5
Front Cable Assembly, Parking Brake,
On-Vehicle Service ............................... SF-3
Front Camber and Caster Adjustment,
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4
Front Countershaft Bearing, Borg-Warner (TS) ...... 78-68-12
Front Cover, Engine, 3.4L VIN S ................... 6A2B-38
Front Cover, Engine, 3.4L VIN S Assembly .......... 6A2B-48
Front Cover, Engine, 3.4L VIN S Disassembly ........ 6A2B-18
Front Disc Brake Inner and Outer Pad
Assemblies Inspection ........................... 581 -2
Front Disc Brake Inner and Outer Pad Assemblies,
On-Vehicle Service ............................. 581-5
14 INDEX
Front Disc Brakes .................................. 581-1
Front Door Jamb Switch Assemblies . . . . . . . . . . . . . . . . 10-5-23
Front Driver and Passenger Seat Buckle-Side
Belt Assemblies ................................ 10-11-2
Front Driver and Passenger Seat Retractor-Side
Belt Assemblies ................................ 10-11-2
.Front End, Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Front End Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Front End Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
Front Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-6
Front Fender Assembly and Brackets . . . . . . . . . . . . . . . . 10-5-7
Front Fender Center Rear Molding Assembly . . . . . . . . 10-5-24
Front Fender Emblem Assembly .................... 10-5-11
Front Floor Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Front Floor Console Assembly, On-Vehicle Service ..... 8C-14
Front Fog Lamp Aiming Procedure,
Front Fog Lamp Assemblies .......................... 88-2
Front Fog Lamp Assemblies, On-Vehicle Service ........ 88-4
Front Fog Lamp Opening Cover . . . . . . . . . . . . . . . . . . . . 10-4-6
Front Latch Assembly Adjustment, Folding Top . . . . . . . 10-9-15
Front Latch Assembly, Folding Top . . . . . . . . . . . . . . . . . 10-9-15
Front Latch Assembly Replacement, Folding Top . . . . . 10-9-16
Front License Plate Bracket . . . . . . . . . . . . . . . . . . . . . . . . 10-4-3
Front Outer Side Rail, Engine Compartment,
Structural Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Front Quarter Trim Finishing Panel Assembly . . . . . . . . . 10-7-1
Front Reading Lamps, On-Vehicle Service ............. 88-16
Front Seat Adjuster Actuator Lever Knob . . . . . . . . . . . 10-10-20
Front Seat Adjuster Assembly, Manual, Diagnosis . . . . 10-10-2
Front Seat Adjuster Assembly, Manual,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-15
Front Seat Adjuster Assembly, Power, Diagnosis . . . . . 10-10-2
Front Seat Adjuster Assembly, Power,
Front Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Front Seat Assembly, Diagnosis . . . . . . . . . . . . . . . . . . . 10-10-2
Front Seat Assembly, On-Vehicle Service ........... 10-10-2
Front Seat Belt Assemblies ......................... 10-11-1
Front Seat Belt Assemblies, On-Vehicle Service ....... 10-11-2
Front Seat Cushion Assemblies . . . . . . . . . . . . . . . . . . . . 10-10-9
Front Seat Recliner Assembly .................... 10-10-13
Front Seatback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Front Seatback, On-Vehicle Service ................ 10-10-2
Front Side Door (Tweeter) Speaker
Assembly, Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-24
Front Side Door Armrest and Map Pocket
and Radio Front Side Door Speaker Grilles . . . . . . . . 10-6-3
Front Side Door Armrest And Radio Front
Side Door Speaker Grille . . . . . . . . . . . . . . . . . . . . . . . . 10-6-3
Front Side Door Assembly, On-Vehicle Service ....... 10-6-35
Front Side Door Bottom Auxiliary Sealing Strip . . . . . . . 10-6-16
Front Side Door Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-31
Front Side Door Center Molding Assembly . . . . . . . . . . . 10-6-10
Front Side Door Courtesy Lamps ...................... 88-3
Front Side Door Courtesy Lamps,
Front Side Door Emblem Assembly . . . . . . . . . . . . . . . . . 10-6-12
Front Side Door Exterior Trim . . . . . . . . . . . . . . . . . . . . . . 10-6-10
Front Side Door Front and Rear Belt Seals . . . . . . . . . . 10-6-15
Front Side Door Hardware and Front
Side Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Front Side Door Inside Handle Assembly,
On-Vehicle Service ............................ 10-6-25
Front Side Door Inside Handle Bezel . . . . . . . . . . . . . . . . 10-6-9

Front Side Door Inside Handle Rod Assembly . . . . . . . . 10-6-28
Front Side Door Inside Handle Seal ................ 10-6-17
Front Side Door Interior Trim . . . . . . . . . . . . . . . . . . . . . . . 10-6-2
Front Side Door Interlock Striker Assembly .......... 10-6-31
Front S!de Door Lock Actuator,- . . . . . . . . . . . . . . . . . . . . 10-6i1
Front Side Door Lock Assemblies . . . . . . . . . . . . . . . . . . . 10- -2
Front Side Door Lock Assembly, On-Vehicle Service . . 10-6-1 6
Front Side Door Lock Cylinder Rod . . . . . . . . . . . . . . . . . 10-6~29
Front Side Door Lock Striker Adjustment . . . . . . . . . . . . 10-6-30
Front Side Door Lock Striker Anchor Plate . . . . . . . . . . . 10-6-30
Front Side Door Lock Striker Assemblies . . . . . . . . . . . . . 10-6-2
Front Side Door Lock Striker Assembly,
Front Side Door Locking Rod . . . . . . . . . . . . . . . . . . . . . . 10-6-28
Front Side Door Locking Rod Knob . . . . . . . . . . . . . . . . . . 10-6-9
Front Side Door Lower Hinge Assembly . . . . . . . . . . . . . 10-6-35
Front Side Door Outside Handle Assemblies . . . . . . . . . . 10-6-2
Front Side Door Outside Handle Assembly,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-24
Front Side Door Outside Handle Rod . . . . . . . . . . . . . . . 10-6-27
Front Side Door Right and Left Trim Assemblies . . . . . . . 10-6-2
Front Side Door Sill Trim Plate, On-Vehicle Service .... 10-3-2
Front Side Door Speaker Assembly, Radio . . . . . . . . . . 10-6-23
Front Side Door Trim Panel Retainer Seals . . . . . . . . . . 10-6-17
Front Side Door Upper and Lower Hinge Assemblies . . . 10-6-2
Front Side Door Upper Hinge Assembly . . . . . . . . . . . . . 10-6-33
Front Side Door Water Deflector,
Front Side Door Water Deflectors . . . . . . . . . . . . . . . . . . . 10-6-2
Front Side Door Weatherstrip Assembly ............. 10-6-12
Front Side Door Window Adjustment . . . . . . . . . . . . . . . . 10-6-36
Front Side Door Window Channel
Assembly and Front Side Door Window
Rear Guide Channel Assembly .................. 10-6-18
Front Side Door Window Front and Rear Bumpers .... 10-6-40
Front Side Door Window, Front Side Door
Hardware and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Front Side Door Window Front Up Stop
Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-39
Front Side Door Window Inner Sealing Strip ......... 10-6-15
Front Side Door Window, On-Vehicle Service . . . . . . . . 10-6-36
Front Side Door Window Outer Sealing
Strip Assembly . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-14
Front Side Door Window Rear Guide Channel
Assembly, Front Side Door Window Channel
Assembly and . .. .. . . . . . . . .. . . . . . .. . . . . . . . . . . . 10-6-18
Front Side Door Window Regulator Assembly . . . . . . . . 10-6-40
Front Side Door Window Regulator
Counterbalance Arm Channel Assembly . . . . . . . . . . 10-6-17
Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-26
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-42
Front Side Door Window Stabilizer Assembly . . . . . . . . 10-6-39
Front Side Rail Link Assemblies, Folding Top ........ 10-9-17
Front Sidemarker Lamp, On-Vehicle Service ............ 88-5
Front Sidemarker Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Front Suspension ................................... 3C-1
Front Toe Adjustment, Wheel Alignment ................ 3A-4
Front Weatherstrip Assembly, Folding Top . . . . . . . . . . . 10-9-28
Front Weatherstrip Retainers, Folding Top . . . . . . . . . . . 10-9-29
Front Wheel Bearing Assembly Repack . . . . . . . . . . . . . . . . 08-4
Front Wheel Bolt .................................... 3C-7
INDEX 15
ront Wheelhouse Assem~ly, Structural Body Repair . . . . 11-13
rent Wheelhouse Panel Liner . . . . . . . . . . . . . . . . . . . . . . 10-5-6
rant Wheelhouse Panel Upper Side Rail
\ Assembly, Structural Body Repair . . . . . . . . . . . . . . . . . . 11-8
Fuel Enable Output, Theft Deterrent . . . . . . . . . . . . . . . . . . . 90-3
Fuel, Engine .................................. 6-2 & 6C-1
Fuel Injection (Port) (3.4L), Driveability
and Emissions - .......................... 6E3 (3.4L)-1
Fuel Injection (SFI) (5.7L), Driveability
and Emissions - Sequential Multiport ........ 6E3 (5.7L)-1
Fuel System Pressure Relief, 3.4L V6
Engine On-Vehicle Service ...................... 6A2A-1
Fuel System Pressure Relief 5.7 Liter V8 Engine ...... 6A3A-1
Fuel Tank, Cap and Lines Inspection ................... OB-5
Fuel Tank Filler Door Assembly ..................... 10-7-11
Fuel Tank Filler Pocket Assembly . , ................. 10-7-11
Functional Control Switches, Cruise Control ............ 98-2
Functional Test, Manual Control NC ................. 181-11
Functional Test Procedure, Trans Diagnosis ....... 7A-14A-12
Fuse Block Access Door Assembly, Instrument Panel ... 8C-31
Fuse Block, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Fuse Block, Auxiliary, On-Vehicle Service .............. 8C-26
G
Gages ............................................ 8C-3
Gages and Console, Instrument Panel, ................. 8C-1
Gages and Console Service Precautions,
Instrument Panel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7
Gages, Paint ..................................... 10-1-11
Gaging Procedure, Pushrod ......................... 501 -4
Garage Shift Test, Electrical/ ..................... 7A-14A-18
Garnish Molding Assembly (With Lift-Off
Window Assemblies). Windshield Side Upper . . . . . . 10-9-4
Garnish Molding Assembly (Without Lift-Off Window
Assemblies), Windshield Side Upper .............. 10-9-4
Garnish Molding, Folding Top Side Rail . . . . . . . . . . . . . 10-9-31
Garnishes, Folding Top Assembly,
Weatherstrips and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-27
Gasket, Cylinder Head Assembly
and, 3.4L V6 Engine On-Vehicle Service .......... 6A2A-20
Gear and Pump Assemblies Leak, Power Steering . . . . . . . 3-15
Gear and Pump On-Vehicle Service, Power Steering ..... 38-1
Gear Assembly Diagnosis, Power Steering . . . . . . . . . . . . . . 3-5
Gear Assembly, Drive, Borg-Warner (T5) ........... 78-68-12
Gear Assembly, Power Steering . . . . . . . . . . . . . . . . . . . . . . 38-1
Gear Assembly, Power Steering, On-Vehicle Service ..... 38-5
Gear Clusters, Shift Rail Assemblies and,
(T56) Assembly ............................. 78-1 OB-26
Gear Clusters, Shift Rail Assemblies and,
(T56) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-1 OB-9
Gear Coupling Shaft Assembly, Steering .............. 3F-12
Gear Disassembly, Drive, Borg-Warner (TS) ......... .78-68-8
Gear Inlet and Outlet Hose Assemblies,
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-6
Gear Noise, Rear Axle .............................. 48-6
Gear Set, Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-148-11
Gear Unit Repair, Power Steering ................... 3B1A-1
Gears, Borg-Warner (TS) ......................... 78-68-8
General Service Procedures Automatic
Generator and Air Conditioning Compressor
and Power Steering Pump Bracket Assembly
(5.7L LT1 Engine) Replacement Procedures ........ 1B-23
Generator and Air Conditioning Compressor

Bracket Assembly (3.4L L32 Engine)
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . 18-23
Generator Assemblies, CS-130 and CS-144 ........... 603-1
Generator Assembly (3.4L L32 Engine),
CS-130 105-Amp, On-Vehicle Service .............. 603-3
Generator Assembly (3.4L L32 Engine),
CS-130 105-Amp, Unit Repair ..................... 603-6
Generator Assembly (5.7L LT1 Engine),
CS-144 124-Amp or 140-Amp, On-Vehicle Service ... 603-6
Generator Assembly Bench Check, CS ............... 603-2
Generator Assembly On-Vehicle Check, CS ........... 603-2
Generator Assembly Replacement ................... 603-3
Generator Disassembly, Test and Reassembl
(5.7L LT1 Engine), CS-144
124-Amp or 140-Amp, Unit Repair ................. 603-7
Glass Cleaning, Windshield ......................... 8E-16
Graphic Equalizer (UP3), ETR AM/FM
Stereo/Compact Disc Player with . . . . . . . . . . . . . . . . . . 9A-11
Graphics Equalizer (UT6), ETR AM/FM
Stereo/Cassette Tape Player with ................... 9A-9
Grid Line Repair, Rear Window Defogger . . . . . . . . . . . . . 10-2-8
Grid Lines, Testing, Rear Window Defogger . . . . . . . . . . . 10-2-8
Ground Straps, Battery ............................ 601 -1 O
Guide Plate, (T56) Assembly .................... 78-108-27
Guide Plate, (T56) Disassembly ................... 78-108-8
H
Halogen Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Handle Assemblies, Front Side Door Outside . . . . . . . . . 10-6-2
Handle Assembly, Front Side Door Inside,
Handle Assembly, Front Side Door Outside,
Handle Assembly, Front Side Door
Window Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-26
Handle Bezel, Front Side Door Inside . . . . . . . . . . . . . . . . 10-6-9
Handle Rod Assembly, Front Side Door Inside . . . . . . . 10-6-28
Handle Rod, Front Side Door Outside . . . . . . . . . . . . . . . 10-6-27
Handle Seal, Front Side Door Inside . . . . . . . . . . . . . . . . 10-6-17
Hanger Assemblies, Exhaust Muffler . . . . . . . . . . . . . . . . . . . 6F-9
Hanger Assembly, Catalytic Converter ................. 6F-7
Hangers, Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Hardware and Front Side Door Window,
Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Harness, Vacuum .................................. 1A-18
Hazard Lamp Flasher Assembly ...................... 88-2
Hazard Lamp Flasher Assembly, On-Vehicle Service ..... 88-5
Hazard Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-6
Hazard Warning Switch Knob . . . . . . . . . . . . . . . . . . . . . . . . . 3F-6
HD6/HR6-HE Air Conditioning Compressor
Service or Unit Repair R-134a .................... 102-1
Head Restraint Assembly ........................ 10-10-12
Header Repair, Aluminum Radiator
Headlamp Aiming After a Collision .................... 88-11
Headlamp Aiming Alternate Procedure ................ 88-10
Headlamp Aiming by Screen Method . . . . . . . . . . . . . . . . . . 88-8
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly ......................... 8C-4
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly, On-Vehicle Service ....... 8C-24
16 INDEX
Headlamp Assemblies, Headlamp Capsule
Assemblies and .................................. 88-2
Headlamp Assemblies, On-Vehicle Service ............. 88-6
Headlamp Capsule Assemblies and
Headlamp Assemblies ............................ 88-2
Headlamp Capsule Assemblies, On-Vehicle Service ..... 88-5
Headlamp Housing Panel Assembly and Brackets . . . . . 10-5-3
Headlamp Opening Door Actuator Control
Module Assembly ................................ 88-8
Headlamp Opening Door Decal . . . . . . . . . . . . . . . . . . . . 10-5-26
Headlining Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10-9-2
Headlining Trim Finish Panel Assembly . . . . . . . . . . . . . 10-9-35
Heat, Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9
Heat Shield Assembly and Exhaust Muffler
Heat Shield, Exhaust Pipe ........................ 6F-12
Heat Shield, Catalytic Converter . . . . . . . . . . . . . . . . . . . . . 6F-11
Heat Shield, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Heat Shield, Exhaust Pipe Heat Shield
Assembly and Exhaust Muffler .................... 6F-12
Heat, Ventilation and Air Conditioning Ducts ........... 8C-18
Heater and Air Conditioning Control Assembly .......... 8C-9
Heater and Air Conditioning Control Lamp .............. 88-4
Heater and Air Conditioning Control Lamp,
Heater and Air Conditioning Evaporator
and Blower Module Assembly ..................... 8C-20
Heater and Defrost Valve, Manual Control A/C ......... 181 -6
Heater and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Heater and Ventilation Functional Test ................. 1A-6
Heater and Ventilation Replacement Procedures ........ 1A-9
Heater Assembly Replacement, Engine Coolant ......... 9E-1
Heater Control Effort, High or Low ..................... 1A-9
Heater Cord Assembly Replacement, Engine Coolant .... 9E-2
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20
Heater Core Assembly, Temperature Valve,
Manual Control A/C ............................. 181-5
Heater Core Replacement Procedures ................ 18-29
Heater Core, Temperature Valve and .................. 1A-5
Heater, Engine Coolant .............................. 9E-1
Heater Hose Assembly and Heater Hose Pipes ........ 1A-19
Heater Hose Pipes, Heater Hose Assembly and ........ 1A-19
Heater Inlet and Outlet Hose Assemblies
Replacement Procedures ........................ 18-28
Heater Output Temperature Check .................... 1A-8
Heater System, Base ................................ 1A-1
Heater, Ventilation and A/C Replacement Procedures ... 18-15
Heater, Ventilation and Air Conditioning ................ 18-1
Heater, Ventilation and Air Conditioning
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Heating or Defrosting, Insufficient ..................... 1A-8
Heavy Knock Hot with Torque Applied,
Engine Knock Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
High-Mount Stoplamp Assembly ...................... 88-3
High-Mount Stoplamp Assembly, On-Vehicle Service .... 88-11
Hinge Assemblies, Front Side Door Upper and Lower . . 10-6-2
Hinge Assemblies, Rear Compartment Lift Window . . . 10-8-12
Hinge Assembly, Front Side Door Lower ....... : ...-. -10~6-35
Hinge Assembly, Front Side Door Upper . . . . . . . . . . . . 10-6-33
Hinge Assembly, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-14
Hinge Assembly, Rear Compartment Lid Panel . . . . . . . 10-8-18
Hinge Cover, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13
Hinge Pillar Inner Panel Sound Barriers, Body . . . . . . . 10-5-22
Hinge Pillar Trim Panel Assembly, Body . . . . . . . . . . . . . 10-5-22

Hold-Down Retainer, Battery Tray Assembly and ....... 601-2
Hood Adjust Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19
Hood Air Extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19
Hood Closeout Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13
Hood Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-14
Hood Hinge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-~ 3
Hood Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13
Hood Open Assist Rod Assembly . . . . . . . . . . . . . . . . . . 10-5L18
Hood Open Assist Rod Bracket Assembly . . . . . . . . . . . 10-5-19
Hood Panel Assembly ............................. 10-5-11
Hood Panel Assembly Adjustment . . . . . . . . . . . . . . . . . . 10-5-27
Hood Primary Latch Assembly . . . . . . . . . . . . . . . . . . . . . 10-5-16
Hood Primary Latch Release Cable Assembly . . . . . . . 10-5-18
Hood Rear Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19
Hood Secondary Latch Assembly . . . . . . . . . . . . . . . . . . 10-5-17
Horn Assemblies ................................... 88-4
Horn Assemblies, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 88-4
Horn Relay, On-Vehicle Service ...................... 88-18
Horn Switch Assembly, Steering Wheel . . . . . . . . . . . . . . . . 3F-9
Horn Switch Contact Plate Assembly, Steering Wheel ... 3F-1 O
Horn Tone Poor .................................... 88-4
Horns Assemblies, On-Vehicle Service ................ 88-17
Horns, Current Adjustment .......................... 88-17
Horns, Lighting Systems and . . . . . . . . . . . . . . . . . . . . . . . . . 88-1
Horns, On-Vehicle Service .......................... 88-17
Hose and Pipe Assembly Inspection, Brake . . . . . . . . . . . . . . 5-5
Hose and Routing, Power Brake Booster Vacuum ...... 501 -4
Hose Assemblies and Clamps Inspection ............... 68-4
Hose Assemblies, Engine Oil Cooler Inlet and Outlet .... 68-20
Hose Assembly and Heater Hose Pipes, Heater ........ 1A-19
Hose Assembly, Brake, On-Vehicle Service ............. 5-21
Hose Clamp Method, Propeller Shaft Balancing ......... 4A-7
Hose Test, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Hose Test, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Housing Bushing, Extension, Borg-Warner (TS) ..... 78-68-1 O
Housing Cover and Gasket, Rear Axle ................ 48-12
Housing Cover, SIR Tilt Steering Column Floor Shift ... 3F5B-9
Housing Oil Seal, Extension, Borg-Warner (TS) ...... 78-68-10
Housing Panel Assembly and Brackets, Headlamp . . . . . 10-5-3
Housing Replacement, Rear Axle .................... 48-26
Hub Cap, Aluminum Wheel Assembly ................. 3E-12
Hydra-Matic 4L60-E Automatic
Transmission Diagnosis ....................... 7A-14A-1
Transmission Diagnosis (RPO M30) Description ....... 7-1
Hydra-Matic 4L60-E Automatic Transmission
Unit Repair .................................. 7A-14B-1
Transmission Unit Repair (RPO M30) Description ...... 7-1
Hydraulic Clutch .................................... 7C-1
Hydraulic Clutch Fluid ............................... 7C-2
Hydraulic Pump Assembly .... , .................... 381 B-7
Hydraulic Pump Flow Control Valve .................... 38-8
Hydraulic System, Bleeding .......................... 7C-4
Hydraulic System Bleeding Procedure, Folding Top . . . 10-9-26
Hydraulic System, Folding Top Assembly . . . . . . . . . . . . 10-9-23
Hydrometer, Built-In, Battery ......................... 601-3
Identification and Usage, Key . . . . . . . . . . . . . . . . . . . . . . . . . OA-6

Identification, Body .................................. OA-2
Identification, Engine ................................ OA-5
INDEX 17
Identification, Fastener Strength . . . . . . . . . . . . . . . . . . . . . . . OA-9
Identification, Fluid Passage ..................... 7A-14A-76
\dentification Label, Service Parts .................... OA-19
Identification, Model ................................. OA-4
Identification Number, Vehicle ......................... OA-2
Identification, Plastic Part . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-12
Identification, Transmission ........................... OA-5
Ignition Coil and Ignition Coil Module
(5.7L LT1 Engine) ............................... 604-9
Ignition Coil Assembly (3.4L L32 Engine) ..... 604-8 & 604-10
Ignition Coil Assembly (5.7L LT1 Engine) .............. 604-7
Ignition Coil Module (5.7L LT1 Engine),
Ignition Coil and ................................ 604-9
Ignition Cylinder Assembly, Steering Column
Lock and, Theft Deterrent ......................... 90-2
Ignition Input, Theft Deterrent ......................... 90-2
Ignition Key Assemblies, Copying,
Ignition Key Assemblies, Replacing Lost .............. 90-17
Ignition Key Assembly, Theft Deterrent ................. 90-1
Ignition Key Assembly, Theft Deterrent
Ignition Key Warning ................................ BC-6
Ignition Lock Systems ............................... 3F-2
Ignition Module, Electronic, 3.4L VIN S Assembly ..... 6A2B-49
Ignition Module, Electronic, 3.4L
Ignition Switch ..................................... 604-3
Ignition Switch and Dimmer Switch Assembly ........... 3F-5
Ignition Switch, Steering Column Diagnosis ............. 3-11
Ignition System .................................... 604-1
Ignition System (3.4L L32 Engine) .................... 604-1
Ignition System (5.7L LT1 Engine) .................... 604-1
Ignition System, Diagnosis .......................... 604-3
Ignition System Service Precautions .................. 604-4
Ignition Timing ..................................... 604-3
Impact Bar Assembly, Front Bumper . . . . . . . . . . . . . . . . . 10-4-5
Impact Bar, Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-10
Impeller Motor Assembly Replacement
Procedures, Blower with . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
Indicator, "LOW OIL" ................................ BC-5
Indicator (VB Only), "LOW COOLANT" ................. BC-5
Indicator and Tube Assemblies, Oil Level,
Indicator Lamp, "ABS INOP" .......................... BC-5
Indicator Lamp, "AIR BAG" ........................... BC-5
Indicator Lamp, "ASA" ............................... BC-6
Indicator Lamp, "BRAKE" ..................... 5F-1 & BC-5
Indicator Lamp, "CHECK GAUGES" ................... BC-6
Indicator Lamp, "FASTEN SAFETY BELTS" ............ BC-4
Indicator Lamp, "SECURITY" ......................... BC-6
Indicator Lamp, "SERVICE ENGINE SOON" ............ BC-5
Indicator Lamp, "TCS OFF" .......................... BC-6
Indicator Lamp (VB Manual Only), "SKIP SHIFT' ........ BC-6
Indicator Lamp (with ASR or TCS Systems),
"LOW TRAC" .................................... BC-6
Indicator Lamp, Automatic Transmission ............... 88-3
Indicator Lamp, Automatic Transmission,
Indicator Lamp Operation, Antilock Warning/ . . . . . . . . . . . . . 5-4
Indicator Lamp Operation, Warning/, Brakes . . . . . . . . . . . . . 5-4
Indicator Lamp Output, Security, Theft Deterrent ......... 90-3
Indicator Lamps, "TURN SIGNAL" ..................... BC-5
Indicators, Tread Wear, Tires ......................... 3-19
Industrial Fallout (Acid Rain) . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 O

Industrial Fallout Damage, Preventing . . . . . . . . . . . . . . . 10-1-12
Inflatable Restraint (SIR) System, Supplemental ......... 9J-1
Inflatable Restraint Steering Wheel Module Assembly . . . . 3F-8
Inflatable Restraint Steering Wheel
Module Assembly, Deployed . . . . . . . . . . . . . . . . . . . . . . . 3F-4
Inflatable Restraint Steering Wheel Module
Assembly, Live (Undeployed) . . . . . . . . . . . . . . . . . . . . . . 3F-4
Assembly Scrapping Procedures . . . . . . . . . . . . . . . . . . . 3F-5
Assembly Shipping Procedures . . . . . . . . . . . . . . . . . . . . 3F-5
Inflation, Tire ............ : .......................... 3E-4
Inflater Module Assembly, Passenger Side ............. BC-32
Information, General ................................ OA-1
Inlet and Outlet Hose Assemblies, Power
Steering Gear ................................... 38-6
Inlet and Outlet Hose Assemblies
Replacement Procedures, Heater .................. 1B-28
Inlet Valve, Air, Manual Control A/C ................... 1 81 -5
Inner Manual Linkage .......................... 7A-14B-13
Inner Panel Cover Assembly, Rear Compartment
Lift Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-17
Inner Tie Rod, Power Steering Gear ................. 381 A-4
Input and Input Clutches, Reverse ................ 7A-148-40
Input Carrier and Sun Gear ...................... 7A-14B-24
Input Clutch Assembly .......................... 7 A-148-25
Input Clutch Assembly, Reverse ................. 7A-14B-37
Input Gear Set, 2-4 Band, Reverse Input Clutch,
Input Clutch and ............................ 7A-14B-10
Input Internal Gear and Output Shaft .............. 7 A-148-23
Input Internal Gear and Reaction Shaft ............ 7A-14B-22
Input Shaft, (T56) Repair and Inspection ........... 78-108-9
Input Shaft/Mainshaft and Countershaft, (T56) ...... 78-108-32
Inside Diameter Check Duo-Servo Drum Brakes ........ 5C2-2
Inside Handle Assembly, Front Side Door,
Inside Handle Rod Assembly, Front Side Door . . . . . . . 10-6-28
Inside Handle Seal, Front Side Door . . . . . . . . . . . . . . . . 10-6-17
Inside Rearview Mirror Assembly . . . . . . . . . . . . . . . . . . . . 10-2-6
Inside Rearview Mirror Support . . . . . . . . . . . . . . . . . . . . . 10-2-6
Inspection and Services, Owner ....................... 08-5
Inspection, Control Arm Ball Stud Assembly ............ 3C-3
Instrument Cluster Assembly ......................... 8C-2
Instrument Cluster Assembly, On-Vehicle Service ....... BC-21
Instrument Panel ................................... 8C-4
Instrument Panel Carrier, On-Vehicle Service .......... BC-22
Instrument Panel Cluster Trim Plate Bezel Assembly .... BC-29
Instrument Panel Compartment Lamp .................. 88-4
Instrument Panel Compartment Lamp,
Instrument Panel Compartment, On-Vehicle Service .... BC-30
Instrument Panel Fuse Block Access Door Assembly .... BC-31
Instrument Panel, Gages and Console ................. BC-1
Instrument Panel, Gages and Console
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-7
Instrument Panel Insulator, On-Vehicle Service ......... BC-24
Instrument Panel Lamp Dimmer Switch
Assembly, Headlamp and . . . . . . . . . . . . . . . . . . . . . . . . . 8C-4
Instrument Panel Lamp Dimmer Switch
Assembly, Headlamp and, On-Vehicle Service ....... 8C-24
Instrument Panel Switches ........................... 8C-4
Instrument Panel Switches, On-Vehicle Service ........ BC-24
Instrument Panel Upper Trim Panel Assembly .......... BC-31
18 INDEX
Instrument Panel Wiring Harness Assembly ............ 8C-26
Insulator Assembly, Sound .......................... 8C-28
Insulator, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13
Insulator, Instrument Panel, On-Vehicle Service ........ 8C-24
Intake Manifold Assembly 5.7 Liter V8 Engine ......... 6A3A-5
Intake Manifold Assembly 5.7 Liter
V8 Engine Unit Repair ...... 6A38-10, 6A38-31 & 6A3B-38
Intake Manifold Assembly, Lower, 3.4L
V6 Engine On-Vehicle Service ................... 6A2A-9
Intake Manifold Assembly, Upper, 3.4L V6
Intake Manifold, Lower, 3.4L VIN S ................. 6A2B-41
Intake Manifold, Lower, 3.4L VIN S Assembly ........ 6A2B-51
Intake Manifold, Lower, 3.4L VIN S Disassembly ..... 6A2B-13
Intake Manifold, Upper, 3.4L VIN S ................. 6A2B-40
Intake Manifold, Upper, 3.4L VIN S Assembly ........ 6A28-51
Intake Manifold, Upper, 3.4L VIN S Disassembly ..... 6A28-11
Interior Bracket Assembly, Exhaust Muffler ............. 6F-1 O
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-2
Interior Lighting ..................................... 88-3
Interior Lighting, On-Vehicle Service .................. 88-15
Interior Moldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-4
Interior Trim, Front Side Door . . . . . . . . . . . . . . . . . . . . . . . 10-6-2
Interior Trim, Rear Compartment . . . . . . . . . . . . . . . . . . . . 10-8-9
Interior Trim, Rear Quarters ........................ 10-7-1
Interlock Striker Assembly, Front Side Door . . . . . . . . . . 10-6-31
Internal Gear and Carrier Assembly, Reaction ...... 7 A-148-17
Internal Gear and Output Shaft, Input ............. 7 A-148-23
Internal Gear and Reaction Shaft, Input ........... 7A-148-22
Internal Gear and Support, Reaction .............. 7A-148-18
Internal Transmission Speed Sensor Rotor ........ 7 A-148-23
Internal Wiring Harness Check ................... 7 A-14A-34
Irregular and Premature Wear, Tires . . . . . . . . . . . . . . . . . . . 3-18
ISO Flare, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
J
Jacking, General Vehicle Lifting and ................... OA-5
Jamb Switch Assemblies, Front Door . . . . . . . . . . . . . . . 10-5-23
Joint, Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Joint, Universal ..................................... 4A-1
Joints, Universal, Propeller Shaft Unit Repair ........... 4A-13
Jounce Bumper Assembly, Rear Suspension ............ 30-1
Jump Starting in Case of Emergency
with Auxiliary (Booster) Battery Assembly ........... 601 -8
K
Key Assemblies, Copying Ignition,
Key Assemblies, Replacing Lost Ignition .............. 90-17
Key Assembly, Ignition, Theft Deterrent ................ 90-1
Key Assembly, Ignition, Theft Deterrent
Key Identification and Usage . . . . . . . . . . . . . . . . . . . . . . . . . OA-6
Key Reminder, Steering Column Diagnosis . . . . . . . . . . . . . 3-12
Key Resistor Inputs, Theft Deterrent ................... 90-2
Keyless Entry Functional Operation, Remote ........... 9K-1
Keyless Entry, Remote .............................. 9K-1
Keys and Springs, Synchronizer,
Borg-Warner (TS) ............................. 78-68-9
Keys, Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-8
Knee Bolster Assembly and Deflector, Driver ........... 8C-13
Knob, Hazard Warning Switch ........................ 3F-6
Knock at Low Speeds, Rear Axle ..................... 48-7

Knock Sensor System .............................. 604-3
Knocks at Idle Hot, Engine Knock Diagnosis . . . . . . . . . . . . . 6-6
Knocks Cold and Continues for
Two to Three Minutes and Increases
with Torque, Engine Knock Diagnosis . . . . . . . . . . . . . . . . 6-5
Knocks on Initial Start-Up But Only Lasts
a Few Seconds, Engine Knock Diagnosis . . . . . . . . . . . . . 6-6
L
Labels, Replacement ............................... OA-19
Lamp, Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Lamp, Ashtray, On-Vehicle Service ................... 88-15
Lamp Bulb, Control Assembly . . . . . . . . . . . . . . . . . . . . . . . 1A-15
Lamp, Console ..................................... 8B-3
Lamp, Console, On-Vehicle Service .................. 88-15
Lamp, Dome, On-Vehicle Service .................... 88-15
Lamp Switch Assembly, Backup, Manual Trans ......... 78-10
Lamp Switch, Compartment ......................... 8C-16
Lamps (Canadian Only), Daytime Running ............. 88-2
Lamps (DRL) (Canadian Only), Daytime Running ........ 8C-2
Lamps, Backup ..................................... 88-2
Lamps, Backup, On-Vehicle Service ................... 88~4
Latch Assembly Adjustment, Front, Folding Top . . . . . . 10-9-15
Latch Assembly, Endgate . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-3
Latch Assembly, Folding Top Front ................. 10-9-15
Latch Assembly, Hood Primary .................... 10-5-16
Latch Assembly, Hood Secondary . . . . . . . . . . . . . . . . . . 10-5-17
Latch Assembly Replacement, Front, Folding Top ..... 10-9-16
Latch Release Cable Assembly, Hood Primary ....... 10-5-18
Lateral Runout Check, Front Disc Brakes .............. 581-2
Lateral Runout Check, Rear Disc Brakes .............. 582-2
Lateral Support Bladders, Lumbar and . . . . . . . . . . . . . 10-10-10
Lead Wire Repair, Braided, Rear Window Defogger . . . . 10-2-9
Leak Check Procedure, Retainer
and Ball Assembly .......................... 7A-148-15
Leak Detection, Seal ............................... 102-8
Leak Detector, Electric Halogen . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Leak Detector, Fluorescent . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Leak Detectors and Pressure Testing, Liquid ............ 1B-6
Leak, Finding the, Oil Leak Diagnosis ................... 6-3
Leak Inspection Points, Transmission ............. 7 A-14A-51
Leak, Repairing the, Oil Leak Diagnosis . . . . . . . . . . . . . . . . . 6-3
Leak Testing, Compressor ......................... 1 02-11
Leak-Testing the Refrigeration System ................. 1B-5
Leakage Check, External, Power Steering
Gear and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . 3-15
Left-Hand Side Engine Wiring Harness Assembly
(3.4L L32) ...................................... 605-3
Left-Hand Side Engine Wiring Harness
Assembly (5.7L LT1) ............................. 605-6
Lever Assembly, Parking Brake ....................... SF-1
Lever Assembly, Parking Brake, On-Vehicle Service ..... SF-3
License Lamp Assembly, Rear . . . . . . . . . . . . . . . . . . . . . . . . 88-3
License Lamp Assembly, Rear, On-Vehicle Service ..... 88-12
License Plate Bracket, Front . . . . . . . . . . . . . . . . . . . . . . . . 10-4-3
Lid Lock Cylinder Assembly, Rear Compartment ....... 10-8-1
Lid Lock Release Actuator, Rear Compartment . . . . . . . . 10-8-5
Lid Lock Switch Assembly, Rear Compartment . . . . . . . . 10-8-5
Lid Panel Assembly and Components,
Rear Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-18
Lid Panel Assembly, Rear Compartment . . . . . . . . . . . . 10-8-21
Lid Panel Hinge Assembly, Rear Compartment . . . . . . . 10-8-18
INDEX 19
Lid Panel Strut Assembly, Rear Compartment . . . . . . . . 10-8-20
Lid Release Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8C-4
lid Release Switch Assembly, On-Vehicle Service ...... 8C-25
Lift Window Closeout Panel Assembly,
Rear Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Lift Window Hinge Assemblies, Rear Compartment ... 10-8-12
Lift Window Inner Panel Cover Assembly,
Lift Window Lock Striker Assembly,
Rear Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Lift Window Panel Adjustment, Rear Compartment .... 10-8-14
Lift Window Panel Assembly and Components, Rear
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-12
Lift Window Panel Assembly, Rear Compartment . . . . . 10-8-13
Lift Window, Rear Compartment ................... 10-8-18
Lift Window Side Molding Assemblies,
Lift Window Strut Assembly, Rear Compartment . . . . . . 10-8-13
Lift Window Weatherstrip, Rear Compartment . . . . . . . . . 10-8-6
Lift-Off Window Assembly Adjustment, Roof . . . . . . . . . 10-9-37
Lift-Off Window Assembly Removal and
Installation, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-37
Lift-Off Window Assembly Repair, Roof . . . . . . . . . . . . . 10-9-38
Lift-Off Window Assembly, Roof . . . . . . . . . . . . . . . . . . . . 10-9-37
Lift-Off Window Lock Cylinder Assembly, Roof . . . . . . . 10-9-39
Lift-Off Window Stowage Retainer Assemblies, Roof ... 10-8-11
Lifter Assemblies, Valve, 3.4L V6 Engine
Lifters, Valve, 3.4L VIN S ......................... 6A2B-39
Lifters, Valve, 3.4L VIN S Assembly ................ 6A2B-50
Lifters, Valve, 3.4L VIN S Disassembly .............. 6A2B-13
Liftgate Window Opening Finish Lace . . . . . . . . . . . . . . . 10-8-16
Lifting and Jacking, General Vehicle . . . . . . . . . . . . . . . . . . . OA-5
Light Knock Hot, Engine Knock Diagnosis . . . . . . . . . . . . . . . 6-6
Lighter Assembly, Cigarette ......................... 8C-15
Lighting, Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Lighting, Exterior, On-Vehicle Service .................. 88-4
Lighting, Interior ............................ 88-3 & 10-9-2
Lighting, Interior, On-Vehicle Service .................. 88-15
Lighting System Troubleshooting ...................... 88-4
Lighting Systems and Horns . . . . . . . . . . . . . . . . . . . . . . . . . . 88-1
Lights-On Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-6
Limited Slip Rear Axle Assembly ............... 48-3 & 48-7
Line Pressure Check Procedure ................. 7A-14A-17
Lines and Fittings, Handling Refrigerant,
On-Vehicle Service ............................... 1B-8
Link Assembly, Stabilizer Shaft ....................... 3C-16
Link Assembly, Stabilizer Shaft Bracket and ............. 30-9
Linkage Assembly Replacement, Wiper ............... 8E-14
Liquid Leak Detectors and Pressure Testing . . . . . . . . . . . . 1B-6
Live (Undeployed) Inflatable Restraint
Steering Wheel Module Assembly . . . . . . . . . . . . . . . . . . 3F-4
Lo and Reverse Clutch Parts .................... 7A-14B-12
Lo and Reverse Clutch Piston ................... 7A-148-16
Lo and Reverse Clutch Spacer Plate Selection ..... 7A-14B-18
Lo and Reverse Clutch Support Assembly ......... 7A-148-21
Load Test, Parasitic, Battery ......................... 601-4
Lock Actuator, Front Side Door . . . . . . . . . . . . . . . . . . . . 10-6-31
Lock Assemblies, Front Side Door . . . . . . . . . . . . . . . . . . . 10-6-2
Lock Assembly and Striker, Seatback . . . . . . . . . . . . . . 10-10-23
Lock Assembly, Front Side Door,
Lock Cylinder Assembly, Rear Compartment Lid . . . . . . . 10-8-1
Lock Cylinder Assembly, Roof Lift-Off Window . . . . . . . 10-9-39
Lock Cylinder Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-6

Lock Cylinder Rod, Front Side Door . . . . . . . . . . . . . . . . 10-6-29
Lock Cylinder Unit, On-Vehicle Service . . . . . . . . . . . . . . 10-6-33
Lock Cylinders, Assembling and Coding . . . . . . . . . . . . . . . . OA-8
Lock Cylinders, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . OA-8
Lock Release Actuator, Rear Compartment Lid . . . . . . . . 10-8-5
Lock Striker Adjustment, Front Side Door . . . . . . . . . . . . 10-6-30
Lock Striker Anchor Plate, Front Side Door . . . . . . . . . . 10-6-30
Lock Striker Assemblies, Front Side Door . . . . . . . . . . . . 10-6-2
Lock Striker Assembly, Front Side Door,
Lock Striker Assembly, Rear Compartment
Lift Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Lock Switch Assembly, Rear Compartment Lid . . . . . . . . 10-8-5
Lock Switches, Side Window, Outside
Remote Control Rearview Mirror
Selector and Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-19
Lock System, Steering Column Assembly ............... 3-7
Lock Systems, Ignition ............................... 3F-2
Locking Rod, Front Side Door . . . . . . . . . . . . . . . . . . . . . 10-6-28
Locking Rod Knob, Front Side Door . . . . . . . . . . . . . . . . . 10-6-9
Lockout Assembly (6-Speed), Reverse, Manual Trans ... 78-14
Lockout Solenoid (6-Speed), Reverse, Manual Trans .... 78-11
"LOW COOLANT" Indicator (VS Only) ................. SC-5
Low Frequency Audio Amplifier Assembly ............ 10-7-9
"LOW OIL" Indicator ................................. SC-5
Low or No Oil Pressure, Engine Mechanical Diagnosis . . . . 6-4
Lower Column, SIR Tilt Steering
Column Floor Shift ............................ 3F5B-15
Lower Control Arm Assembly . . . . . . . . . . . . . . . . . . 3C-8 & 30-5
Lower Control Arm Ball Stud Assembly ................ 3C-3
Lower Control Arm Ball Stud Assembly Replacement . . . . 3C-4
Lower Control Arm Bushing Assembly .......... 3C-9 & 30-1
Lower Hinge Assembly, Front Side Door . . . . . . . . . . . . 10-6-35
Lower Intake Manifold, 3.4L VIN S ................. 6A2B-41
Lower Intake Manifold, 3.4L VIN S Assembly ........ 6A2B-51
Lower Intake Manifold, 3.4L VIN S Disassembly ...... 6A2B-13
Lower Intake Manifold Assembly,
Lower Mode Valve, Upper and, Manual Control NC ..... 181 -6
Lower Rail, Structural Body Repair ................... 11-12
(with ASR or TCS Systems) ....................... SC-6
Lubricant Fill and Check, Rear Axle . . . . . . . . . . . . . . . . . . . 48-12
Lubricants, Recommended Fluids and ................. 08-8
Lubrication 5.7 Liter VS Engine Unit Repair ........... 6A38-6
Lubrication, Body Front End . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Lubrication, Body On-Vehicle Service . . . . . . . . . . . . . . . . 10-1-2
Lubrication, Chassis ................................. 08-4
Lubrication, Cranking System ........................ 602-2
Lubrication, Maintenance and ......................... 08-1
Lubrication, Maintenance and, Rear Axle ............... 48-5
Lubrication, Parking Brake, On-Vehicle Service .......... 5F-3
Lubrication, Steering Wheel and Column
Lumbar and Lateral Support Bladders . . . . . . . . . . . . . . 10-10-10
M
Main Bearing and Rod Bearing Selection,
3.4L VIN S ................................... 6A28-29
Main Bearing Noise, Engine Noise Diagnosis . . . . . . . . . . . . 6-4
Main Oil Seal, Rear, 3.4L VIN S Assembly ........... 6A2B-43
Main Seal, Rear, 3.4L VIN S Disassembly ........... 6A2B-22
20 INDEX
Mainshaft, (T56) Repair and Inspection ........... 78-108-10
Mainshaft Assembly, Borg-Warner (TS) ............. 78-68-13
Mainshaft Disassembly, Borg-Warner (TS) ........... 78-68-7
Maintenance and Lubrication ......................... OB-1
Maintenance and Lubrication, Rear Axle ............... 48-5
Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-8
Maintenance Service, Scheduled . . . . . . . . . . . . . . . . . . . . . . OB-1
Maintenance Services, Explanation of Scheduled . . . . . . . . 08-1
Manifold Assemblies, Exhaust, 3.4L V6
Manifold, Exhaust, 3,4L VIN S Disassembly ......... 6A2B-14
Manual Control Air Conditioning ...................... 181-1
Manual Control Air Conditioning Overview ............. 181-1
Manual Front Seat Adjuster Assembly, Diagnosis ..... 10-10-2
Manual Front Seat Adjuster Assembly,
On-Vehicle Service ........................... 10-10-15
Manual Linkage, Inner .......................... 7 A-148-13
Manual Shaft Seal Replacement ................. 7A-14B-13
Manual Transmission Assembly
(RPO M49), 5-Speed ............................. 78-1
Manual Transmission Assembly (RPO M49),
5-Speed, On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 78-14
Manual Transmission Assembly (RPO MM6),
6-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-1
Manual Transmission Assembly (RPO MM6),
6-Speed, On-Vehicle Service ..................... 78-16
Manual Transmission Assembly Fluid Level, Checking .... 78-4
Manual Transmission, Automatic and ................... 7-1
Manual Transmission Control Assembly (5-Speed) ....... 78-7
Manual Transmission Control Assembly (6-Speed) ....... 78-8
Manual Transmission Control Lever Boot Assembly ...... 78-6
Manual Transmission Control Lever Handle
Assembly (6-Speed) .............................. 78-8
Manual Transmission On-Vehicle Service ............... 78-1
Manual Transmission On-Vehicle Service
(RPO M49 and MM6) Description .................... 7-1
Manual Transmission Unit Repair (RPO M49)
Description, Borg-Warner (TS) 5-Speed ............... 7-1
Manual Transmission Unit Repair (RPO MM6)
Description, Borg-Warner (T56) 6-Speed ............. 7-2
Map Pocket and Radio Front Side Door
Speaker Grilles, Front Side Door Armrest and . . . . . . 10-6-3
Master and Actuator Cylinder Assembly, Clutch ......... 7C-7
Master Cylinder .................................... SA-1
Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1
Master Cylinder Assembly Bench Bleeding . . . . . . . . . . . . . SA-4
Master Cylinder Assembly Check . . . . . . . . . . . . . . . . . . . . . SA-2
Master Cylinder Assembly, Diagnosis . . . . . . . . . . . . . . . . . . SA-2
Ma$ter Cylinder Assembly, On-Vehicle Service .......... SA-3
Master Cylinder Assembly, Unit Repair ................. SA-4
Master Cylinder Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1
Master Cylinder Reservoir, Filling ...................... SA-2
Master Cylinder Reservoir, Unit Repair . . . . . . . . . . . . . . . . . SA-5
Mechanical Diagnosis, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Mechanical, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Metal Part Refinishing - BasecoaVClearcoat . . . . . . . . . . 10-1-9
Methods for Locating Leak Automatic
Metric Conversions. English - . . . . . . . . . . . . . . . . . . . . . . . OA-11
Metric Equivalents, Decimal and . . . . . . . . . . . . . . . . . . . . . OA-11
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-9
Metric Thread Size Information ...................... 1 02-3
Metric Wheel Nuts and Bolts ......................... 3E-4
Mid Column, SIR Tilt Steering Column Floor Shift ..... 3F5B-11
Mirror Assemblies, Outside Rearview . . . . . . . . . . . . . . . . 10-6-2

Mirror Assembly, Inside Rearview . . . . . . . . . . . . . . . . . . . 10-2-6
Mirror Assembly, Outside Rearview,
Mirror Support, Inside Rear . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-6
Mode Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Mode Control, Manual Control NC ................... 181 -3
Mode Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Mode Valve, Upper and Lower, Manual Control NC ..... 181-6
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-4
Module (5.7L LT1 Engine), Ignition
Coil and Ignition Coil ............................. 604-9
Module Assembly, Cruise Control . . . . . . . . . . . . . . . . . . . . . 98-1
Module Assembly, Cruise Control,
Module Assembly Replacement Procedures . . . . . . . . . . . 1B-30
Module Assembly, Theft Deterrent ..................... 90-2
Module Assembly, Theft Deterrent,
Module, Electronic Ignition, 3.4L VIN S Assembly ..... 6A2B-49
Module, Electronic Ignition, 3.4L VIN S Disassembly .. 6A2B-16
Module Lower Case Replacement Procedures ......... 1B-31
Molding Assemblies, Adhesive . . . . . . . . . . . . . . . . . . . . . . 10-1-3
Molding Assemblies, Rear Compartment
Lift Window Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-17
Molding Assemblies, Secure Loose . . . . . . . . . . . . . . . . . . 10-1-3
Molding Assembly Completely Removed (Method 1) . . . 10-1-3
Molding Assembly Completely Removed (Method 2) . . . 10-1-4
Molding Assembly, Front Fender Center Rear . . . . . . . . 10~5-24
Molding Assembly, Front Side Door Center . . . . . . . . . . 10~6-10
Molding Assembly, Rear Quarter Center .............. 10-7-11
Molding Assembly Replacement . . . . . . . . . . . . . . . . . . . . 10-1-4
Molding Assembly, Rocker Panel . . . . . . . . . . . . . . . . . . . 10-5-24
Molding Assembly, Windshield Reveal,
Stationary Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1
Molding Assembly, Windshield Reveal,
Stationary Windows On-Vehicle Service ........... 10-2-1
Moldings and Decal, Exterior . . . . . . . . . . . . . . . . . . . . . . 10-5-24
Moldings, Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-4
Motor Assembly Disassembly, PG-250 Starter ......... 602-9
Motor Assembly Disassembly, 80210 Starter ......... 602-10
Motor Assembly Noise, Blower ........................ 1A-9
Motor Assembly, PG-250 Starter .................... 602-13
Motor Assembly Relay, Blower ........................ 1B-5
Motor Assembly Relay, Blower, Manual Control NC .... 181 -15
Motor Assembly Replacement, Starter ................ 602-2
Motor Assembly Replacement, Wiper ................. 8E-13
Motor Assembly, SD210 Starter ..................... 602-14
Motor Assembly, Starter ............................ 602-1
Motor Assembly Usage Chart, Starter ................ 602-15
Motor Cover Assembly Replacement, Wiper ........... 8E-15
Mount Assemblies and Brackets. Engine,
Mounting and Dismounting, Tire ....................... 3E-8
Mounting Plate, Rear Brake Caliper Anchor
Bracket and .................................... 582-8
Mounting, Steering Unit, On-Vehicle Service . . . . . . . . . . 10-3-2
Mounting Surface Check, Steel Wheel Assembly ........ 3E-8
Muffler Assembly, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Muffler Assembly, Exhaust, On-Vehicle Service .......... 6F-6
Muffler Hanger Assemblies, Exhaust . . . . . . . . . . . . . . . . . . . 6F-9
Muffler Interior Bracket Assembly, Exhaust . . . . . . . . . . . . . 6F-10
Music System/Cassette (UU8), Delco-GM/BOSE ........ 9A-5
Music System/Compact Disc (U1 T), Delco-GM/Bose .... 9A-6
INDEX 21
Music Systems, Delco-GM/Bose . . . . . . . . . . . . . . . . . . . . . . 9A-2
N
Nameplate/Emblem Assemblies, Adhesive . . . . . . . . . . . 10-1-3
Negative Cable Assembly ........................... 601-9
No Air Tool Recommendation Automatic Transmission
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A-4
No-Load Test, Cranking System ...................... 602-7
Noise and Vibration Analysis Automatic Transmission
On-Vehicle Service ............................... 7 A-3
Noise Conditions Automatic Transmission
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Noise Conditions, Trans Diagnosis ................ 7A-14A-2
Nomenclature for Electrical/Electronic
Components and Systems, Standard ............... OA-11
Non-Uniform Tires, Correcting ....................... 3E-12
Number Five Bow Assembly, Folding Top ............ 10-9-14
Number Four Bow Assembly, Folding Top ............ 10-9-11
Number One Bow Assembly, Folding Top . . . . . . . . . . . . . 10-9-7
Number Two Bow Assembly, Folding Top ............. 10-9-11
Number Two Bow Assembly, Folding Top . . . . . . . . . . . . . 10-9-9
Nylon Injected Ring Type, Universal Joints ............. 4A-13
0
0-Ring Seals, Cylinder Line Assembly and ........... 381 A-5
0-Rings, Replacing, On-Vehicle Service ................ 1 B-7
Odometer Repair Notice Label ....................... SC-26
Off-On-Resume/Accelerate Switch .................... 98-2
Off-Vehicle Balancing, Tires and Wheels .............. 3E-10
Oil and Oil Filter Change, Engine ...................... 08-1
Oil Charge Replenishing, NC System ................. 1 B-13
Oil Cooler Assembly, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 68-2
Oil Cooler Assembly, Transmission .................... 68-2
Oil Cooler Flushing Procedures Automatic Transmission
On-Vehicle Service .............................. 7 A-15
Oil Cooler Gasket, Transmission ..................... 68-14
Oil Cooler Inlet and Outlet Hose Assemblies, Engine .... 68-20
Oil Cooler, Transmission ............................ 68-15
Oil Cooler Upper Pipe and Upper and Lower
Hose Assemblies Automatic Transmission
Oil Distribution, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B-14
Oil Filter Change, Engine Oil and . . . . . . . . . . . . . . . . . . . . . . 08-1
Oil Leak Diagnosis, Engine Mechanical Diagnosis . . . . . . . . 6-3
Oil Level Indicator and Tube Assemblies,
Oil Level Indicator and Tube Assemblies
5.7 Liter VS Engine ............................. 6A3A-4
Oil Loss Due to a Large Leak, Refrigerant . . . . . . . . . . . . . 1B-14
Oil Loss, Excessive, Engine Mechanical Diagnosis . . . . . . . . 6-3
Oil Pan, 3.4L VIN S .............................. 6A2B-39
Oil Pan, 3.4L VIN S Assembly ..................... 6A2B-50
Oil Pan, 3.4L VIN S Disassembly .................. 6A2B-15
Oil Pan Assembly, 3.4L V6 Engine
Oil Pan Assembly 5.7 Liter VS Engine ............... 6A3A-20
Oil Pan Assembly 5. 7 Liter VS Engine Unit Repair ... 6A3B-12,
6A3B-30 & 6A3B-35
Oil Pressure, Low or No, Engine Mechanical
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Oil Pump, 3.4L VIN S Assembly ................... 6A2B-45
Oil Pump, 3.4L VIN S Disassembly ................. 6A2B-20

Oil Pump Assembly, 3.4L V6 Engine
Oil Pump Assembly 5.7 Liter VS Engine ............. 6A3A-22
Oil Pump Assembly 5.7 Liter VS
Engine Unit Repair ......... 6A3B-15, 6A3B-26 & 6A3B-34
Oil Pump Assembly, Trans
Disassembly . . . . . . . . . . . . . . . . . . . . 7 A-148-9 & 7 A-148-41
Oil Pump Body ................................ 7 A-148-41
Oil Pump Body (Assemble) ...................... 7A-14B-44
Oil Pump Cover (Assemble) ..................... 7A-14B-44
Oil Pump Cover (Disassemble) .................. 7A-14B-42
Oil Pump Cover and Body . . . . . . . . . . . . . . . . . . . . . . 7 A-148-45
Oil Pump Unit Repair, 3.4L VIN S .................. 6A2B-31
Oil Seal Assembly, Crankshaft Rear,
Oil Seal, Drive Gear Bearing Retainer,
Borg-Warner (T5) ............................. 78-68-1 O
Oil Seal, Extension Housing, Borg-Warner (T5) ...... 78-68-1
Oil Seal, Rear Main, 3.4L VIN S Assembly ........... 6A2B-43
On-Vehicle Balancing, Tires and Wheels .............. 3E-10
One and Two-Piece Propeller Shaft
Assembly Replacement ........................... 4A-9
Opening Cover Assembly, Accessory
Switch Panel Assembly and Accessory Switch.... . . 10-6-7
Option and Process Codes . . . . . . . . . . . . . . . . . . . . . . . . . . OA-20
Option Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-1 9
Out-of-Round or Taper Check
Duo-Servo Drum Brakes ......................... 5C2-2
Out-of-Round or Tapered Duo-Servo Drum Brakes ...... 5C2-7
Outer Air Outlet Duct Assemblies .................... SC-20
Outer Arm Assemblies, Folding Top . . . . . . . . . . . . . . . . 10-9-19
Outer Arm Weatherstrip Assemblies, Folding Top . . . . . 10-9-27
Outer Arm Weatherstrip Retainers, Folding Top . . . . . . . 10-9-28
Outer Panel Replacement, Door,
Outer Panel, Roof, Structural Body Repair . . . . . . . . . . . . . 11-23
Outer Tie Rod, Power Steering Gear ................. 381 A-3
Outer-Side Belt Assemblies, Rear Seat .............. 10-11-4
Outlet and Inlet Tanks, Cross-Flow Radiator Core and .... 68-2
Outlet Hose Assemblies, Power
Steering Gear Inlet and ........................... 38-6
Outlets, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Outlets, Ducts and, Manual Control NC . . . . . . . . . . . . . . . 181 -6
Output Shaft, Input lnterqal Gear and ............. 7 A-148-23
Output Shaft Seal, Manual Trans ...................... 78-9
Outside Handle Assemblies, Front Side Door . . . . . . . . . 10-6-2
Outside Handle Assembly, Front Side Door,
Outside Handle Rod, Front Side Door . . . . . . . . . . . . . . . 10-6-27
Outside Rearview Mirror Applique Assembly . . . . . . . . . 10-6-22
Outside Rearview Mirror Assemblies . . . . . . . . . . . . . . . . . 10-6-2
Outside Rearview Mirror Assembly,
Outside Rearview Mirror Reflective Glass . . . . . . . . . . . 10-6-21
Overheating, Cooling System : ........................ 68-4
p
P Series Power Steering Pump Assembly ............ 381 B-2
P Series Power Steering Pump Service .............. 381 B-3
P-Metric Tires ...................................... 3E-2
22 INDEX
Pad Assemblies, Front Disc Brake Inner and
Outer, On-Vehicle Service ........................ 581 -5
Pad Assemblies Inspection, Front Disc Brake
Inner and Outer ................................. 581 -2
Pad Assemblies Inspection, Rear Disc Brake
Inner and Outer ................................. 582-2
Pad Assemblies, Rear Disc Brake Inner and
Outer, On-Vehicle Service ........................ 582-6
Paint Gages ..................................... 10-1-11
Pan and Filter Assembly ......................... 7 A-148-6
Pan Assembly, Oil, 3.4L V6 Engine
Pan, Oil, 3.4L VIN S .............................. 6A2B-39
Pan, Oil, 3.4L VIN S Assembly ..................... 6A2B-50
Pan, Oil, 3.4L VIN S Disassembly .................. 6A2B-15
Panel Assembly Adjustment and Alignment, Body . . . . 10-1-19
Panel Assembly, Hood ............................ 10-5-11
Panel Carrier, Instrument, On-Vehicle Service .......... 8C-22
Panel Cluster Bezel Assembly, Upper Trim
Panel Assembly and Compartments, Trim .......... 8C-29
Panel Identification, Structural Body Repair . . . . . . . . . . . . . 11-2
Panel, Instrument ................................... 8C-4
Panel Liner, Front Wheelhouse . . . . . . . . . . . . . . . . . . . . . 10-5-6
Parasitic Load Test, Battery ......................... 601 -4
Adjustment Using New Switch Assembly
Adjustment Using Old Switch Assembly
Parking and Turn Signal Lamp Assemblies ............. 88-3
Parkrng and Turn Signal Lamp Assemblies,
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Parking Brake Adjustment ............................ 5F-7
Parking Brake Free-Travel Adjustment ................ 582-9
Parking Brake Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Parking Brake Lever Assembly, On-Vehicle Service ...... 5F-3
Parking Brake System ............................... 5F-1
Parking Pawl .................................. 7 A-148-17
Parts Cleaning, Inspection and Replacement
Automatic Transmission On-Vehicle Service .......... 7A-4
PASS-KEY II System ................................ 90-1
Passenger Seat Adjuster Assemblies . . . . . . . . . . . . . . 10-10-17
Passenger Seat Buckle-Side Belt Assemblies,
Front Driver and ............................... 10-11-2
Passenger Seat Retractor-Side Belt Assemblies,
Front Driver and ............................... 10-11-2
Passenger Side lnflator Module Assembly ............. 8C-32
Patch Panel, Fabricating a . . . . . . . . . . . . . . . . . . . . . . . . 10-1-12
Pawl, Parking ................................. 7A-14B-17
Pedal Assembly, Brake, On-Vehicle Service ............. 5-8
Pedal Assembly, Clutch .............................. 7C-7
Pedal Assembly Travel, Brake ......................... 5-4
Pedal Assembly with Bracket, Brake, On-Vehicle Service .. 5-5
Pedal Position Switch Assembly
(Clutch Start Switch Assembly), Clutch .............. 7C-8
Performance Diagnosis, Engine . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Performance Switch (V8 Automatic) Second
Gear Start Switch (V6 Automatic) .................. 8C-17
Performance Test, Air Conditioning, Manual Control .... 181-15
PG-250 Starter Motor Assembly .................... 602-13
PG-250 Starter Motor Assembly Disassembly .......... 602-9

Pilot Bearing, Clutch ................................ 7C-2
Pilot Bearing, Clutch, On-Vehicle Service .............. 7C-13
Pin Length, Servo ............................... 7A-14B-3
Pinion Boot, Rack&, Power Steering Gear ........... 381 A-4
Pinion Clearance (PG-250 and SD210 Starter Motor
Assemblies), Checking .......................... 602-12
Pinion Gear Yoke Runout Measurement,
Differential Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4A-5
Pinion Seal, Dust Seal and Bearing
Annulus Assembly ...................... ; ...... 381 A-6
Pinion Steering Gear Assembly, Power Rack & ........ 381A-2
Pinion Support Mount Plates, Steering Unit Rack and . . 10-3-2
Pipe Assembly, Brake, On-Vehicle Service .............. 5-11
Pipe Assembly Inspection, Brake Hose and . . . . . . . . . . . . . . 5-5
Piston and Connecting Rod,
3.4L VIN S Disassembly ....................... 6A2B-21
Piston and Connecting Rod Assemblies,
Piston and Connecting Hod Assemblies
5.7 Liter V8 Engine ............................ 6A3A-24
Piston and Connecting Rod
Assembly 5.7 Liter V8
Engine Unit Repair . . . . . . . . . 6A3B-15, 6A38-23 & 6A38-33
Piston Noises, Engine Noise Diagnosis . . . . . . . . . . . . . . . . . 6-4
Piston Travel Check, Forward Clutch ............. 7 A-148-34
Pistons and Connecting Rods, 3.4L VIN S ........... 6A28-26
Pistons and Connecting Rods,
3.4L VIN S Assembly .......................... 6A28-44
Pivot and Switch Assembly,
Steering Column Diagnosis ........................ 3-15
Pivot Bracket Assembly, Folding Top . . . . . . . . . . . . . . . . 10-9-23
Placard, Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-3
Plastic Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-12
Plastic Part Refinishing, Flexible . . . . . . . . . . . . . . . . . . . 10-1-17
Plastic Part Refinishing, Rigid . . . . . . . . . . . . . . . . . . . . . . 10-1-19
Plastic Part Repair and Refinishing, Flexible . . . . . . . . . 10-1-12
Plastic Part Repair and Refinishing, Rigid . . . . . . . . . . . . 10-1-17
Plastic Part Repair, Flexible . . . . . . . . . . . . . . . . . . . . . . . 10-1-16
Plastic Part Repair, Rigid . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-17
Plastic Parts, How to Identify . . . . . . . . . . . . . . . . . . . . . . 10-1-12
Plate Assembly (5-Speed), Clutch Driven ............... 7C-8
Plate Assembly (6-Speed), Clutch Driven ............... 7C-9
Plenum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
Plug Assembly Replacement, Spark . . . . . . . . . . . . . . . . . . . 08-5
Plugs, Spark ...................................... 604-3
Plugs, Spark, Diagnosis ............................ 604-3
Plugs, Spark, On-Vehicle Service .................... 604-5
Pneumatic Comfort Controls . . . . . . . . . . . . . . . . . . . . . . . 10-10-2
Porosity Repair, Aluminum Wheel Assembly ........... 3E-12
Position Switch Assembly (Clutch Start
Switch Assembly), Clutch Pedal .................... 7C-8
Positive Cable Assembly ............................ 601-10
Possible Points of Fluid Leak Automatic
Power Brake Booster Assembly ...................... 501-1
Power Brake Booster Assembly, On-Vehicle Service .... 501 -2
Power Brake Booster Vacuum Hose and Routing ....... 501-4
Power Front Seat Adjuster Assembly, Diagnosis . ., .. J0-10-2
Power Front Seat Adjuster Assembly,
Power Rack & Pinion Steering Gear Assembly ........ 381 A-2
Power Steering Fluid, Checking and Adding ............ 38-4
Power Steering Fluid Replacement .................... 38-4
INDEX 23
Power Steering Fluid Reservoir Assembly ............. 38-12
Power Steering Fluid Reservoir Hose Assembly ........ 38-12
Power Steering Gear and Pump Assemblies Leak . . . . . . . 3-15
Power Steering Gear and Pump
Assemblies Leak General Procedures .. . . . . . . . . . . . . . 3-15
Power Steering Gear and Pump On-Vehicle Service . . . . . 38-1
Power Steering Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . 38-1
Power Steering Gear Assembly Diagnosis . . . . . . . . . . . . . . . 3-5
Power Steering Gear Assembly, On-Vehicle Service ..... 38-5
Power Steering Gear Inlet and Outlet
Hose Assemblies ................................ 38-6
Power Steering Gear Unit Repair .................... 381 A-1
Power Steering Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 38-1
Power Steering Pump Assembly Diagnosis . . . . . . . . . . . . . . 3-6
Power Steering Pump Assembly, On-Vehicle Service .... 38-10
Power Steering Pump Assembly, P Series ............ 381 B-2
Power Steering Pump Assembly, Reverse Rotation .... 381 B-5
Power Steering Pump Belt (Serpentine Belt) ............ 38-5
Power Steering Pump Bracket (5.7L LT1 Engine)
Replacement Procedures, Generator
and Air Conditioning Compressor and .............. 1B-23
Power Steering Pump Pulley Assembly ................ 38-5
Power Steering Pump Service, P Series .............. 381 B-3
Power Steering Pump Service, Reverse Rotation ...... 381 B-6
Power Steering Pump Support . . . . . . . . . . . . . . . . . . . . . . . . 38-9
Power Steering Pump Unit Repair ................... 381 B-1
Power Steering System, Bleeding the .................. 38-4
Power Steering System, Flushing the .................. 38-4
Power Steering System Test Procedure ................ 3-15
Precautions, Aluminum Radiator On-Vehicle Service ..... 68-9
Preliminary Checking Procedure Automatic
Pressure Differential Warning Switch, Brake . . . . . . . . . . . . . 5-2
Pressure Regulator Valve Automatic
Pressure Relief, Fuel System, 3.4L V6 Engine
On-Vehicle Service ............................. 6A2A-1
Pressure Relief Valve Assembly, Quarter
Outer Panel . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 10-7-10
Pressure Relief Valve, Compressor .................. 1D2-10
Pressure Sensor Assembly, Air Conditioning
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Pressure Switch Assembly Resistance Check ...... 7A-14A-37
Pressure Test, Cooling and Radiator Diagnosis .......... 68-5
Pressure Testing, Cooling and Radiator ................ 68-4
Pressure Testing, Liquid Leak Detectors and ............ 1B-6
Primary and Secondary Shoes Duo-Servo
Drum Brakes ................................... 5C2-4
Primary and Secondary Shoes Inspection
Duo-Servo Drum Brakes ......................... 5C2-1
Process Codes, Option and . . . . . . . . . . . . . . . . . . . . . . . . . OA-20
Programming Receiver Assembly, Remote
Keyless Entry .................................. 9K-19
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A 1
Propeller Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Propeller Shaft Assembly and Universal
Joint, Diagnosis of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Propeller Shaft Assembly Balance Check ............... 4A-7
Propefler Shaft Assembly Balancing ................... 4A-7
Propeller Shaft Assembly Replacement, One
and Two-Piece .................................. 4A-9
Propeller Shaft Assembly Runout Measurement ......... 4A-5
Propeller Shaft Assembly, Two-Piece ................. 4A-12
Propeller Shaft Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Propeller Shaft On-Vehicle Service .................... 4A-4

Propeller Shaft Unit Repair .......................... 4A-12
Proportion Valve, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pulley Assembly, Power Steering Pump ................ 38-5
Pump Assemblies Leak, Power Steering Gear and . . . . . . . 3-15
Pump Assembly Coolant Weepage, Water .............. 68-4
Pump Assembly Diagnosis, Power Steering . . . . . . . . . . . . . 3-6
Pump Assembly, Hydraulic ......................... 3818-7
Pump Assembly, Oil, 3.4L V6 Engine
Pump Assembly, Oil, Trans Disassembly ........... 7A-14B-9
Pump Assembly, Oil, Trans Reassembly .......... 7A-14B-41
Pump Assembly, Power Steering . . . . . . . . . . . . . . . . . . . . . . 38-1
Pump Assembly, Power Steering, On-Vehicle Service ... 38-10
Pump Assembly, Reverse Rotation Power Steering .... 381 B-5
Pump Assembly, Water, On-Vehicle Service ........... 68-17
Pump Assembly with Motor, Folding Top . . . . . . . . . . . . 10-9-26
Pump Belt (Serpentine Belt), Power Steering ............ 38-5
Pump, Coolant, 3.4L VIN S ........................ 6A28-39
Pump, Coolant, 3.4L VIN S Assembly ............... 6A2B-48
Pump, Coolant, 3.4L VIN S Disassembly ............ 6A2B-17
Pump Flow Control Valve, Hydraulic ................... 38-8
Pump, Oil, 3.4L VIN S Assembly ................... 6A2B-45
Pump, Oil, 3.4L VIN S Disassembly ................ 6A28-20
Pump On-Vehicle Service, Power Steering Gear and ..... 38-1
Pump Pulley Assembly, Power Steering ................ 38-5
Pump Replacement, Washer ........................ BE-1 O
Pump Reservoir Replacement, Power Steering ........ 381 8-3
Pump Service, Reverse Rotation Power Steering ...... 381 8-6
Pump Support, Power Steering ....................... 38-9
Pump Unit Repair, Oil, 3.4L VIN S .................. 6A28-31
Pump Unit Repair, Power Steering .................. 3818-1
Pushrod Assemblies, Valve Rocker Arms
and, 3.4L V6 Engine On-Vehicle Service ........... 6A2A-8
Pushrod Gaging Procedure ......................... 501 -4
Pushrod, Valve Rocker Arm and,
3.4L VIN S Assembly .......................... 6A2B-50
Pushrod, Valve Rocker Arm and,
3.4L VIN S Disassembly ....................... 6A2B11
Pushrods, Valve Rocker Arms and, 3.4L VIN S ....... 6A2840
Q
Quarter Belt Reveal Moldings and Seals . . . . . . . . . . . . 10-9-30
Quarter Courtesy Lamp Assembly . . . . . . . . . . . . . . . . . . . 10-7-5
Quarter Inner Rear Trim Finishing Panel Assembly . . . . . 10-7-3
Quarter Outer Panel Pressure Relief Valve Assembly . 1O7-10
Quarter Panel Assembly, Structural Body Repair . . . . . . . 11-26
Quarter Trim Finishing Panel Assembly, Front . . . . . . . . . 10-7-1
Quarter Trim Finishing Panel Extension
(With Lift-Off Roof Assemblies) ................... 1074
Quarters, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1O 7-1
R
Rack & Pinion Boot, Power Steering Gear ............ 381 A-4
Rack & Pinion Steering Gear Assembly, Power ........ 381 A-2
Rack and Pinion Support Mount Plates, Steering Unit . . 10-3-2
Rack Bearing Preload, Power Steering Gear .......... 3B1A-4
Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Radiator Air Baffle Assemblies and Deflectors ........... 68-3
Radiator Air Baffle Assemblies and Deflectors,
24 INDEX
Radiator Air Lower Baffle Assembly and
Deflector, On-Vehicle Service ..................... 68-21
Radiator Air Lower Deflector . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Radiator Air Upper Baffle Assembly,
Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-2
Radiator Assembly Cleaning, Exterior . . . . . . . . . . . . . . . . . . 68-4
Radiator Assembly, On-Vehicle Service ............... 68-20
Radiator, Cooling and .......................... 6-2 & 68-1
Radiator Core and Outlet and Inlet Tanks, Cross-Flow .... 68-2
Radiator Drain Cock Assembly . . . . . . . . . . . . . . . . . . . . . . . 68-2
Radiator Drain Cock Assembly, On-Vehicle Service ..... 68-15
Radiator Filler Cap Assembly . . . . . . . . . . . . . . . . . . 68-2 & 68-5
Radiator Maintenance Recommendations,
Cooling and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Radiator Service, Aluminum, On-Vehicle Service ........ 68-9
Radiator Side Tank Gasket Leak Repair . . . . . . . . . . . . . . . 68-13
Radiator Support Assembly, Structural Body Repair . . . . . . 11-4
Radio Anti-Theft Feature, Setting ..................... 9A-12
Radio Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Radio Assembly Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
Radio Assembly Operation (U1 C) . . . . . . . . . . . . . 9A-7 & 9A-10
Radio Assembly Operation (U1 T) ..................... 9A-6
Radio Assembly Operation (UN6) . . . . . . . . . . . . . . 9A-4 & 9A-8
Radio Assembly Operation (UP3) .................... 9A-11
Radio Assembly Operation (UT6) ..................... 9A-9
Radio Assembly Operation (UU8) ..................... 9A-5
Radio Control Switch Assembly . . . . . . . . . . . . . . . . . . . . . . 3F-11
Radio Fixed Antenna Assembly . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Radio Fixed Antenna Assembly Diagnosis ............. 9A-14
Radio Fixed Antenna Assembly, On-Vehicle Service .... 9A-15
Radio Front Side Door (Tweeter) Speaker Assembly .. 10-6-24
Radio Front Side Door Speaker Assembly . . . . . . . . . . . 10-6-23
Radio Front Side Door Speaker Grille,
Front Side Door Armrest and . . . . . . . . . . . . . . . . . . . . 10-6-3
Radio Front Side Door Speaker Grilles, Front
Side Door Armrest and Map Pocket and . . . . . . . . . . . 10-6-3
Radio Rear Sail Panel Speaker Assembly . . . . . . . . . . . . 10-7-6
Radio Rear Sail Panel Speaker Grille Assembly . . . . . . . 10-7-5
Radio Rear Speaker Assembly . . . . . . . . . . . . . . . . . . . . . 10-7-8
Radio Speaker Grille Assembly, Rear Quarter Rear . . . . 10-7-6
Radio Suppression Equipment ....................... 9A-15
Rail Assemblies, Folding Top . . . . . . . . . . . . . . . . . . . . . . 10-9-16
Rail Assemblies, Folding Top Side . . . . . . . . . . . . . . . . . . 10-9-17
Rail Dust Damage Repair .......................... 10-1-11
Rail Link Assemblies, Front Side, Folding Top . . . . . . . . 10-9-17
Rail Link Assembly, Folding Top Side . . . . . . . . . . . . . . . 10-9-21
Rail, Lower, Structural Body Repair . . . . . . . . . . . . . . . . . . . 11-12
Rail, Upper, Structural Body Repair . . . . . . . . . . . . . . . . . . . . 11-5
Range Reference Chart ........................ 7 A-14A-1 O
Ratings, Battery Assembly .......................... 601 -2
Rattle Diagnosis and Repair, Squeak and . . . . . . . . . . . . 10-1-7
Reaction Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A-148-11
Reaction Internal Gear and Carrier Assembly ...... 7A-14B-17
Reaction Internal Gear and Support .............. 7A-14B-18
Reaction Shaft, Input Internal Gear and ........... 7A-14B-22
Reaction Sun Gear and Shell .................... 7A-14B-22
Reading Lamp, Dome and . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Reading Lamps, Front, On-Vehicle Service ............ 88-16
Rear Alignment Angles, Measuring, Wheel Alignment .... 3A-5
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-1
Rear Axle, Adjustments Affecting Tooth Contact ......... 48-9
Rear Axle Assembly ............................... 48-15
Rear Axle Assembly Identification . . . . . . . . . . . . . . . . . . . . . 48-5
Rear Axle Assembly, Limited Slip ............... 48-3 & 48-7

Rear Axle Assembly, Standard . . . . . . . . . . . . . . . . . . . . . . . . 48-1
Rear Axle Assembly with Disc Brakes ................ 48-27
Rear Axle Backlash Clunk ........................... 48-7
Rear Axle Bearing Noise ............................. 48-7
Rear Axle Checking Limited Slip Operation . . . . . . . . . . . . 48-7
Rear Axle, Differential Bearing Assembly
Preload Adjustment ............................. 48-21
Rear Axle, Differential Case . . . . . . . . . . . . . . . . . . . . . . . . . 48-18
Rear Axle, Differential Case (Limited Slip) ............. 48-26
Rear Axle, Differential Drive Pinion Gear .............. 48-22
Rear Axle, Differential Drive Pinion Gear Depth ......... 48-24
Rear Axle, Differential Drive Pinio.n
Gear Yoke and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-14
Rear Axle, Differential Ring Gear Tooth Nomenclature .... 48-9
Rear Axle, Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . 48-20
Rear Axle, Differnetial Drive Pinion Gear Inner
Bearing Assembly ............................... 48-23
Rear Axle, Differnetial Drive Pinion Gear Outer
Bearing Assembly ............................... 48-23
Rear Axle, Effects of Differential Drive
Pinion Gear Position on Tooth Pattern .............. 48-11
Rear Axle, Effects of Increasing Load on
Tooth Contact Pattern ............................. 48-9
Rear Axle Filler Plug Torque .......................... 08-9
Rear Axle Gear Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-6
Rear Axle Housing Cover and Gasket . . . . . . . . . . . . . . . . 48-12
Rear Axle Housing Replacement . . . . . . . . . . . . . . . . . . . . . 48-26
Rear Axle Inspection and Diagnosis ................... 48-8
Rear Axle Knock at Low Speeds ...................... 48-7
Rear Axle Lubricant FiU and Check . . . . . . . . . . . . . . . . . . . 48-12
Rear Axle Noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-6
Rear Axle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-3
Rear Axle, Rear Wheel Bolt/Screw ................... 48-16
Rear Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-12
Rear Axle Shaft Bearing Assembly
and/or Bearing Seal ............................. 48-13
Rear Axle Shaft Bearing Noise ........................ 48-7
Rear Axle, Speed Sensor Reluctor Wheel ............. 48-20
Rear Axle Standard and Limited Slip Diagnosis .......... 48-8
Rear Axle Suspension ............................... 30-1
Rear Axle, Tooth Contact Pattern Test ................. 48-9
Rear Bearings, Front and, Borg-Warner (T5) ......... 78-68-8
Rear Brake (Center) Hose Assembly . . . . . . . . . . . . . . . . . . 5-22
Rear Brake Caliper Anchor Bracket
and Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-8
Rear Brake Caliper Assembly Inspection .............. 582-3
Rear Brake Caliper Assembly, On-Vehicle Service ...... 582-3
Rear Brake Caliper Assembly, Unit Repair ............ 582-11
Rear Brake Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Rear Brake Rotor Assemblies, Burnishing . . . . . . . . . . . . 582-11
Rear Brake Rotor Assemblies Non-Directional
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-11
Rear Brake Rotor Assemblies Off-Vehicle ............ 582-10
Rear Brake Rotor Assemblies On-Vehicle ............ 582-10
Rear Brake Rotor Assemblies, Refinishing . . . . . . . . . . . . . 582-9
Rear Brake Rotor Assembly Inspection ............... 582-2
Rear Brake Rotor Assembly, On-Vehicle Service ....... 582-8
Rear Brake Rotor Assembly Tolerance
and Surface Finish .............................. 582-2
Rear Bumper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-8
Rear Bumper Energy Absorber . . . . . . . . . . . . . . . . . . . . 10-4-10
Rear Bumper Fascia ............................. 10-4-10
INDEX 25
Rear Bumper Impact Bar . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-10
Rear Cable Assembly (Disc Brakes), Parking Brake,
Rear Cable Assembly (Drum Brakes), Parking Brake,
On-Vehicle Service ...................~ ............ 5F-5
Rear Compartment Closeout Panel Assembly . . . . . . . . 10-8-1 O
Rear Compartment Exterior Trim . . . . . . . . . . . . . . . . . . . . 10-8-6
Rear Compartment Interior Trim . . . . . . . . . . . . . . . . . . . . . 10-8-9
Rear Compartment Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-4
Rear Compartment Lid Lock Cylinder Assembly ....... 10-8-1
Rear Compartment Lid Lock Release Actuator . . . . . . . . 10-8-5
Rear Compartment Lid Lock Switch Assembly . . . . . . . . 10-8-5
Rear Compartment Lid Panel Assembly . . . . . . . . . . . . . 10-8-21
Rear Compartment Lid Panel Assembly
and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-18
Rear Compartment Lid Panel Hinge Assembly . . . . . . . 10-8-18
Rear Compartment Lid Panel Strut Assembly . . . . . . . . 10-8-20
Rear Compartment Lift Window . . . . . . . . . . . . . . . . . . . . 10-8-18
Rear Compartment Lift Window Closeout
Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Rear Compartment Lift Window Hinge Assemblies .... 10-8-12
Rear Compartment Lift Window Inner
Panel Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-17
Rear Compartment Lift Window Lock
Striker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Rear Compartment Lift Window Panel Adjustment . . . . 10-8-14
Rear Compartment Lift Window Panel Assembly . . . . . 10-8-13
Rear Compartment Lift Window Panel Assembly
and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-12
Rear Compartment Lift Window Side Molding
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-17
Rear Compartment Lift Window Strut Assembly . . . . . . 10-8-13
Rear Compartment Lift Window Weatherstrip . . . . . . . . . 10-8-6
Rear Compartment Lock System . . . . . . . . . . . . . . . . . . . . 10-8-1
Rear Compartment Side Trim Assembly ............. 10-8-10
Rear Compartment Trim Assembly .................. 10-8-11
Rear Defogger Relay Replacement Procedures . . . . . . . . 18-27
Rear Disc Brake Inner and Outer Pad
Assemblies Inspection ............ : .............. 582-2
Rear Disc Brake Inner and Outer Pad
Assemblies, On-Vehicle Service ................... 582-6
Rear Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-1
Rear Drum Brake Adjustment Duo-Servo
Drum Brakes ................................... 5C2-7
Rear End, Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Rear End Finish Panel Assembly .................... 10-8-7
Rear End Finish Panel Emblem Assembly . . . . . . . . . . . . 10-8-6
Rear End Spoiler Assembly (Convertible) ............ 10-8-22
Rear End Spoiler Assembly (Coupe) ................ 10-8-15
Rear License Lamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Rear License Lamp Assembly, On-Vehicle Service ...... 88-12
Rear Main Oil Seal, 3.4L VIN S Assembly ........... 6A2B-43
Rear Main Seal, 3.4L VIN S Disassembly ........... 6A2B-22
Rear Oil Seal Assembly, Crankshaft,
Rear Quarter Center Molding Assembly .............. 10-7-11
Rear Quarter Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . . 88-4
Rear Quarter Rear Radio Speaker Grille Assembly . . . . 10-7-6
Rear Quarters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Rear Seal Assembly, Hood . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19
Rear Seat Assembly . . . . . . . . . . . . . . . . . . . 10-10-1 & 10-10-21
Rear Seat Belt Assemblies ......................... 10-11-1
Rear Seat Belt Assemblies, On-Vehicle Service ....... 10-11-4
Rear Seat Cushion Assembly . . . . . . . . . . . . . . . . . . . . . 10-10-21
Rear Seat Outer-Side Belt Assemblies ............... 10-11-4

Rear Seat Shoulder Belt Retractor
Bracket Assembly .............................. 10-11-6
Rear Seat Shoulder Belt Retractor
Trim Cover Assembly ........................... 10-11-6
Rear Seatback Cushion Assembly ................ 10-10-21
Rear Sidemarker Lamp Assemblies ................... 88-3
Rear Sidemarker Lamp Assemblies,
Rear Spring Seat, On-Vehicle Service ................. 30-4
Rear Springs, On-Vehicle Service ..................... 30-1
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Rear Thrust Angle Adjustment, Wheel Alignment ........ 3A-6
Rear Trim and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-23
Rear Trim Finishing Panel Assembly, Quarter Inner . . . . 10-7-3
Rear View Engine Wiring Harness
Assembly (3.4L L32) ............................. 605-4
Rear Wheel BolVScrew Rear Axle . . . . . . . . . . . . . . . . . . . . 48-16
Rear Window Assembly, Folding Top . . . . . . . . . . . . . . . 10-9-33
Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-8
Rearview Mirror Applique Assembly, Outside . . . . . . . . . 10-6-22
Rearview Mirror Assemblies, Outside . . . . . . . . . . . . . . . . 10-6-2
Rearview Mirror Assembly, Inside . . . . . . . . . . . . . . . . . . . 10-2-6
Rearview Mirror Assembly, Outside,
Rearview Mirror Reflective Glass, Outside . . . . . . . . . . . 10-6-21
Rearview Mirror Selector and Door Lock
Switches, Side Window, Outside Remote Control . . 10-6-19
Rearview Mirror Support, Inside . . . . . . . . . . . . . . . . . . . . . 10-2-6
Receiver and Dehydrator Assembly, Air Conditioning . . . . . 18-4
Receiver and Dehydrator Assembly
Replacement Procedures, Air Conditioning .......... 1B-19
Receiver Assembly, Programming,
Remote Keyless Entry ........................... 9K-19
Receiver Assembly, Remote Keyless Entry ............. 9K-2
Receiver Assembly, Remote Keyless Entry
On-Vehicle Service .............................. 9K-19
Receiver Dehydrator Assembly, Manual Control NC . . . 1B1-11
Receiver Dehydrator Tube Replacement
Procedures, Air Conditioning ...................... 18-16
Recliner Assembly, Front Seat . . . . . . . . . . . . . . . . . . . . 10-10-13
Recore, On-Vehicle Service ......................... 68-15
Recovery System, Coolant ........................... 68-3
Refilling Cooling System, Draining and ................. 68-7
Refinishing, Aluminum Wheel Assembly ............... 3E-12
Refinishing - BasecoaVClearcoat, Metal Part . . . . . . . . . 10-1-9
Refinishing Duo-Servo Drum Brakes .................. 5C2-7
Refinishing, Flexible Plastic Part Repair and . . . . . . . . . 10-1-12
Reflective Glass, Outside Rearview Mirror . . . . . . . . . . . 10-6-21
Refrigerant Lines and Fittings, Handling,
Refrigerant Oil Distribution .......................... 1B-14
Refrigerant Oil Loss Due to a Large Leak . . . . . . . . . . . . . . 18-14
Refrigerant Pressure Sensor Assembly,
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
Refrigerant Pressure Sensor Assembly,
Air Conditioning, Manual Control ................. 181 -15
Refrigerant R-134a, Manual Control NC .............. 181 -9
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-11
Refrigerant Recovery and Recycling, Adding
Oil, Evacuating and Recharging Procedures . . . . . . . . . . 1B-9
Refrigerant Service Valve Replacement Procedures,
Air Conditioning ................................. 1B-22
Refrigerant-134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
26 INDEX
Refrigerant-134a, Handling, On-Vehicle Service ......... 18-8
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Refrigeration System, Leak-Testing the ................. 1B-5
Refrigeration System, Maintaining Chemical
Stability in the . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Refrigeration System, Manual Control NC ............. 181-6
Refrigeration System Service, On-Vehicle Service ....... 18-7
Regulator Assembly, Front Side Door Window . . . . . . . 10-6-40
Regulator Motor Assembly, Front Side Door Window . . 10-6-42
Relay Assembly, Theft Deterrent ...................... 90-3
Relay Assembly, Theft Deterrent, On-Vehicle Service ... 90-18
Relay, Horn, On-Vehicle Service ..................... 88-18
Relays and Switches, Heater, Ventilation and NC . . . . . . . . 1B-5
Release Bearing Assembly (5-Speed), Clutch
Fork Assembly and Clutch ........................ 7C-12
Release Bearing Assembly (6-Speed), Clutch
Fork Assembly and Clutch ........................ 7C-12
Release Cable Assembly, Hood Primary Latch . . . . . . . 10-5-18
Release Lever Assembly, Steering Column Tilt Wheel .... 3F-7
Relief Valve, High Pressure .......................... 1 B-5
Remote Control Rearview Mirror Selector and
Door Lock Switches, Side Window, Outside . . . . . . . 10-6-19
Remote Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9K-1
Remote Keyless Entry Functional Operation ............ 9K-1
Repainting, Clearcoat Repair without . . . . . . . . . . . . . . . . 10-1-9
Repair Materials, Flexible Plastic Part . . . . . . . . . . . . . . . 10-1-12
Repair Materials, Rigid Plastic Part . . . . . . . . . . . . . . . . . 10-1-17
Repair Methods, Aluminum Radiator
Repairable Leaks, Aluminum Radiator
Repairing the Leak Automatic Transmission
Replacement Procedure - Third Accumulator
Retainer and Ball Assembly .................. 7 A-148-15
Reserve Capacity, Battery ........................... 601 -2
Reservoir Assembly, Battery Tray and
Coolant Recovery ............................... 68-19
Reservoir Assembly, Power Steering Fluid ............. 38-12
Reservoir, Filling Master Cylinder ...................... SA-2
Reservoir Hose Assembly, Power Steering Fluid ........ 38-12
Reservoir, Master Cylinder ........................... SA-1
Reservoir, Master Cylinder, Unit Repair ................ SA-5
Reservoir Replacement, Power Steering Pump ........ 381 B-3
Reservoir Replacement, Washer ..................... 8E-1 O
Resistance Chart, Component . . . . . . . . . . . . . . . . . . . 7A-14A-36
Resistance Check, Pressure Switch Assembly ..... 7A-14A-37
Resistor Assembly, Blower Motor . . . . . . . . . . . . . . . . . . . . . 1A-17
Resistor Inputs, Key, Theft Deterrent ................... 90-2
Restraint (SIR) System, Supplemental Inflatable ......... 9J-1
Restraint Assembly, Head . . . . . . . . . . . . . . . . . . . . . . . . 10-10-12
Restraint Guide, Shoulder . . . . . . . . . . . . . . . . . . . . . . . . 10-10-22
Retainer and Ball Assembly Leak
Check Procedure ........................... 7A-14B-15
Retainer and Ball Assembly, Third Accumulator .... 7A-14B-15
Retainer Seals, Front Side Door Trim Panel . . . . . . . . . . 10-6-17
Retractor Bracket Assembly, Rear Seat
Shoulder Belt .................................. 10-11-6
Retractor Trim Cover Assembly, Rear
Seat Shoulder Belt ............................. 10-11-6
Retractor-Side Belt Assemblies, Front Driver
and Passenger Seat ............................ 10-11-2
Reveal Moldings and Seals, Quarter Belt . . . . . . . . . . . . 10-9-30
Reverse Clutch Parts, Lo and .................... 7A-14B-12
Reverse Clutch Piston, Lo and ................... 7 A-148-16

Reverse Clutch Spacer Plate Selection, Lo and .... 7 A-148-18
Reverse Clutch Support Assembly, Lo and ........ 7A-14B-21
Reverse Input and Input Clutches ................ 7A-148-40
Reverse Input Clutch Assembly .................. 7A-14B-37
Reverse Input Clutch Backing Plate Selection ...... 7A-14B-39
Reverse Input Clutch, Input Clutch and
Input Gear Set, 2-4 Band, .................... 7A-14B-10
Reverse Lockout Assembly (6-Speed), Manual Trans ... 78-14
Reverse Lockout Solenoid (6-Speed), Manual Trans .... 78-11
Reverse Rotation Power Steering Pump Assembly ..... 381 B-5
Reverse Rotation Power Steering Pump Service ...... 381 B-6
Reverse Shift Fork, (T56) Assembly .............. 78-1 OB-29
Reverse Shift Fork, (T56) Disassembly ............. 78-108-6
Reverse Speed Gear, (T56) Assembly ............ 78-1 OB-29
Reverse Speed Gear, (T56) Disassembly . . . . . . . . . . . 78-1 OB-5
Right and Left Trim Assemblies, Front Side Door . . . . . . 10-6-2
Right-Hand Side Engine Wiring
Harness Assembly (3.4L L32) ..................... 605-2
Right-Hand Side Engine Wiring Harness
Assembly (5.7L LT1} ............................. 605-5
Rigid Plastic Part Refinishing . . . . . . . . . . . . . . . . . . . . . . 10-1-19
Rigid Plastic Part Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-17
Rigid Plastic Part Repair and Refinishing . . . . . . . . . . . . 10-1-17
Road Test Procedure ........................... 7A-14A-20
Road Test, Propeller Shaft Diagnosis .................. 4A-3
Road Test, Vibration, Tires and Wheels . . . . . . . . . . . . . . . . 3-22
Rocker Arm and Pushrod, Valve, 3.4L
VIN S Assembly .............................. 6A2B-50
Rocker Arm and Pushrod, Valve, 3.4L
Rocker Arm Cover Assemblies, Valve,
Rocker Arm Studs 5.7 Liter VS Engine .............. 6A3A-11
Rocker Arms and Pushrod Assemblies, Valve,
Rocker Arms and Pushrods, Valve, 3.4L VIN S ....... 6A2B-40
Rocker Cover, Valve, 3.4L VIN S ................... 6A2B-40
Rocker Cover, Valve, 3.4L VIN S Assembly .......... 6A2B-51
Rocker Cover, Valve, 3.4L VIN S Disassembly ....... 6A2B-11
Rocker Panel Molding Assembly . . . . . . . . . . . . . . . . . . . 10-5-24
Rod Assembly, Tie, Rear Suspension
Rod Bearing Selection, Main Bearing and,
3.4L VIN S ................................... 6A2B-29
Rod Bearings, Connecting, 3.4L V6 Engine
Rod Knob, Front Side Door Locking . . . . . . . . . . . . . . . . . 10-6'9
Roller Bearing Diagnosis, Tapered, Tires and Wheels . . . . 3-23
Rollers and Spacers, Bearing, Borg-Warner (TS) ...... 78-68-8
Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-2
Roof and Folding Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-1
Roof Drip Scalp Molding Assembly . . . . . . . . . . . . . . . . . . 10-9-5
Roof Lift-Off Window Assembly . . . . . . . . . . . . . . . . . . . . 10-9-37
Roof Lift-Off Window Assembly Adjustment . . . . . . . . . . 10-9-37
Roof Lift-Off Window Assembly Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-37
Roof Lift-Off Window Assembly Repair . . . . . . . . . . . . . . 10-9-38
Roof Lift-Off Window Lock Cylinder Assembly . . . . . . . . 10-9~39
Roof Lift-Off Window Stowage Retainer Assemblies .... 10-8-11
Roof Outer Panel, Structural Body Repair . . . . . . . . . . . . . 11-23
Roof Panel Longitudinal Bow Finish
Molding Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-39
Roof Side Rail Weatherstrip Retainer . . . . . . . . . . . . . . . 10-5-26
INDEX 27
Rotating Group Replacement, End Plate and,
Power Steering Pump .......................... 3818-4
Rotation. Tire and Wheel Assembly .................... 3E-7
Rotation, Tire and WheeLAssembly Inspection and ...... 08-4
Rotor Assemblies, Burnishing Front Brake ............. 581-8
Rotor Assemblies. Burnishing Rear Brake ............ 582-11
Rotor Assemblies Non-Directional Finishing,
Front Brake .................................... 581-8
Rotor Assemblies Non-Directional Finishing,
Rear Brake .................................... 582-11
Rotor Assemblies Off-Vehicle Procedure, Front Brake ... 581-7
Rotor Assemblies Off-Vehicle, Rear Brake ............ 582-10
Rotor Assemblies On-Vehicle Procedure, Front Brake .... 5.81-7
Rotor Assemblies On-Vehicle, Rear Brake ............ 582-10
Rotor Assemblies, Refinishing Front Brake ............ 581-7
Rotor Assemblies, Refinishing Rear Brake ............. 582-9
Rotor Assembly, Front Brake ........................ 581-1
Rotor Assembly, Front Brake, .On-Vehicle Service ....... 581-7
Rotor Assembly Inspection, Front Brake ............... 581-2
Rotor Assembly Inspection, Hear Brake ............... 582-2
Rotor Assembly, Rear Brake, On-Vehicle Service ....... 582-8
Rotor Assembly Tolerance and Surface
Finish, Front Brake ............................... 581-2
Rotor Assembly Tolerance and Surface Finish,
Rear Brake ................................. , ... 582-2
Runout Check Duo-Servo Drum Brakes ............... 5C2-2
Runout Check, Lateral, Front Disc Brakes ............. 581-2
Runout Check, Lateral, Rear Disc Brakes ............. 582-2
Runout Check, Vibration, Tires and Wheels . . . . . . . . . . . . . 3-22
Runout Measurement, Differential Drive Pinion
Gear Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Runout Measurement, Propeller Shaft Assembly . . . . . . . . 4A-5
Runout, Measuring Wheel Assembly ................... 3E-9
s
Sail Panel Speaker Assembly, Radio Rear . . . . . . . . . . . . 10-7-6
Sail Panel Speaker Grille Assembly, Radio Rear ....... 10-7-5
Scalp Molding Assembly, Roof Drip . . . . . . . . . . . . . . . . . . 10-9-5
Schrader Valve Core Replacement Procedures ......... 18-34
Scrapping Procedures, Inflatable Restraint
Screen Assemblies, Air Inlet . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
SD210 Starter Motor Assembly ..................... 602-14
80210 Starter Motor Assembly Disassembly .......... 602-10
Seal and Bearing Locations, Transmission ......... 7A-148-71
Seal, Drive Shaft, Power Steering Pump ............. 3818-6
Seal Leak Detection ................................ 1 02-8
Seal Replacement, Drive Shaft, Power
Steering Pump ................................. 3818-3
Seal Replacement, Power Steering Gear and Pump ..... 38-2
Seal Replacement Recommendations.
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Sealing, Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-21
Sealing Strip Assembly, Front Side
Door Window Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-14
Sealing Strip, Front Side Door Bottom Auxiliary . . . . . . . 10-6-16
Sealing Strip, Front Side Door Window Inner ......... 10-6-15
Seals. Cylinder Line Assembly and 0-Ring ........... 381 A-5
Seat Adjuster Actuator Lever Knob, Front . . . . . . . . . . 10-10-20
Seat Adjuster and Drive Motor Assemblies, Driver . . . 10-10-15
Seat Adjuster Assemblies, Passenger . . . . . . . . . . . . . 10-10-17
Seat Adjuster Assembly, Manual Front. Diagnosis . . . . 10-10-2
Seat Adjuster Assembly, Manual Front,

On-Vehicle Service ........................... 10-10-15
Seat Adjuster Assembly, Power Front. Diagnosis . . . . . 10-10-2
Seat Adjuster Assembly, Power Front,
Seat Assembly, Front............................. 10-10-1
Seat Assembly, Front, Diagnosis . . . . . . . . . . . . . . . . . . . 10-10-2
Seat Assembly, Front, On-Vehicle Service . . . . . . . . . . . 10-10-2
SEJat Assembly, Rear . . . . . . . . . . . . . . . . . . . 10-10-1 & 10-10-21
Seat Belt Assemblies. Front ........................ 10-11-1
Seat Belt Assemblies, Front. On-Vehicle Service ...... 10-11-2
Seat Belt Assemblies, Rear ........................ 10-11-1
Seat Belt Assemblies, Rear, On-Vehicle Service ....... 10-11-4
Seat Belt Assembly Warning, Fasten .................. 8C-6
Seat Belts ....................................... 10-11-1
Seat Belts Operational and Functional Checks ......... 10-11-1
Seat Belts Service Precaution's .... '. ................ 10~11-2
Seat, Child ....................................... 10-11-6
Seat Cushion Assemblies, Front . . . . . . . . . . . . . . . . . . . 10-10-9
Seat Cushion Assembly, Rear . . . . . . . . . . . . . . . . . . . . 10-10-21
Seat, Rear Spring, On-Vehicle Service ................. 30-4
Seat Recliner Assembly, Front ........ : . . . . . . . . . . . 10-10-13
Seatback Cushion Assembly, Rear . . . . . . . . . . . . . . . . 10-10-21
Seatback, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Seatback, Front, On-Vehicle Service ...... : . . . . . . . . . 10-10-2
Seatback Lock Assembly and Striker . . . . . . . . . . . . . . 1o:10-23
Seats and Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Second Gear Start Switch (V6 Automatic),
Performance Switch (V8 Automatic) . . . . . . . . . . . . . . . .. 8C-17
Secure Loose Molding Assemblies . . . . . . . . . . . .. . . . . . . 10-1-3
Secured Radio Assembly after Power
Loss, Unlocking ................................. 9A-13
Secured Radio Assembly, Determining

Factory Backup Unlocking Code for ................ 9A-14
Secured Radio Assembly, Unlocking .................. 9A-13
"SECURITY" Indicator Lamp ......................... 8C-6
Security Indicator Lamp Output, Theft Deterrent ......... 90-3
Sensor Assembly (3.4L L32 Engine), 24.X
Signal Crankshaft Position, On-Vehicle Service ...... 604-8
Sensor Assembly (3.4L L32 Engine),
3X Signal Crankshaft Position ..................... 604-2
3X Signal Crankshaft Position, On-Vehicle Service ... 604-8
Camshaft Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604-2
Sensor Assembly (3.4L L32 Engine).
Camshaft Position, On-Vehicle Service ............. 604-9
Sensor Assembly (3.4L L32 Engine)
24X Signal Crankshaft Position ................... 604-2
Sensor. Coolant Level .............................. 68-20
Sensor, Engine Coolant Temperature (ECT) ............ 68-3
Sensor, Engine Coolant Temperature Gage . . . . . . . . . . . . . 68-3
Sensor, Speed, Cruise Control ........................ 98-2
Sensor System, Knock ............................. 604-3
Sensors, Instrument Panel, Gages and Console ......... 8C-4
Serpentine Drive Belt ................................ 68-3
Serpentine Drive Belt and Tensioner Assembly,
Serpentine Drive Belt and Tensioner Assembly
5.7 Liter V8 Engine ............................. 6A3A-2
Serpentine Drive Belt, Diagnosis . . . . . . . . . . . . . . . . . . . . . . 68-5
Serpentine Drive Belt Inspection ...................... 013-4
"SERVICE ENGINE SOON" Indicator Lamp ............ 8C-5
28 INDEX
Service Parts Identification Label . . . . . . . . . . . . . . . . . . . . . OA-19
Service Precautions, Ignition System ................. 604-4
Service Precautions, Steering Wheel and Column
Servo Assembly, 2-4, Trans Disassembly ........... 7A-14B-2
Servo Assembly, 2-4, Trans Reassembly .......... 7 A-14855
Servo Pin Length ............................... 7 A-148-3
Set/Coast Button Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-2
Shaft Assemblies, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Shaft Bearing Assembly and/or Bearing
Seal Rear Axle ................................. 48-13
Shaft Bearing Noise, Rear Axle ....................... 48-7
Shaft, Propeller ..................................... 4A-1
Shaft, Rear Axle ................................... 48-12
Shaft Seal, Output, Manual Trans ..................... 78-9
Shaft Seal Replacement, Compressor . . . . . . . . . . . . . . . . 1 02-8
Shaft Seal Replacement, Manual ................. 7 A-148-13
Shaft Seals, Turbine ........................... 7A-14B-36
Shift Conditions Automatic Transmission
Shift Conditions, Trans Diagnosis ................. 7 A-14A-1
Shift Fork, Reverse, {T56) Assembly .............. 7B-1 OB-29
Shift Fork, Reverse, {T56) Disassembly ............ 78-108-6
Shift Rail and Fork Assemblies, (T56) Repair
and Inspection .............................. 78-108-19
Shift Rail Assemblies and Gear Clusters,
(T56) Assembly ............................. 78-108-26
Shift Rail Assemblies and Gear Clusters,
(T56) Disassembly ........................... 78-108-9
Shift Solenoid (6-Speed), Skip, Manual Trans .......... 78-14
Shift Speed Chart .............................. 7 A-14A-33
Shifter, (T56) Assembly ......................... 78-108-31
Shifter, (T56) Disassembly ....................... 78-108-1
Shimming Procedures, (T56) .................... 78-108-32
Shipping Procedures, Inflatable Restraint
Shock Absorber and Spring Assembly . . . . . . . . . . . . . . . . 3C-11
Shock Absorber Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Shock Absorber Assembly ........................... 30-9
Short Method, Windshield Assembly
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-2
Shoulder Belt Retractor Bracket Assembly,
Rear Seat ..................................... 10-11-6
Shoulder Belt Retractor Trim Cover Assembly,
Rear Seat ..................................... 10-11-6
Shoulder Restraint Guide . . . . . . . . . . . . . . . . . . . . . . . . 10-10-22
Side Door Courtesy Lamps, Front ..................... 88-3
Side Door Courtesy Lamps, Front,
Side Door Lower Weatherstrip Assembly,
Folding Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-30
Side Door Opening Frame Replacement,
Side Door Opening Frame Sectioning,
Side Door Opening Frame, Structural Body Repair . . . . . . 11-16
Side Rail Garnish Molding, Folding Top . . . . . . . . . . . . . 10-9-31
Side Rail Weatherstrip Assemblies, Folding Top . . . . . . 10-9-27
Side Rail Weatherstrip Retainer, Roof . . . . . . . . . . . . . . . 10-5-26
Side Rail Weatherstrip Retainers, Folding Top . . . . . . . . 10-9-27
Side Tank Gasket Leak Repair, Radiator .............. 68-13
Side Trim Assembly, Rear Compartment . . . . . . . . . . . . 10-8-10
Side Window, Outside Remote Control
Rearview Mirror Selector and Door Lock Switches . 10-6-19
Sidemarker Lamp Assemblies, Rear ................... 88-3

Sidemarker Lamp Assemblies, Rear,
Sidemarker Lamp, Front, On-Vehicle Service ........... 88-5
Sidemarker Lamps, Front ............................ 88-2
Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine), 24X,
Assembly (3.4L L32 Engine), 24X ................. 604-2
Assembly (3.4L L32 Engine), 3X .................. 604-2
Assembly (3.4L L32 Engine), 3X,
Signal Lever Assembly, Turn ......................... 3F-6
Signal Switch Assembly, Turn . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sill Trim Plate, Front Side Door, On-Vehicle Service .... 10-3-2
SIR System, Disabling the, On-Vehicle Service .......... 8C-7
SIR System, Disabling the, Steering Wheel and
SIR System, Enabling the, On-Vehicle Service .......... 8C-7
SIR System, Enabling the, Steering Wheel and
"SKIP SHIFT" Indicator Lamp (V8 Manual Only) ......... 8C-6
Skip Shift Solenoid (6-Speed), Manual Trans ........... 78-14
Slight Clearcoat Damage - Wet Sanding,
Finesse Polishing .............................. 10-1-11
Snap Ring Type, Universal Joints .................... 4A-13
Solenoid Switch Replacement, Starter ................ 602-5
Sound Barrier Assembly, Dash . . . . . . . . . . . . . . . . . . . . . 10-5-22
Sound Barriers, Body Hinge Pillar Inner Panel . . . . . . . . 10-5-22
Sound Insulator Assembly .......................... 8C-28
Spacers, Bearing Rollers and, Borg-Warner (T5) ...... 78-68-8
Spare Tire Assembly, Compact ....................... 3E-9
Spark Plug Assembly Replacement . . . . . . . . . . . . . . . . . . . . 08-5
Spark Plug Wire Assembly Inspection .................. 08-5
Spark Plug Wire Harness Assembly .................. 604-2
Spark Plug Wire Harness Assembly, Diagnosis ......... 604-4
Spark Plug Wire Harness Assembly Replacement ...... 604-5
Spark Plugs ....................................... 604-3
Spark Plugs, Diagnosis ............................. 604-3
Spark Plugs, On-Vehicle Service ..................... 604-5
Speaker Assemblies, On-Vehicle Service .............. 9A-15
Speaker Assembly, Radio Front Side Door . . . . . . . . . . 10-6-23
Speaker Assembly, Radio Front Side
Door (Tweeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-24
Speaker Assembly, Radio Rear ..................... 10-7-8
Speaker Assembly, Radio Rear Sail Panel ............ 10-7-6
Speaker Grille Assembly, Radio Rear Sail Panel ....... 10-7-5
Speaker Grille Assembly, Rear Quarter Rear Radio . . . . 10-7-6
Speaker Grille, Front Side Door Armrest
and Radio Front Side Door . . . . . . . . . . . . . . . . . . . . . . 10-6-3
Speaker Grilles, Front Side Door Armrest and
Map Pocket and Radio Front Side Door . . . . . . . . . . . 10-6-3
Speaker Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Special Tool Ordering Information ..................... OA-2
Special Tools, Trans Diagnosis .............. 7A-14A-11 & 85
Speed Chart, Shift ............................. 7 A-14A-33
Speed Control, Blower Motor, Manual Control A/C ...... 181-4
Speed Control Knob, Blower Motor Assembly . . . . . . . . . . . 1A-5
Speed Gear, Reverse, (T56) Assembly ............ 78-108-29
Speed Gear, Reverse, {T56) Disassembly .......... 78-108-5
Speed Sensor (6-Speed), Electronic, Manual Trans ..... 78-11
INDEX 29
Speed Sensor (VSS) Assembly, Vehicle, Cruise Control .. 98-2
Speed Sensor and Case Extension ................ 7A-148-5
Speed Sensor and Case Extension,
Trans Reassembly .......................... 7A-14B-58
Speed Sensor Assembly (5-Speed), Manual Trans ...... 78-11
Speed Sensor, Cruise Control ........................ 98-2
Speed Sensor Reluctor Wheel Rear Axle .............. 48-20
Speed Sensor Rotor, Internal Transmission ........ 7A-148-23
Speedometer Gear, (T56) Assembly .............. 78-108-30
Speedometer Gear, (T56) Disassembly . . . . . . . . . . . . 78-108-5
Spoiler Assembly (Convertible), Rear End ........... 10-8-22
Spoiler Assembly (Coupe), Rear End ............... 10-8-15
Spring Assembly, Shock Absorber and ................ 3C-11
Springs, Rear, On-Vehicle Service ..................... 30-1
Springs, Synchronizer Keys and, Borg-Warner (TS) ... 78-68-9
Sprockets, Timing Chain and, 3.4L VIN S ............ 6A2B-38
Sprockets, Timing Chain and,
3.4L VIN S Assembly .......................... 6A28-46
Sprockets, Timing Chain and,
3.4L VIN S Disassembly ....................... 6A2B-18
Squeak and Rattle Diagnosis and Repair . . . . . . . . . . . . . 10-1-7
Stabilizer Assembly, Front Side Door Window . . . . . . . . 10-6-39
Stabilizer Shaft .................................... 3C-15
Stabilizer Shaft Bracket and Link Assembly ............. 30-9
Stabilizer Shaft Link Assembly ....................... 3C-16
Stabilizer Shaft, Rear Suspension, On-Vehicle Service ... 30-8
Standard and Limited slip Diagnosis, Rear Axle ......... 48-8
Standard Rear Axle Assembly ........................ 48-1
Starter Enable Output, Theft Deterrent ................. 90-2
Starter Motor Assembly ............................. 602-1
Starter Motor Assembly Disassembly, PG-250 ......... 602-9
Starter Motor Assembly Disassembly, SD21 o ......... 602-1 O
Starter Motor Assembly, PG-250 .................... 602-13
Starter Motor Assembly Replacement ................. 602-2
Starter Motor Assembly, SD210 ..................... 602-14
Starter Motor Assembly Usage Chart ................ 602-15
Starter Solenoid Switch Replacement ................. 602-5
Station (ACR 4 ) Setup and Maintenance ............... 18-1 O
Stationary Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1
Steel Wheel Assembly Mounting Surface Check ......... 3E-8
Steering Column Assembly ...................... 3-8 & 3F-2
Steering Column Assembly Diagnosis .................. 3-7
Steering Column Assembly Removal ................. 3F-14
Steering Column Lock and Ignition Cylinder
Assembly, Theft Deterrent ......................... 90-2
Steering Column, Parts ............................ 3F58-2
Steering Column Tilt Wheel Release Lever Assembly .... 3F-7
Steering Gear Assembly, Power Rack & Pinion ........ 381A-2
Steering Gear Coupling Shaft Assembly ............... 3F-12
Steering Knuckle Assembly ......................... 3C-16
Steering Linkage Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Steering, Suspension, Tires and Wheels Diagnosis ....... 3-1
Steering Unit Mounting, On-Vehicle Service . . . . . . . . . . . 10-3-2
Steering Unit Rack and Pinion Support Mount Plates . . . 10-3-2
Steering Wheel and Column On-Vehicle Service ......... 3F-1
Steering Wheel Assembly Controls .................... 3F-2
Steering Wheel Assembly, On-Vehicle Service ......... 3F-10
Steering Wheel Horn Switch Assembly ................. 3F-9
Steering Wheel Horn Switch Contact Plate Assembly ... 3F-10
Steering Wheel Module Assembly, Deployed
Inflatable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-4
Steering Wheel Module Assembly, Inflatable Restraint . . . . 3F-8
Steering Wheel Module Assembly, Live
(Undeployed) Inflatable Restraint . . . . . . . . . . . . . . . . . . . 3F-4
Steering Wheel Module Assembly Scrapping

Procedures, Inflatable Restraint . . . . . . . . . . . . . . . . . . . . 3F-5
Steering Wheel Module Assembly Shipping
Procedures, Inflatable Restraint .................... 3F-5
Stem Seals, Valve Springs and,
Stereo and Clock Radio Assembly, AM/FM . . . . . . . . . . . . . BC-7
Stereo/Cassette (UN6), ETA AM/FM ................... 9A-4
Stereo/Cassette Tape Player (UN6), ETA AM/FM ........ 9A-8
Stereo/Cassette Tape Player with Graphics
Equalizer (UT6), ETR AM/FM . . . . . . . . . . . . . . . . . . . . . . 9A-9
Stereo Certification (U1 C), AMAX .................... 9A-1 O
Stereo Certification (UNG), AMAX ..................... 9A-8
Stereo Certification (UP3), AMAX .................... 9A-11
Stereo Certification (UT6), AMAX ..................... 9A-9
Stereo Certification, AMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
Stereo/Compact Disc Player (U1 C), ETA AM/FM ....... 9A-1 O
Stereo/Compact Disc Player (U1 C), ETA AM/FM ........ 9A-7
Stereo/Compact Disc Player with Graphics
Equalizer (UP3), ETA AM/FM ..................... 9A-11
Stereo, FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-3
Stoplamp and Cruise Control Switch Assemblies . . . . . . . . . 5-9
Stoplamp Assembly, High-Mount ...................... 88-3
Stoplamp Assembly, High-Mount, On-Vehicle Service ... 88-11
Storage Tray ...................................... BC-17
Stowage Retainer Assemblies, Roof Lift-off Window .... 10-8-11
Straps, Ground, Battery ............................ 601-10
Striker Assemblies, Front Side Door Lock . . . . . . . . . . . . 10-6-2
Striker Assembly, Front Side Door Interlock . . . . . . . . . . 10-6-31
Striker Assembly, Front Side Door Lock,
Striker, Seatback Lock Assembly and . . . . . . . . . . . . . . 10-1 0-23
Stripes and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-2
Strobe Light Method, Propeller Shaft Balancing .......... 4A-8
Structural Body Repair and Dimensions . . . . . . . . . . . . . . . . 11-1
Strut Assembly, Rear Compartment Lid Panel . . . . . . . . 10-8-20
Strut Assembly, Rear Compartment Lift Window . . . . . . 10-8-13
Sun Gear and Shell, Reaction ................... 7A-148-22
Sun Gear, Input Carrier and ..................... 7A-148-24
Sunshade Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-2
Supplemental Inflatable Restraint (SIR) Handling ........ OA-1
Supplemental Inflatable Restraint (SIR),
Steering Wheel and Column On-Vehicle Service ...... 3F-2
Supplemental Inflatable Restraint (SIR) System ......... 9J-1
Supplemental Inflatable Restraint (SIR)
Tilt Steering Column Floor Shift Unit Repair ........ 3F5B-1
Support Bearing, Center, Propeller Shaft ............... 4A-1
Support Bearing Replacement, Center . . . . . . . . . . . . . . . . 4A-12
Support Mount Plates, Steering Unit Rack and Pinion . . 10-3-2
Suppression Equipment, Radio . . . . . . . . . . . . . . . . . . . . . . 9A-1 5
Surface Finish Duo-Servo Drum Brakes ............... 5C2-2
Surface Level Contamination Repair . . . . . . . . . . . . . . . . 10-1-10
Suspension, Front .................................. 3C-1
Suspension, Rear ................................... 3D-1
Suspension, Rear Axle .............................. 3D-1
Suspension, Tires and Wheels Diagnosis, Steering, . . . . . . . 3-1
Switch Assemblies, Cruise Control .................... 98-1
Switch Assemblies, Cruise Control,
Switch Assemblies, Stoplamp and Cruise Control . . . . . . . . . 5-9
Switch Assembly, Lid Release . . . . . . . . . . . . . . . . . . . . . . . . BC-4
Switch Assembly, Lid Release, On-Vehicle Service ...... BC-25
Switch Assembly, Pivot and, Steering
Column Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
30 INDEX
Switch, Engagement, On-Vehicle Service .............. 98-14
Switch, Ignition .................................... 604-3
Switch Opening Cover Assembly,
Accessory Switch Panel Assembly and Accessory . . 10-6-7
Switch Panel Assembly and Accessory
Switch Opening Cover Assembly, Accessory . . . . . . . 10-6-7
Switch Replacement, Starter Solenoid ................ 602-5
Switch, SeVCoast Button ............................. 98-2
Switches, Instrument Panel .......................... 8C-4
Switches, Instrument Panel, On-Vehicle Service ........ 8C-24
Switches, Relays and, Heater, Ventilation and NC ....... 18-5
Synchronizer Blocker Rings, Borg-Warner (T5) ....... 78-68-9
Synchronizer Keys and Springs, Borg-Warner (T5) .... 78-68-9
Synchronizers, (T56) Repair and Inspection ........ 78-108-16
T
Taillamp Assemblies ................................ 88-3
Taillamp Assemblies, On-Vehicle Service .............. 88-13
Taillamp Closeout Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Taillamp Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Tailpipe Extension Assembly (5.7L LT1 Engine),
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6
Tank Gasket Leak Repair, Radiator Side .............. 68-13
Tank Replacement Procedures, Vacuum .............. 18-35
Tank, Vacuum ..................................... 1A-18
Tanks, Cross-Flow Radiator Core and Outlet and Inlet .... 68-2
Tape Player (UN6), Cassette ......................... 9A-8
Tape Player (UN6), ETR AM/FM Stereo/Cassette ........ 9A-8
Tape Player (UT6), Cassette ........................ 9A-10
Tape Player (UU8), Cassette ......................... 9A-5
Tape Player and Cassette Care, On-Vehicle Service .... 9A-14
Tape Player, Cassette (UN6) ......................... 9A-4
Tape Player with Graphics Equalizer (UT6),
ETR AM/FM Stereo/Cassette . . . . . . . . . . . . . . . . . . . . . . 9A-9
Taper Check or Out-of-Round Duo-Servo
Drum Brakes ................................... 5C2-2
Tapered Roller Bearing Diagnosis, Tires and Wheels . . . . . 3-23
TCC Shudder ................................. 7A-14A-21
TCC Solenoid and Wiring Harness
Replacement Automatic Transmission
"TCS OFF" Indicator Lamp ........................... 8C-6
Temperature (ECT) Sensor, Engine Coolant ............ 68-3
Temperature Check, Heater Output .................... 1A-8
Temperature Control Cable Assembly ................. 1A-16
Temperature Control Knob ........................... 1A-2
Temperature Control, Manual Control NC ............. 181-3
Temperature Gage Sensor, Engine Coolant ............. 68-3
Temperature Sensor Assembly, Air
Conditioning Evaporator ........................... 18-5
Temperature Valve and Heater Core . . . . . . . . . . . . . . . . . . . 1A-5
Temperature Valve and Heater Core
Assembly, Manual Control NC .................... 181-5
Tensioner Assembly, Serpentine Drive Belt
and, 3.4L V6 Engine On-Vehicle Service ........... 6A2A-2
Theft Deterrent Module Assembly ..................... 90-2
Theft Deterrent Module Assembly,
Theft Deterrent Relay Assembly ...................... 90-3
Theft Deterrent Relay Assembly, On-Vehicle Service .... 90-18
Theft Deterrent System Components .................. 90-1
Theft Deterrent System Operation ..................... 90-1
Theft Deterrent Systems ............................. 90-1
Thermostat Assembly, Engine Coolant ................. 68-3

Thermostat Assembly, Engine Coolant,
Thermostat Assembly Test, Engine Coolant ............. 68-4
Thermostatic Expansion Valve Assembly . . . . . . . . . . . . . . . 18-4
Thermostatic Expansion Valve Assembly,
Manual Control NC ............................ 181-1 O
Thermostatic Expansion Valve Assembly
Replacement Procedures. Air Conditioning .......... 1B-18
Thickness Variation Check, Front Disc Brakes .......... 581-2
Thickness Variation Check, Rear Disc Brakes .......... 582-2
Third Accumulator Retainer and Ball Assembly ..... 7A-148-15
Third Accumulator Retainer and Ball
Assembly, Replacement Procedure ............ 7A-148-15
Third/Fourth Blocker Rings, Borg-Warner (T5) ........ 78-68-9
Thread Locking Fasteners, Doors . . . . . . . . . . . . . . . . . . . 10-6-2
Thread Repair, 3.4L V6 Engine On-Vehicle Service ... 6A2A-32
Thread Repair, 3.4L VIN S ........................ 6A2B-25
Thread Repair 5.7 Liter V8 Engine ................. 6A3A-31
Throttle Positions Automatic Transmission
Throttle Positions, Trans Diagnosis ................ 7A-14A-1
Thrust Angle, Wheel Alignment ....................... 3A-1
Tie Rod Assembly, Rear Suspension
Tie Rod, Inner, Power Steering Gear ................. 381A-4
Tie Rod, Outer, Power Steering Gear ................ 381A-3
Tilt Steering Column Floor Shift Unit Repair,
Supplemental Inflatable Restraint (SIR) ............ 3F58-1
Tilt Wheel Release Lever Assembly, Steering Column . . . . 3F-7
Timing Chain and Sprockets, 3.4L VIN S ............ 6A2B-38
Timing Chain and Sprockets, 3.4L VIN S Assembly ... 6A2B-46
Timing Chain and Sprockets, 3.4L
Timing Chain Assembly, and Crankshaft and
Camshaft Sprockets, 3.4L V6 Engine
Timing Chain Assembly, Crankshaft and
Camshaft Sprockets, and Water Pump
Driveshaft Assembly 5.7 Liter V8 Engine
Unit Repair ................................... 6A3B-34
Driveshaft Assembly 5.7 Liter V8 Engine .......... 6A3A-13
Unit Repair ................................... 6A3B-12
Unit Repair ................................... 6A38-29
Timing Gear or Chain and Sprocket Noises,
Timing, Ignition .................................... 604-3
Tip Pressure Check, Wiper Arm ...................... 8E-16
Tire and Wheel Assembly Balance . . . . . . . . . . . . . . . . . . . . 3-22
Tire and Wheel Assembly, Balancing ................. 3E-10
Tire and Wheel Assembly Inspection and Rotation ....... 08-4
Tire and Wheel Assembly Rotation . . . . . . . . . . . . . . . . . . . . 3E-7
Tire Assembly, Compact Spare . . . . . . . . . . . . . . . . . . . . . . . 3E-9
Tire Chain Usage ................................... 3E-2
Tire Force Variation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Tire Inflation ....................................... 3E-4
INDEX 31
Tire Information, Differential Ratios and ................ OA-5
Tire Lead/Pull, Radial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Tire Mounting and Dismounting ....................... 3E-8
Tire Placa1d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-3
Tire Repair ............................... : . . . . . . . . 3E-9
Tire Waddle Complaint . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 3-19
Tires .............................................. 3-18
Tires, All Season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
Tires and Wheels ................................... 3E-1
Tires and Wheels Diagnosis, Steering, Suspension, ....... 3-1
Tires, Correcting Non-Uniform ....................... 3E-12
Tires, P-Metric ..................................... 3E-2
Tires, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-1
Toe Adjustment, Front, Wheel Alignment ............... 3A-4
Toe, Wheel Alignment ............................... 3A-1
Tolerance and Surface Finish, Front Brake
Rotor Assembly ................................. 581 -2
Tolerance and Surface Finish, Rear Brake
Rotor Assembly ................................. 582-2
Tooth Contact Pattern Test Rear Axle .................. 48-9
Top (Convertible), Folding, On-Vehicle Service . . . . . . . . 10-9-5
Top Operation, Folding, On-Vehicle Service . . . . . . . . . . . 10-9-5
Top Switch, Convertible ............................. 8C-16
Top-Tether Anchor Bracket. Child Seat ............... 10-11-7
Torque Arm, Rear Suspension On-Vehicle Service ....... 30-6
Torque Converter Assembly ..................... 7A-148-59
Torque Converter Clutch (TCC) Diagnosis ......... 7A-14A-20
Torque Converter Clutch (TCC) Diagnosis Charts ... 7A-14A-40
Torque Converter Clutch Diagnosis
Torque Converter Clutch Electrical Controls
Automatic Transmission On-Vehicle Service .......... ?A-8
Torque Converter Evaluation .................... 7A-14A-20
Torque Converter Vibration Test Procedure,
Flexplate/ .................................. 7A-14A-22
Torque Fasteners, Prevailing ........................ OA-10
Torsional Damper, 3.4L VIN S Assembly ............ 6A2B-49
Torsional Damper, 3.4L VIN S Disassembly .......... 6A2B-17
Traction Control Switches ........................... 8C-17
Traction Control System, Antilock Brake System with .... 5E2-1
Transmission Adapt Function ..................... 7A-14A-3
Transmission Adapter Plate, (T56) Repair
and Inspection .............................. 78-108-21
Transmission Assembly (RPO M49), 5-Speed Manual .... 78-1
Transmission Assembly (RPO M49),
5-Speed Manual, On-Vehicle Service ............... 78-14
Transmission Assembly (RPO MM6),
6-Speed Manual ................................. 78-1
Transmission Assembly (RPO MM6),
6-Speed Manual, On-Vehicle Service ............... 78-16
Transmission Assembly, Borg-Warner (T5) ......... 78-68-14
Transmission Assembly Definitions Automatic
Transmission Assembly Identification Information
Transmission, Automatic and Manual ................... 7-1
Transmission Case, (T56) Assembly .............. 78-108-28
Transmission Case, (T56) Disassembly ............ 78-1 OB-7
Transmission Case, (T56) Repair and Inspection ... 78-1 OB-21
Transmission Case, Borg-Warner (T5) .............. 78-68-8
Transmission Case Porosity Repair Automatic
Transmission Component and System Descriptions .. 7A-14A-3
Transmission Control Assembly (5-Speed), Manual ...... 78-7
Transmission Control Assembly (6-Speed), Manual ...... 78-8

Transmission Converter Cover Automatic
Transmission On-Vehicle Service .................. ?A-20
Transmission Cover, 13org-Warner (T5) .... ,..... , ... 7B-6B-11
Transmission Definitions and Abbreviations ......... 7A-14A-1
Transmission Diagnosis, Hydra-Matic 4L60-E
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14A-1
Transmission Disassembled View, (T56) ........... 78-108-2
Transmission Disassembled Views ............... 7A-148-62
Transmission Disassembly ....................... 7A-148-2
Transmission Disassembly, Borg-Warner (T5) ........ 78-68-1
Transmission Electrical Connector ................. 7A-14A-9
Transmission End Play Check, Disassembly ........ 7A-14B-9
Transmission End Play Check, Reassembly ....... 7A-14B-46
Transmission Engine Wiring Harness Assembly (All) .... 605-7
Transmission Fluid Checking and Filling
Procedures Automatic Transmission
Transmission Fluid Checking Procedure ........... 7A-14A-16
Transmission Fluid Filler Tube Assembly Automatic
Transmission General Description ................. 7A-14A-2
Transmission General Service Information .......... 7A-148-2
Transmission Identification ........................... OA-5
Transmission Mount Assembly, Transmission
Support and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-4
Transmission Oil Cooler ............................ 68-15
Transmission Oil Cooler Assembly .................... 68-2
Transmission Oil Cooler Gasket ...................... 68-14
Transmission On-Vehicle Service Description, Automatic ... 7-1
Transmission On-Vehicle Service, Manual .............. 78-1
Transmission Plate Assembly ........................ 8C-17
Transmission Reassembly,
Component Repair and ...................... ?A-148-14
Transmission Service ................................ OB-4
Transmission Speed Sensor Rotor, Internal ........ 7A-148-23
Transmission Support and Transmission
Mount Assembly ................................. 78-4
Transmission Unit Repair, Hydra-Matic
4L60-E Automatic ............................ ?A-148-1
Transmission Usage ................................ OA-5
Transmitter Assembly, Remote Keyless Entry ........... 9K-1
Travel Check, 3-4 Clutch Piston .................. 7A-148-35
Tray Assembly Replacement, Battery ................. 601 -8
Tread Wear Indicators, Tires .......................... 3-19
Trim and Covers, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-23
Trim Assemblies, Front Side Door Right and Left . . . . . . 10-6-2
Trim Assembly, Rear Compartment .................. 10-8-11
Trim Covers, Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-5
Trim, Exterior, Rear Quarters . . . . . . . . . . . . . . . . . . . . . . 10-7-10
Trim Finish Panel Assembly, Headlining . . . . . . . . . . . . . 10-9-35
Trim Finishing Panel Assembly, Front Quarter . . . . . . . . . 10-7-1
Trim Finishing Panel Assembly, Quarter Inner Rear . . . . 10-7-3
Trim Finishing Panel Extension
(With Lift-Off Roof Assemblies), Quarter ... : ....... 10-7-4
Trim, Front Side Door Exterior ..................... 10-6-10
Trim, Front Side Door Interior . . . . . . . . . . . . . . . . . . . . . . . 10-6-2
Trim Height, Tires and Wheels Diagnosis . . . . . . . . . . . . . . . 3-24
Trim, Interior, Rear Quarters . . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Trim Panel Assembly and Compartments,
Trim Panel Cluster Bezel Assembly, Upper .......... 8C-29
Trim Panel Assembly, Body Hinge Pillar . . . . . . . . . . . . . 10-5-22
Trim Panel Assembly, Instrument Panel Upper ......... 8C-31
32 INDEX
Trim Panel Cluster Bezel Assembly, Upper Trim
Panel Assembly and Compartments ............... 8C-29
Trim Panel Retainer Seals, Front Side Door . . . . . . . . . . 10-6-17
Trim Plate Bezel Assembly, Instrument Panel Cluster .... 8C-29
Trim Plate, Front Side Door Sill, On-Vehicle Service . . . . 10-3-2
Trouble Code Actions, Trans Diagnosis ........... 7A-14A-14
Troubleshooting Hints, Windshield
Wiper/Washer System (Pulse) ..................... BE-3
Troubleshooting, Lighting System ..................... 88-4
Tube Assemblies, Oil Level Indicator and
3.4L V6 Engine On-Vehicle Service . .' ............. 6A2A-5
Tube Blocking, Aluminum Radiator On-Vehicle Service .. 68-11
Turbine Shaft Seals ............................ 7A-148-36
''TURN SIGNAL" Indicator Lamps ..................... 8C-5
Turn Signal Lamp Assemblies, Parking and ............. 88-3
Turn Signal Lamp Assemblies, Parking and,
Turn Signal Lamp Flasher Assembly ................... 88-3
Turn Signal Lamp Flasher Assembly,
Turn Signal Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-6
Turn Signal Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Two-Piece Propeller Shaft Assembly .................. 4A-12
Two-Piece Propeller Shaft Assembly Replacement,
One and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
u
Underbody, Body Dimensions and . . . . . . . . . . . . . . . . . . . 10-3-1
Underbody Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2
Underbody, Frame and, On-Vehicle Service . . . . . . . . . . . 10-3-1
Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Universal Joint, Diagnosis of Propeller Shaft
Assembly and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Universal Joints, Propeller Shaft Unit Repair ........... 4A-13
Unlocking Code for Secured Radio Assembly,
Determining Factory Backup ...................... 9A-14
Unlocking Secured Radio Assembly .................. 9A-12
Unlocking Secured Radio Assembly after
Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-13
Up Stop Support Assembly, Front Side Door
Window Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-39
Upper and Lower Hinge Assemblies, Front Side Door . . 10-6-2
Upper and Lower Mode Valve, Manual Control NC ..... 181 -6
Upper Column, SIR Tilt Steering Column Floor Shift .... 3F5B-4
Upper Control Arm Assembly ........................ 3C-17
Upper Control Arm Ball Stud Assembly ................ 3C-4
Upper Control Arm Ball Stud Assembly Replacement . . . . 3C-5
Upper Control Arm Bushing Assembly ................ 3C-18
Upper Hinge Assembly, Front Side Door . . . . . . . . . . . . 10-6-33
Upper Intake Manifold, 3.4L VIN S ................. 6A28-40
Upper Intake Manifold, 3.4L VIN S Assembly ........ 6A2B-51
Upper Intake Manifold, 3.4L VIN S Disassembly ...... 6A2B-11
Upper Intake Manifold Assembly, 3.4L V6
Upper Rail, Structural Body Repair . . . . . . . . . . . . . . . . . . . . 11-5
Upper Side Rail Assembly, Front Wheelhouse
Panel, Structural Body Repair . . . . . . . . . . . . . . . . . . . . . . 11-8
Upstop Adjustment, Folding Top . . . . . . . . . . . . . . . . . . . 10-9-36
v
V-6 VIN Code S, 3.4 Liter .......................... 6A28-1
V-6 VIN Code S Disassembly, 3.4 Liter ............... 6A2B-6
V6 Engine On-Vehicle Service, 3.4 Liter .............. 6A2A-1

Vacuum Actuators ................................. 1A-19
Vacuum Actuators Replacement Procedures ........... 18-34
Vacuum Booster System ............................ 501-1
Vacuum Check Valve ............................... 501 -4
Vacuum Harness .................................. 1A-18
Vacuum Hose and Routing, Power Brake Booster ...... 501 -4
Vacuum Selector Valve and/or Blower Motor
Assembly Switch, Control Assembly and ............. 1A-9
Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Vacuum System, Manual Control NC ................. 181 -4
Vacuum Tank ..................................... 1A-18
Vacuum Tank Replacement Procedures ............... 18-35
Valve Assembly, Combination, Brakes . . . . . . . . . . . . . . . . . . 5-2
Valve Assembly, Combination,
Brakes On-Vehicle Service ........................ 5-20
Valve Assembly, Quarter Outer Panel
Pressure Relief ............................... 10-7-10
Valve Body and Associated Parts ................ 7A-148-49
Valve Body and Wiring Harness . . . . . . . . . . . . . . . . . . . 7A-148-6
Valve Core Replacement Procedures, Schrader ........ 1 8-34
Valve Housing, Mode ................................ 1A-5
Valve Lifter Assemblies, 3.4L V6 Engine
Valve Lifter Assemblies 5.7 Liter V8 Engine .......... 6A3A-11
Valve Lifter Assemblies 5.7 Liter V8 Engine
Unit Repair ................ 6A3B-11, 6A38-30 & 6A38-37
Valve Lifters, 3.4L VIN S .......................... 6A28-39
Valve Lifters, 3.4L VIN S Assembly ................. 6A28-50
Valve Lifters, 3.4L VIN S Disassembly .............. 6A28-13
Valve Mechanism or Valve Train Noises,
Valve Rocker Arm and Pushrod, 3.4L VIN S
Assembly .................................... 6A28-50
Valve Rocker Arm and Pushrod, 3.4L VIN S
Disassembly ................................. 6A28-11
Valve Rocker Arm Ball Studs 5. 7 Liter VB
Engine Unit Repair ............................ 6A38-37
Valve_ Rocker Arm Cover Assemblies, 3.4L
V6 Engine On-Vehicle Service ................... 6A2A-7
Valve Rocker Arm Cover Assemblies
5. 7 Liter V8 Engine
Unit Repair ................ 6A3B-11, 6A38-31 & 6A38-38
Valve Rocker Arm Cover Assemblies
5.7 Liter V8 Engine ............................. 6A3A-9
Valve Rocker Arms and Pushrod
Assemblies, 3.4L V6 Engine On-Vehicle Service .... 6A2A-8
Valve Rocker Arms and Pushrod
Assemblies 5.7 Liter VB Engine Unit Repair ...... 6A38-11,
6A3B-31 & 6A38-37
Valve Rocker Arms and Pushrod Cover
Assemblies 5.7 Liter V8 Engine ................. 6A3A-10
Valve Rocker Arms and Pushrods, 3.4L VIN S ....... 6A28-40
Valve Rocker Cover, 3.4L VIN S ................... 6A28-40
Valve Rocker Cover, 3.4L VIN S Assembly .......... 6A28-51
Valve Rocker Cover, 3.4L VIN S Disassembly ........ 6A28-11
Valve Spring and Stem Seal 5.7 Liter V8 Engine ...... 6A3A-16
Valve Springs and Stem Seals, 3.4L
Valve Train Noises, Valve Mechanism or,
Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . OA-2
Vehicle Lifting and Jacking, General ................... OA-5
INDEX 33
Vehicle Speed Sensor (VSS) Assembly,
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-2
Vehicle Speed Sensor (VSS) Automatic Transmission
Vehicle Storage, Battery Assembly Protection During .... 601-3
Vehicle Theft Prevention Standard, Federal . . . . . . . . . . . . . OA-2
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Ventilation and NC Replacement
Procedures, Heater, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Ventilation and Air Conditioning Ducts, Heat, ........... 8C-18
Ventilation and Air Conditioning, Heater, . . . . . . . . . . . . . . . . 1B-1
Ventilation and Air Conditioning System
Operation, Heater, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Ventilation Functional Test, Heater and . . . . . . . . . . . . . . . . . 1A-6
Ventilation, Heater and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Ventilation, Manual Control NC ...................... 181 -6
Ventilation Replacement Procedures, Heater and . . . . . . . . 1A-9
Vibration Substitution Method, Tires and Wheels . . . . . . . . . 3-23
Vibration Test Procedure, Flexplaterrorque
Converter .................................. 7A-14A-22
Vibration, Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
w
Waddle Complaint, Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Warning, Fasten Seat Belt Assembly .................. 8C-6
Warning, Ignition Key ................................ 8C-6
Warning/Indicator Lamp Operation, Antilock . . . . . . . . . . . . . . 5-4
Warning/Indicator Lamp Operation, Brakes . . . . . . . . . . . . . . 5-4
Warning/Indicator Lamps, Cluster ...................... 8C-4
Warning, Lights-On ................................. 8C-6
Warning/Reminder Chimes ........................... 8C-6
Warning/Reminder Chimes, On-Vehicle Service ........ 8C-32
Warning Switch, Brake Pressure Differential . . . . . . . . . . . . . 5-2
Warning Switch, Hazard ............................. 3F-6
Warning Switch Knob, Hazard . . . . . . . . . . . . . . . . . . . . . . . . 3F-6
Washer Pump Replacement ......................... 8E-1 O
Washer Reservoir Replacement ...................... 8E-10
Washer, Windshield, On-Vehicle Service .............. 8E-13
Water Deflector, Front Side Door,
Water Deflectors, Front Side Door . . . . . . . . . . . . . . . . . . . 10-6-2
Water Hose Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Water Pump Assembly 5.7 Liter V8 Engine .......... 6A3A-12
Water Pump Assembly 5.7 Liter V8 Engine
Unit Repair ......................... 6A3B-11 & 6A3B-36
Water Pump Assembly Coolant Weepage . . . . . . . . . . . . . . 68-4
Water Pump Assembly, On-Vehicle Service ............ 68-17
Water Pump Assemlby 5.7 Liter V8 Engine
Unit Repair ................................... 6A3B-30
Waterleak Correction, Stationary Windows . . . . . . . . . . . . 10-2-5
Waterleak Diagnosis and Repair . . . . . . . . . . . . . . . . . . . . 10-1-4
Waterleak, Generalized Testing . . . . . . . . . . . . . . . . . . . . . 10-1-5
Waterleak, Localized Testing (Spot Test) . . . . . . . . . . . . . 10-1-5
Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Weatherstrip Assemblies, Folding Top Outer Arm . . . . . 10-9-27
Weatherstrip Assemblies, Folding Top Side Rail . . . . . . 10-9-27
Weatherstrip Assembly, Folding Top Front . . . . . . . . . . . 10-9-28
Weatherstrip Assembly, Folding Top Side
Door Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-30
Weatherstrip Assembly, Front Side Door . . . . . . . . . . . . 10-6-12
Weatherstrip, Rear Compartment Lift Window . . . . . . . . . 10-8-6
Weatherstrip Retainer, Roof Side Rail . . . . . . . . . . . . . . . 10-5-26
Weatherstrip Retainers, Folding Top Front . . . . . . . . . . . 10-9-29
Weatherstrip Retainers, Folding Top Outer Arm . . . . . . . 10-9-28

Weatherstrip Retainers, Folding Top Side Rail . . . . . . . . 10-9-27
Weatherstrips and Garnishes, Folding
Top Assembly . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-27
Weights, Wheel Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Weld Stud Replacement, Body On-Vehicle Service .... 10-1-1
Welded Connections, Clamps and, Exhaust System . . . . . 6F-2
Wet Sanding, Finesse Polishing, Slight
Clearcoat Damage ............................. 10-1-11
Wheel Alignment ................................... 3A-1
Wheel Alignment Preliminary Inspections ............... 3A-2
Wheel Assemblies .................................. 3E-3
Wheel Assemblies, Aluminum ....................... 3E-12
Wheel Assembly Balance, Tire and . . . . . . . . . . . . . . . . . . . . 3-22
Wheel Assembly, Balancing Tire and ................. 3E-1 O
Wheel Assembly Hub Cap, Aluminum ................. 3E-12
Wheel Assembly Inspection and Rotation, Tire and ...... OB-4
Wheel Assembly Mounting Surface Check, Steel . . . . . . . . 3E-8
Wheel Assembly Porosity Repair, Aluminum ........... 3E-12
Wheel Assembly Refinishing, Aluminum ............... 3E-12
Wheel Assembly Removal and Installation .............. 3E-4
Wheel Assembly Repair ............................. 3E-4
Wheel Assembly Rotation, Tire and .................... 3E-7
Wheel Assembly Runout, Measuring ................... 3E-9
Wheel Assembly, Steering, On-Vehicle Service ......... 3F-10
Wheel Balance Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Wheel Bearing Assembly ........................... 3C-19
Wheel Bearing Assembly Repack, Front ............... 08-4
Wheel Bolt, Front ................................... 3C-7
Wheel Bolt Replacement ............................. 3E-4
Wheel Cylinder Duo-Servo Drum Brakes . . . . . . 5C2-5 & 5C2-8
Wheel Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-6
Wheel Nut Torque .................................. OB-9
Wheel Nuts and Bolts, Metric ......................... 3E-4
Wheelhouse Assembly, Front, Structural Body Repair . . . 11-13
Wheelhouse Panel Liner, Front . . . . . . . . . . . . . . . . . . . . . 10-5-6
Wheelhouse Panel Upper Side Rail Assembly,
Front, Structural Body Repair . . . . . . . . . . . . . . . . . . . . . . 11-8
Wheels, Tires and .................................. 3E-1
Windnoise Diagnosis and Repair . . . . . . . . . . . . . . . . . . . . 10-1-6
Window Adjustment, Front Side Door . . . . . . . . . . . . . . . 10-6-36
Window Assembly, Rear, Folding Top . . . . . . . . . . . . . . . 10-9-33
Window Channel Assembly and Front Side
Door Window Rear Guide Channel
Assembly, Front Side Door . . . . . . . . . . . . . . . . . . . . . 10-6-18
Window Closeout Panel Assembly, Rear
Compartment Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Window Front and Rear Bumper, Front Side Door . . . . 10-6-40
Window, Front Side Door Hardware
and Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-12
Window, Front Side Door, On-Vehicle Service . . . . . . . . 10-6-36
Window Front Up Stop Support Assembly,
Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-39
Window Inner Panel Cover Assembly, Rear
Compartment Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1 7
Window Inner Sealing Strip, Front Side Door . . . . . . . . . 10-6-15
Window Lock Striker Assembly,
Rear Compartment Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Window Opening Finish Lace, Liftgate . . . . . . . . . . . . . . 10-8-16
Window Outer Sealing Strip Assembly,
Front Side Door......... . . . . . . . . . . . . . . . . . . . . . . 10-6-14
Window Panel Adjustment, Rear Compartment Lift . . . . 10-8-14
Window Panel Assembly and Components,
Rear Compartment Lift . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-12
34 INDEX
Window Panel Assembly, Rear Compartment Lift . . . . . 10-8-13
Window, Rear Compartment Lift . . . . . . . . . . . . . . . . . . . 10-8-18
Window Rear Guide Channel Assembly,
Front Side Door Window Channel Assembly
and Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-18
Window Regulator Assembly, Front Side Door . . . . . . . 10~6-40
Window Regulator Counterbalance Arm Channel
Assembly, Front Side Door ..................... 10-6-17
Window Regulator Handle Assembly,
Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-26
Window Regulator Motor Assembly,
Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-42
Window Side Molding Assemblies, Rear
Compartment Lift . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 10-8-17
Window Stabilizer Assembly, Front Side Door . . . . . . . . 10-6-39
Window Weatherstrip, Rear Compartment Lift . . . . . . . . . 10-8-6
Windows, Stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1
Windshield Assembly, Extended Method
On-Vehicle Service ............................. 10-2-4
Windshield Assembly, Short Method
Windshield Assembly, Stationary Windows
Windshield Glass Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
Windshield Replacement, Structural Body Repair . . . . . . . 11-25
Windshield Reveal Molding Assembly,
Stationary Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1
Windshield Reveal Molding Assembly,
Stationary Windows On-Vehicle Service ........... 10-2-1
Windshield Side Upper Garnish
Molding Assembly (With Lift-Off
Window Assemblies) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-4
Windshield Side Upper Garnish Molding
Assembly (Without Lift-Off Window Assemblies) . . . . 10-9-4
Windshield Washer, On-Vehicle Service ............... 8E-13
Windshield Wiper/Washer System (Pulse) .............. 8E-1

Windshield Wiper/Washer System (Pulse)
Circuit Operation ................................. 8E-1
Component Locations ............................ 8E-3
Windshield Wiper/Washer System (Pulse) Diagnosis ..... 8E-3
Troubleshooting Hints ............................. 8E-3
Wiper Arm Replacement ............................ 8E-10
Wiper Arm Tip Pressure Check ...................... 8E-16
Wiper Blade Assembly Replacement ................. 8E-11
Wiper Blade Element Replacement ................... BE-13
Wiper Chatter Repair ............................... BE-16
Wiper Linkage Assembly Replacement ................ 8E-14
Wiper Motor Assembly Replacement ................. BE-13
Wiper Motor Cover Assembly Replacement ............ 8E-15
Wiper/Washer System (Pulse) Circuit
Operation, Windshield ............................ 8E-1
Wiper/Washer System (Pulse) Component Locations,
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-3
Wiper/Washer System (Pulse) Diagnosis, Windshield .... 8E-3
Wiper/Washer System (Pulse) Diagnosis, Windshield .... 8E-3
Wiper/Washer System (Pulse) Troubleshooting Hints,
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-3
Wiper/Washer System (Pulse), Windshield ............. 8E-1
Wire Assembly Inspection, Spark Plug ................. 08-5
Wire Harness Assembly Replacement, Spark Plug ...... 604-5
Wire Harness Assembly, Spark Plug .................. 604-2
Wire Harness Assembly, Spark Plug, Diagnosis ........ 604-4
Wire Repair, Braided Lead, Rear Window Defogger . . . . 10-2-9
Wiring, Engine .................................... 605-1
Wiring Harness Assembly, Instrument Panel ........... 8C-26
Wiring Harness Check, Internal .................. 7A-14A-34
Wiring Harness, Valve Body and .................. 7A-14B-6

1994 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 2

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1994 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 2

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CHEVROLET CAMARO AND PONTIAC FIREBIRD

ELECTRICAL - BODY AND CHASSIS

DRIVEABILITY AND EMISSIONS- FUEL INJECTION 6E-1

DRl'JEABILITY AND EMISSIONS

Reading Diagnostic Trouble Codes Using

Flashing Diagnostic Trouble Codes with

The driveability and emissions section describes

On-Board Diagnostic System Check. This must be

SECTION A: ENGINE COMPONENTS/WIRING

This sub-section assists in dia.gnosis of

SECTION C: COMPONENT SYSTEMS

Component and Circuit Descriptions.

6E-2 DRIVEABILITY AND EMISSIONS - FUEL INJECTION

Sc. No Matching Symptom - Analyze the complaint

and develop a plan for diagnostics utilizing the

STRATEGY BASED DIAGNOSTICS

The strategy based diagnostic is a uniform

Sd. lntermittents - Conditions that are not always

present are intermittent. These may be resolved

Verify the Customer Complaint

To verify the customer complaint the technician

This step is a visual confirmation of systems or

Service Diagnostics (Paper/Electronic)

Sa. OTC Stored - Follow the designated OTC chart

exactly to make an effective repair.

tables and follow the diagnostic paths or

Re-Examine the Complaint

When the complaint cannot be successfully found

Service information (Manual) System Check(s)

Most service manual sections contain "System

This condition exists when the vehicle is found to

Check Bulletins and Other Service Information

From the steps above the technician should have

Se. Vehicle operates as designed/No trouble Found -

Repair and Verification Tests

After a cause has been isolated the repairs should

DRIVEABILITY AND EMISSIONS - FUEL INJECTION 6E-3

STRATEGY BASED DIAGNOSTICS

CHECK BULLETINS AND

Figure 1 Strategy Based Diagnostics

6E-4 DRIVEABlUTY AND EMISSIONS - FUEL INJECTION

Electrostatic Discharge Damage

The underhood "Vehicle Emissions Control

Refer to SECTION OA for handling electronic

VISUAL/PHYSICAL UNDERHOOD INSPECTION

problem without further steps. Inspect all vacuum

BASIC KNOWLEDGE AND TOOLS REQUIRED

Malfunction Indicator Lamp {MIL)

DRIVEABILITY AND EMISSIONS - FUEL INJECTION 6E-5

--- ----- --'"'

"ALWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL

..__ _ EVAPORATIVE EMISSION SYSTEM

,___--------EXHAUST EMISSION SYSTEM

VEHICLE CLASS AND STANDARDS

Figure 2 - Vehicle Emission Control Information Label

6E-6 DRIVEABILITY AND EMISSIONS - FUEL INJECTION.

Once terminals "A" and "B" have been connected,

Data Link Connector (DLC)

The provision for communicating is the Data Link

TCC (IF USED)

SERIAL DATA (IF USED)

Reading Diagnostic Trouble Codes Using a

Flashing 't>iagnostic Trouble Codes With 12

SERIAL DATA (CLASS 2)

1994 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

1994 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2