1991

ELECTRICAL DIAGRAMS
AND
DIAGNOSIS MANUAL

F t/V , P M O D E L S

When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in
place of the recommended item.
All information, illustrations, and specifications contained in this manual are based on the latest product information
available at the time of publication approval. The right is reserved to make changes at any time without notice.
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any fornror by any
means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of the GMC Truck Division of General Motors Corporation. This includes all text, illustrations, tables and
charts.

X-9140
© 1990 General Motors Corporation June 1990
All rights reserved. Printed in U.S.A.
 NOTICE

CONTENTS SENSITIVE
TO
STATIC ELECTRICITY

F-05403

ELECTRONIC DISCHARGE WARNING

When handling an electronic part that has an ESD sensitive sticker, the service technician should
follow these guidelines to reduce any possible electrostatic charge build-up on the service
technician’s body and the electronic part in the dealership.

1. Do not open the package until it is time to install the part.

2. Avoid touching the electrical terminals of the part.
3. Before removing the part from its package, ground the package to a known good ground on
the vehicle.
4. Always touch a known good ground before handling the part. This should be repeated while
handling the part and more frequently after sliding across the seat, sitting down from a
standing position or walking a distance.
 1991 R/V, P TRUCK MODELS
TABLE OF CONTENTS

INTRODUCTION Circuit Circuit

Page Operation Diagram
Introduction ...................................................................................... ......... 3 Page Page
How to Use This Manual ................................................................. ......... 3
Handling Electrostatic Discharge Air Conditioning.............................................................................................. A-91 A-94
(ESD) Sensitive P a r ts ................................................................... ......... 3 H e a te r............................................................................................................... A-91 A-96
Circuit O p eratio n............................................................................... ......... 3 Auxiliary Heater ............................................................................................... A-91 A-99
Circuit Diagrams ............................................................................... ......... 3 Gages and Warning Indicators.....................................................................A-100 A-104
Component Locations ...................................................................... ......... 3 Audio Alarm M odule....................................................................................... A-111 A-112
Diagnosis ...................................................................................... ......... 4 Rear Wheel Antilock Brakes/Brake Warning ............................................. A-114 A-116
Basic Electricity ............................................................................. ......... 4 Dome L a m p s ................................................................................................... A-118 A-119
Circuit Malfunctions.......................................................................... ......... 4 Cruise Control .................................................................................................A-122 A-124
Electrical Test Equipment............................................................. ......... 4 Four-Wheel D riv e ............................................................................................ A-125 A-126
Circuit Wiring Repair Procedures ................................................ ......... 6 Power Mirrors and Door L o c k s ........................................................... .. A-127 A-129
Weather-Pack Connectors ........................................................... ......... 8 Power W indow s...............................................................................................A-136 A-139
Metri-Pack Connectors .................................................................. ......... 8 Radio AM and AM/FM S te re o .......................................................................A-143 A-144
Special T o o ls ...................................................................................... ......... 9 Rear D efo g g er................................................................................................. A-146 A-147
Regular Production Option (RPO) List .......................................... ......... 10
Rear L a m p s ......................................................................................................A-149
Abbreviation List ............................................................................... ......... 10 Rear Park and Marker L a m p s .......................................................................A-149 A-156
General Index .................................................................................... Index 1 Taillam ps.......................................................................................................... A-149 A-150
Trailer T o w ........................................................................................................ A-149 A-160
R/V TRUCK MODELS - SECTION A Backup Lam ps................................................................................................. A-149 A-154
Page License Lam ps................................................................................................. A-149 A-158
Vacuum S ystem s............................................................................................ A-161 A-164
Phantom Views ............................................................................... ......... A-2 Component Locator V ie w s ............................................................................A-166
Symptom Index ............................................................................... ......... A-8 Component Locater Index ............................................................................A-194
Power Distribution .......................................................................... . . . . A-10 ECM Pinouts ............................... A-57
Fuse Block D e ta ils .......................................................................... . . . . A-14 PCM Pinouts ............................... A -66
Bulb Data and Fuse Block Identification ....................................... . . . . A-15 TCM Pinouts ............................... A-67
Ground Distribution ........................................................................ A-16 PCM Inputs ................................. A-68
PCM O utputs............................... A-70
Circuit Circuit TCM ............................................. A-72
Hot Fuel Handling ..................... A-79
Operation Diagram
Torque Converter Clutch Control A-74
Page Page Ignition ........................................ A-76
ECM Inputs ................................. A-63
Headlamps (B a s e )............................................................................... .... A-23 A-25 ECM O utputs............................... A-64
Canadian Daytime Running Lamps................................................... .... A-23 A-26 Fuel Control and Idle Air Control A-78
Quad H a lo g en ...................................................................................... .... A-23 A-32 Instrument C lu s te r..................... A-103
Hazard L a m p s ...................................................................................... .... A-33 A-34
Front Park and Sider Marker Lam ps................................................. .... A-33 A-36
Turn L am p s........................................................................................... .... A-42 A-44
Horns .................................................................................................... .... A-48 A-49
Cigarette Lighter ............................................................................. .... A-48 A-49
Windshield Wipers and Washers (Pulse).......................................... .... A-50 A-52
Start and C h a rg e ................................................................................. .... A-53 A-55
Auxiliary Cooling F a n .......................................................................... .... A-89 A-90

TABLE OF CONTENTS 1
 P TRUCK MODELS - SECTION B P MOTORHOME - SECTION C
Page Page

Phantom Views ................................................................................................. B-2 Phantom Views ................................................................................................ C-2

Symptom Index ................................................................................................. B-3 Symptom Index ................................................................................................ C-3
Power Distribution .............................................................................................B-4 Power Distribution ........................................................................................... C-4
Fuse Block D e ta ils .......................................................................................... B-10 Fuse Block D e ta ils ........................................................................................... C-8
Lamp Bulb D a ta ............................................................................................... B-14 Lamp Bulb D a ta .............................................................................................. C-10
Ground Distribution ........................................................................................ B-15 Ground Distribution ....................................................................................... C-11

C irc u it Circuit Circuit Circuit

O p e ra tio n Diagram Operation Diagram
Page Page Page Page

Headlamps (B a s e ).......................................................................................... .B-22 B-23 Headlamps (B a s e )......................................................................................... .C-13 C-14

Canadian Daytime Running Lam ps...............................................................B-25 B-27 Canadian Daytime Running Lam ps............................................................ .C-16 C-18
Park, Marker and Hazard Signal L a m p s .................................................... .B-30 B-31 Park, Marker and Hazard Signal Lamps ................................................... .C-21 C-22
Turn L a m p s ...................................................................................................... .B-33 B-34 Turn L a m p s ......................................................................................................C-23 C-24
Horns .................................................................................................................B-35 B-36 Horns .............................................................................................................. .C-25 C-26
Windshield Wipers and Washers ................................................................ .B-37 B-38 Windshield Wipers and Washers ................................................................C-27 C-28
Starting/Charging..............................................................................................B-39 B-40 Starting/Charging........................................................................................... .C-29 C-30
Glow Plugs ...................................................................................................... .B-59 B-60 Glow Plugs ......................................................................................................C-43 C-44
Fuel C ontrols.....................................................................................................B-62 B-63 Fuel C ontrols.................................................................................................. .C-46 C-47
Instrument Panel ..............................................................................................B-66 Auxiliary Cooling F a n .................................................................................... .C-48 C-49
Indicator L a m p s ............................................................................................... .B-66 B-70 Provisions for Air Conditioning.....................................................................C-48 C-49
G a g e s .................................................................................................................B-66 B-71 Cruise C o n tro l................................................................................................ .C-51 C-52
Instrument Panel Lam ps..................................................................................B-66 B-72 Instrument Panel ........................................................................................... .C-53
Brake Warning S ystem ................................................................................... .B-73 B-74 Instrument C lu s te r......................................................................................... .C-53 C-55
Rear Exterior Lam ps.........................................................................................B-75 B-76 Indicator L a m p s ...............................................................................................C-53 C-56
Backup Lam ps................................................................................................. .B-75 B-77 G a g e s .............................................................................................................. .C-53 C-57
Taillamps, Rear Marker and License Lamps ............................................. .B-75 B-78 Instrument Panel Lam p s............................................................................... .C-53 C-58
Vacuum S ystem ............................................................................................... .B-79 B-80 Provisions for Dome Lamps ........................................................................ C-53 C-59
Component Locator V ie w s ............................................................................ .B-81 Rear L a m p s ......................................................................................................C-60
Component Locater Index ............................................................................ .B-87 Taillam ps.......................................................................................................... C-60 C-62
ECM P in o u ts .......... B-43 Backup Lam ps................................................................................................ .C-60 C-63
ECM In p u ts ............ B-44 Vacuum S ystem ...............................................................................................C-64 C-65
ECM O utputs.......... B-46 Component Locator Views C-66
PCM P in o u ts .......... B-49 Component Locater Index C-70
PCM In p u ts ............ B-50 Ignition ............................... C-32
PCM O utputs.......... B-52 PCM Pinouts ..................... C-33
TCM Pinouts .......... B-55 PCM Inputs ........................ C-34
TCM Inputs/Outputs B-56 PCM O utp u ts..................... C-36
Instrument Cluster . B-69 Throttle Body Injection . . . C-38
TCM Pinouts ..................... C-39
TCM Inputs/Outputs......... C-40
DRAC ................................. C-42

2 TABLE OF CONTENTS
HOW TO USE THIS MANUAL Circuit diagrams provide a schematic picture of how a COMPONENT LOCATIONS
circuit is provided voltage, what the current path is to the
components, and how the circuit is grounded.
•
•
The purpose of this manual is to provide:
Clean and simple electrical circuit diagrams.
Discussion of circuit electrical operation.
NOTICE For ease of diagnosis, all connectors (C), splices (S),
When you are ready to locate the schematic compo­
nents on the vehicle, use the Component Locations chart,
see Figure 3.
grounds (G) and grommets (GT) are identified by their
• Simplified diagnosis and testing procedures.

A
own unique number. This number is used to reference Listed in the LH column are the components shown on
• Component location views. component locations and also for identification in the the schematic. Next to the Fuse Block is the location,
diagnostic charts. The beginning digit designates the “Behind LH side of l/R” Reference to LH and RH is made
Each electrical system or circuit will provide the follow­ ZONE at which the connector, splice or ground can be as though the technician were sitting in the driver’s seat.
ing information: found. For example: C302. The “C ” is for connector, the On the same line, in the far right column, is the page-fig-
• Circuit Operation. “3” represents Zone 300 and 02 is the connector number. ure reference. In this case, you are directed to Figure 37
• Circuit Diagrams.
The following is a list of Zones for the vehicle: in the Component Locator Views.
• Component Location. C O N T E N T S S E N S IT IV E
• Diagnosis Charts. TO Where connectors are listed, the number of cavities is
ZONE LOCATION
provided. This represents the total number of cavities in
S TA TIC E L E C T R IC IT Y 100 — At and forward of bulkhead.
HANDLING ELECTROSTATIC DISCHARGE 200 — Within l/R
the connector, regardless of how many are actually used.
(ESD) SENSITIVE PARTS H A N D L E I N A C C O R D A N C E W IT H S T A T I C C O N T R O L
300 — From l/P to rear of cab.
This information is provided to help you identify connec­
P R O C E D U R E S G M 9107P A N D GM 9108P, tors on the vehicle. Only in-line connector locations are
O R G M D IV IS IO N A L S E R V IC E M A N U A L S . 400 — Rearward of cab. given.
When handling an electronic part that has an ESD sen­ F -0 5 4 0 3 500 — Within left door.
sitive sticker (Figure 1), the service technician should fol­
600 — Within right door. Grounds are listed next in the table. The location
low these guidelines to reduce any possible electrostatic
Figure 1 — Electronic Discharge Warning 900 — Within rear doors. description for ground G302 reads, “Behind LH side of
charge build-up on the service technician’s body and the
IIP, on ALDL bracket.” You are directed to Figure 32.
electronic part in the dealership: All connectors are shown with their part numbers and
CIRCUIT OPERATION are viewed from the mating end. The part number is used Nearly every component, connector, ground or splice
1. Do not open the package until it is time to install the shown on a schematic can be pinpointed visually by using
to save time when ordering replacement parts. All compo­
part. the Component Location Views in the back of this manual.
The description of circuit operation provides a simpli­ nents and switches are shown in their rest position,
2. Avoid touching the electrical terminals of the part.
fied discussion of what is happening within each circuit. unless otherwise marked.
3. Before removing the part from its package, ground the
The discussion includes power application, ground paths Each wiring circuit is identified by circuit number, size
package to a known good ground on the vehicle.
and component operation. The explanation is tied to the (in mm2) and color. Wire colors are shown in the abbrevi­
4. Always touch a known good ground before handling
circuit diagram, and in some cases, to specific switch ated form. Figure 2 shows how the circuit numbers and
the part. This should be repeated while handling the
movement or components in a circuit. color abbreviations are identified in this manual.
part and more frequently after sliding across the seat,
sitting down from a standing position or walking a dis­ There are three types of lines used to depict circuits
tance. CIRCUIT DIAGRAMS throughout the circuit diagrams. They are as shown:
The circuit diagrams show the circuits and components
^ H 2 -s .o n E D B i^ Solid Color Circuit Line
that are covered in that particular system. By eliminating
circuits and components not related to the systems being 2 - 3.0 r e d / w h t mm Circuit Line With Tracer
covered, the circuit diagrams are greatly simplified.
RPO Variant Circuit Line

COMPONENT LOCATION Page - Figure

9- BRN
..162-37
Headlamp Dimmer Switch........................................... .. 162-36
-------------------- 1 Low Beam Headlamp Relay........................................ ..171-57
COLOR OF WIRE INSULATION C100 (36 Cavities) (Diesel)......................................... .................... Engine compartment, on LH front of dash.................. ..159-28
C100 (36 Cavities) (Gasoline)..................................... ..156-19
B L K ___ .........Black P P L ___ G104............................................................................ ... 149-5
WIRE BRN .........Brown YEL . . . . . . . . Yellow G105............................................................................ .. 166-47
CIRCUIT -» L WIRE SIZE GRN . . . .........Green W H T ___ ___ White G302............................................................................ ..161-32
NUMBER IN SQ. MM. ORN . . . B L U .................... Blue S101.............................................................................
GRA . . . ........... Gray P N K ....................Pink S102............................................................................. .166-47
S103............................................................................. .166-47
RST . . . . ...........Rust DK ......... ......... Dark
S104.............................................................................. .166-47
L T ........... .........Light S307..............................................................................
steering column....................................................... . 167-37
Grommet 10Q................................................................ 159-29
F-05975

Figure 2 — Wire Coding Figure 3 — Component Location Chart

3
DIAGNOSIS Check for the cause of the problem BASIC ELECTRICITY
(Diagnosis Charts)
Before beginning any diagnosis, there are several Ohm’s Law states that voltage (E) is equal to resistance
important steps that should be taken: The Diagnosis Charts (Figure 4) are a step-by-step (R) (ohms) time current (I) (amperes) in a circuit
approach to diagnosis of the problem (or condition). Each (E = R x I). The equation can also be shown as I = E/R
or R = E/I.
Verify the problem chart covers one symptom. For example, “Horn(s) will not
operate.” If any two of the values are known for a given circuit,
Operate the system and list symptoms in order to: the missing one can be found by substituting the values in
The charts are divided into three columns; Test, Result amperes, volts or ohms and solving for the missing value.
• Check the accuracy and completeness of the com­ and Action.
plaint. In a typical simple circuit, battery voltage is applied to a
The Test procedures are listed in numerical sequence bulb through a 10-amp fuse and a switch. Closing the
• Learn more that might give a clue to the nature and and must be followed in that order. Each test step will
location of the problem. switch turns on the bulb.
describe what must be done to the circuit, what test
• Analyze what parts of the system are working. equipment to use and where to connect the test equip­ To find the circuit current flow, use the equation:
ment. Figure 6 — Short Circuit
I = E/R. Filling in the numbers for the equation:
Check the circuit diagram After the test procedure has been performed, refer to I = 12 volts (E)/2 ohms (R), or I = 6 amps. Grounded Circuit (Figure 7)
the Result column. This will list possible results of the
Refer to the Circuit Diagram for clues to the problem. test. Once the result has been found, follow it directly over The bulb in this circuit operates at 6 amps and is rated
Location and identification of circuit components may give to the Action column. to operate at this level. With 12 volts applied to the bulb, it A grounded circuit is like a short circuit but the current
some idea of where the problem is. will glow at the rated level. flows directly into a ground circuit that is not part of the
The Action column will instruct what must be done to original circuit. This may be caused by a wire rubbing
The circuit diagrams are designed to make it easy to correct the problem or will list the next test step to be per­ against the frame or body. Sometimes a wire will break
identify common points in circuits. This knowledge can formed. CIRCUIT MALFUNCTIONS and fall against metal that is connected electrically to the
help narrow the problem to a specific area. For example, if ground side of the voltage supply. A grounded circuit may
several circuits fail at the same time, check for a common It is important to remember that a problem in one sys­ There are three electrical conditions that can cause a
tem could result in a symptom in another system. also be caused by deposits of oil, dirt or moisture around
voltage or ground connection. If part of a circuit fails, non-working circuit; an “Open Circuit,” a “Short Circuit,” connections or terminals, which provide a good path to
check the connections between the part that works and or a “Ground Circuit.” ground.
the part that does not work. Make the repair
For example, if the low beam headlamps work, but the Open Circuit (Figure 5)
high beams and the indicator lamp do not, then voltage Repair the problem circuit as directed in the diagnosis
and ground paths are good. Since the dimmer switch is charts. An open circuit occurs whenever there is a break in the
the component which switches this voltage, it is most circuit. The break can be corrosion at the connector, a
likely the cause of failure. Verify that the repair is complete wire broken off in a component, a wire that burned open
from too much current, or a component not operating as it
Read “circuit operation” Operate the system and check that the repair has should.
removed all symptoms, and also has not caused any new
Read the Circuit Operation for the problem circuit. By symptoms.
studying the circuit diagram and circuit operation, enough
information should be learned to narrow the cause to one
component or one portion of the circuit.

HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS— BOTH SIDES Figure 7 — Grounded Circuit
TEST RESULT ACTION JL JL ELECTRICAL TEST EQUIPMENT

1
1. Check condition of PARK LP fuse. Fuse is not blown. GO to step 2.
Fuse is blown. LOCATE and REPAIR source of Various electrical testers have been developed over the
overload. Then, REPLACE fuse. years. A few of these are basic but are required to per­
2. With the light switch ON, Test lamp lights. GO to step 3. form a thorough electrical diagnosis. These include:
B-00723
connect a test lamp from ORN • Jumper wires • Voltmeter
Test lamp does not light. LOCATE and REPAIR open in ORN
(240) wire at light switch
connector C304 to ground. (240) wire from light switch to Figure 5 — Open Circuit
fuse block. • Test lamps • Ohmmeter

3. Connect a test lamp from YEL (10) Test lamp lights. GO to step 4. • Self-powered test lamps • Ammeter
wire at light switch connector
Short Circuit (Figure 6)
C 304 to ground.
Test lamp does not light. REPLACE light switch. All of these testers come in a variety of models and any
A short circuit happens when the current bypasses part working model will be adequate for simple tests. However,
4. Connect a test lamp from LT GRN Test lamp lights. REPAIR open in LT GRN (11) wire accuracy becomes important when the value of a reading
(11) wire at dimmer switch from dimmer switch to lights.
of the normal circuit. This bypassing is usually caused by
wires touching, salt water in or on a component such as a obtained using a meter is critical to the diagnosis proce­
connector C305 to ground.
Test lamp does not light. REPLACE dimmer switch. switch or a connector, or solder melting and bridging con­ dure. Make sure any electrical test meter used is of suffic­
ductors in a component. ient quality and accuracy to make the measurements
Figure 4 — Typical Diagnosis Chart required in the electrical testing.

4
Jumper Wires NOTICE: Test lamps are to be used only on circuits
Meters At normal operating voltage, most circuits have a char­
that do not contain solid state devices. If a test lamp acteristic amount of current flow, referred to as normal
Jumper wires allow “jumping” across a suspected Three types of meters are generally used for diagnosis. current draw. Current draw is measured in amperes
is used in a circuit containing a solid state device,
open or break in a circuit. They are: (amps) with an ammeter. Comparing measured current
the current that the test lamp draws is above the
draw with the specified current draw rating provides use­
• If the circuit works properly with the jumper wire in current that the solid state device is able to handle. 1 . The Ammeter. ful diagnostic information.
place, but does not work when the jumper wire is Using a test lamp on a solid state device may
destroy the device. ____________ 2. The Ohmmeter.
removed, the circuit has an open spot. Disconnect the circuit from the voltage source before
3. The Voltmeter. connecting the ammeter. The ammeter (Figure 8) must be
• A circuit without any opens or breaks has continuity placed in series with the circuit being tested. Be sure that
and needs no further testing. Once one becomes familiar with the test lamp and the These meters are available in two designs. They are:
the ammeter’s positive terminal is connected to the posi­
brilliance of the bulb in a normal circuit, high-resistance
1. Analog (Needle-Type). tive (battery) side of the circuit and its negative terminal to
The jumper is usually a long wire with alligator clamps. circuits can be recognized by the effect they have on the
the negative (ground) side of the circuit.
A version of the jumper has a fuse holder in it with a 10- bulb. As the current drops in a high-resistance circuit, the 2. Digital (Electronic Display-Type).
amp fuse. This will prevent damaging the circuit if the bulb in the test lamp will glow less brightly. Although the
jumper is connected in the wrong way. 12-volt test lamp cannot be used as a foolproof test for CAUTION: Never connect an ammeter across a
high resistance, a less than normal brilliance of the lamp CAUTION: The correct type of meter must be
The jumper is used to locate opens in a circuit. One end circuit like a voltmeter. The ammeter could be
is an indication of circuit high resistance. Further testing used when diagnosing circuits containing solid
of the jumper is attached to a voltage source and the other damaged by the vehicle electrical system.
will verify the condition and locate the cause. state devices. Incorrect use of the meters will
end is attached to the load in the circuit, i.e., lamps motor.
If the load works, try “jumping” to circuit points that are result in damage to the solid state devices.
progressively closer to the voltage supply. When the cir­ Powered Test Lamp Excessive current draw is responsible for blowing fuses
Analog meters may be used for any circuit not
cuit load stops working, the open has been located. and, in some cases, draining the battery. An ammeter wiM
containing a solid state device, while a digital
This lamp is a pencil shaped unit with a self-contained meter MUST be used to diagnose any circuit help diagnose these conditions by locating the cause of
The jumper is also used to test components in the cir­ the excessive current draw. On the other hand, there are
battery, a 1.5 volt lamp bulb, a sharp probe and a ground with a solid state device. Circuits which contain
cuit such as connectors, switches, and suspected high times when a reduced current draw at a component (a
lead fitted with an alligator clip. a solid state device, such as the Electronic Con­
resistance points. power window motor for example) causes unsatisfactory
This test lamp is used mainly for testing components trol Module, should be tested only with a 10-
megaohm or higher impedance digital performance of an electrical system.
Unpowered Test Lamp that are disconnected from the vehicle voltage supply. The
powered test lamp is also useful for testing suspected multimeter (J 29125 or equivalent).
This tool consists of a 12-volt lamp with leads. The ends high resistance points in a circuit such as connectors and Ohmmeter (Figures 9 and 11)
of the leads usually have alligator clamps, but various ground circuits that are corroded or loose.
kinds of probes, terminal spades, and special connectors Ammeter (Figures 8 and 11) The ohmmeter is used to read resistance (ohms) or to
also are used. check for opens or shorts in a circuit or component. There
NOTICE: The following instruments: Ammeter, An ammeter is used to measure current flow (amper­ are both analog-type and digital-type ohmmeters.
The 12-volt test lamp continuity tester uses the vehicle’s age) in a circuit. Amperes are units of electron flow which
Voltmeter, and Ohmmeter, each have a particu­ • An analog-type meter shows the actual resistance on a
battery to provide voltage to the circuit under test. 12 -volt indicate how many electrons are passing through the cir­
lar application for diagnosing electrical circuits. scale by the movement of a needle.
testers are manufactured with a variety of tips, to permit cuit. Ohm’s Law indicates that current flow in a circuit is
touching them to connectors, bare wires, insulated wires When using an ammeter or voltmeter, and the equal to the circuit voltage divided by total circuit resist­ • On a digital-type meter, the resistance measured is con­
or even wires within wiring harnesses. To check the tester value being tested is unknown, always use the ance. verted inside the meter to a numerical output which is
before use, briefly touch the clip to one side of the battery highest scale first and work downward to a shown on a display panel.
and the probe to the other. 12-volt testers are NOT sensi­ midscale reading whenever possible. This will
tive to polarity in a circuit, and can be connected either avoid damage to the instrument. Ohmeters use a small battery to supply the voltage and
way. current which flows through the circuit being tested. The
Never use an ohmmeter in a voltage circuit, or current flows through the circuit, positions the needle on
The 12-volt test lamp generally has a sharp probe tip so as a substitute for a voltmeter or ammeter as analog-type meters, or converts to a digital readout on
it can be inserted into connector terminals or through the damage to the instrument will result. digital-type meters. This is done in terms of resistance as
wire insulation for testing. It is important to keep the probe shown in Ohm’s Law - R = E/I.
tip sharp to minimize the damage to wire insulation.
When the test is complete at a particular point, be sure to Although there are several different styles of analog
tape any holes made in wire insulation. ohmmeters, all will usually have the following features in
addition to the meter movement:
The unpowered test lamp is used on an open circuit.
One lead of the test lamp is grounded and the other lead • A range selector switch which permits the selection of
is moved around the circuit to find the open. Depending different ranges of resistance.
on the physical layout of the circuit, sometimes it will be • A set adjust control which allows the meter to be set at
easier to start at the voltage supply and other times it is zero for accurate measurements.
easier to start at the circuit load or ground circuit.
• Some model ohmmeters also have a built-in feature
that allows the ohmmeter to be used as a self-powered
test lamp.

5
 Digital meters do not have to be zeroed. They have vari­ Voltmeter (Figures 10 and 11) terminals, loose connections or other similar problems
ous ranges just like the analog meters. reduce the voltage available across the key circuit com­
The voltmeter (properly observed) will give the techni­ ponents. The current flow is reduced in the circuit and
cian more information than the ammeter, ohmmeter and all of the affected components operate at less than
test lamp combined. Its application for diagnosis here is peak efficiency. A small drop across wires (conductors),
to measure the electrical pressure (voltage) drop in a switches, connectors, etc., is normal. (This is due to the
resistance circuit (Figure 10). Voltage drop is a reduction resistance of the conductors but should be less than 10
or “using up” of the voltage to push electricity through a percent of the total drop.)
resistance. It can be compared to the pressure of water When using a voltmeter:
flowing through a metering valve.
• Be sure to connect the positive lead to the battery side
and the negative lead to the ground side of the compo­
nent being checked.
• Voltage drop occurs when electricity (current) flows
through a resistance. Make sure the voltage drop being
measured is only through the component being
checked, not through the component and a poor con­
nection.
• The circuit must be operating (lamp ON or motor run­
ning, for example) to measure voltage drop.
The instrument panel voltmeter (in the vehicle) should
also be observed for monitoring proper operation of the
generator, battery, cranking motor, and cranking circuit. In
this application, battery voltage drop can be monitored
CAUTION: Like a self-powered test lamp, the while the engine is cranking; and after the engine is run­
ohmmeter can only be used on circuits where ning, generator output voltage can be monitored. This can
voltage has been removed (Figure 9). It is be a valuable first step before diagnosing other electrical
designed to be operated on its own voltage sup­ problems.
ply. This voltage supply provides low voltage and
current levels for the meter to make resistance
measurements. The 12-volt electrical system volt­ CIRCUIT WIRING REPAIR PROCEDURES
age in the automotive circuits could damage the
meter. Low voltage to a lamp will make the lamp glow dimly. Maintenance and Repair
This can be caused by low source voltage (battery dis­
charge or low alternator output), or by high resistance in All electrical connections must be kept clean and tight.
Electrical circuits can be checked for opens using basi­ the circuit due to a poor connection. Before making any Loose or corroded connections may cause a discharged
cally the same procedure as previously described for the meter measurements, it is important to review the relation­ battery, difficult starting, dim lamps, and possible damage
self-powered test lamp. The circuit must be separated ship between current, voltage and resistance (Ohm’s to the generator and regulator. Wires must be replaced if
from all voltage sources. The ohmmeter is connected Law). insulation becomes burned, cracked, or deteriorated.
across the two open ends of the circuit to be checked. A
high reading (infinity) is an indication of an open circuit. A Being able to determine voltage drop is important Always use rosin flux solder to splice a wire or repair
low reading (near zero) is an indication of a continuous cir­ because it provides the following information: one that is frayed or broken and use insulating tape to
cuit. cover all splices or bare wires.
• Too high of a voltage drop indicates excessive resist­
Checks for short circuits are made in a similar manner ance. If, for instance, a blower motor runs too slowly or When replacing wire, it is important that the correct size
to that used for open circuits, except that the circuit being a lamp glows too dimly, one can be sure there is exces­ wire be used as shown on applicable wiring diagrams or
checked must be isolated from both voltage and normal sive resistance in the circuit. By taking voltage drop parts book. Each harness or wire must be held securely in
readings in various parts of the circuit, the problem place to prevent chafing or damage to the insulation due
ground.
(corroded terminals) for example can be isolated. to vibration.
Connecting the ohmmeter between an isolated circuit
and a good ground point will allow checking the circuit for • Too low of a voltage drop, likewise, indicates low resist­ Wire size in a circuit is determined by the amount of
ance. If, for instance, a blower motor runs too fast, the current, the length of the circuit and the voltage drop
shorts to ground.
problem could be isolated to a low resistance in a resis­ allowed. Wire size is specified using the metric gage. The
A short to ground in the circuit will be indicated on the tor pack by taking voltage drop readings. metric gage describes the wire size directly in cross sec­
meter by a near zero reading. A good circuit (no short to tion area measured in square millimeters.
ground) will show up as infinity (very high resistance) indi­ • Maximum allowable voltage drop under a load is criti­
cated on the meter. cal, especially if there is more than one high resistance
problem in a circuit. It is important because like all
To measure the resistance of a component or a circuit, resistances, all voltage drops are cumulative. Corroded
the component or circuit must be isolated from all other
components (or circuits). The ohmmeter leads are then
placed across the component or circuit and the resistance Figure 11 — Meter Scales
is read on the ohmmeter.

6
 Wiring Connector Terminal Replacement
CAUTION: Never replace a wire with one of a (Blade-Type)
smaller size or replace a fusible link with a wire
of a larger size.
Remove or Disconnect (Figure 14)

1. Terminal lock tang.

WIRE SIZE CONVERSION TABLE 2. Terminal (61).

+ 4-
METRIC AWG Install or Connect (Figure 15)
SIZE SIZE
(mm)" 1. Pry up on the tang (70).
2. Terminal into the connector.
0.22 24
0.35 22
0.5 20
0.8 18
1.0 16
2.0 14
3.0 12
5.0 10
8.0 8
13.0 6
19.0 4
32.0 2
40.0 1
50.0 0
62.0 00

Wire Repair

The wire repair is very important for the continued reli­ Figure 14 — Removing the Terminals from
able operation of the vehicle. This repair must be done as Twisted Wires/Shielded Cable (Figure 13) the Connector
described in the following procedures.
Remove or Disconnect

Twisted Wires (Figure 12)

1. Jacket (100).
107
Remove or Disconnect 2. Unwrap aluminum/myiar tape (101).
3. Drain wire (102).
1. Jacket (90).
4. Leads.
2. Twisted wires (91).
5. Insulation on the leads. 100. Jacket
3. Insulation from the wire. 101. A lum inum /M ylar Tape
+«- 102. Drain Wire
Install or Connect 103. Splice Clip
Install or Connect 104. Crim p and Solder
1. Splice clips (103). 105. Electrical Tape Wrap
1. Splice clip (92). 106. Drain Wire Splice Clip, Crimped And
2. Crimp and solder the splice clips (104).
2. Crimp and solder the splice clips (93). Soldered.
3. Electrical tape wrap (105) on the splices. 107. O uter Electrical Tape Wrap
3. Electrical tape wrap (94) on the splices.
4. Aluminum/mylar tape by wrapping and taping.
4. Outer jacket electrical tape wrap (95).
5. Drain wire with a splice clip (106). Crimp and solder the B-06231
splice clip.
Figure 13 — Twisted/Shielded Wire Repair Figure 15 — Resetting the Lock Tang
6. Outer jacket electrical tape wrap (107).

7
Wiring Connector Terminal Replacement Molded-on connectors require complete replacement of
Install or Connect (Figure 17)
(Twin Lock-Type) the connection. This means splicing a new connector
assembly into the harness. Environmental connections
Remove or Disconnect (Figure 16) cannot be replaced with standard connections. Instruc­ 1. Terminal insulator (134) on the wire. Slide the insulator
tions are provided with the Weather-Pack connector and back on the wire about 8 cm (3 inches).
Tool Required: terminal packages. 2. Terminal (131) on the wire.
J 22727 Terminal Remover With the low current and voltage levels found in some • Roll crimp (132) and solder the terminal.
1. Connector lock tangs (81). circuits, it is important that the best possible bond at all 3. Terminal insulator (134) and the roll crimp (133).
wire splices be made by soldering the splices.
2. Terminal locks using J 22727 (82). 4. Terminal into the connector.
Use care when probing the connections or replacing
3. Terminal (80). 5. Secondary lock (125).
terminals in them. It is possible to short between two ter­
minals. If this happens, it is possible that damage may be
Install or Connect done to certain components. Always use jumper wires
6. Connector sections until the primary lock (121)
engages.
1. Pry out the tangs. between connectors for circuit checking. Never probe
through the Weather-Pack seals.
2. Terminal (80) into the connector (81). Metri-Pack Connector Replacement
When diagnosing for possible open circuits, it is often
difficult to locate them by sight because oxidation or ter­ -►4-
minal misalignment is hidden by the connectors. Merely Remove or Disconnect (Figure 17)
wiggling a connector on a sensor or in the wiring harness
may pinpoint the open circuit condition. This should Tool Required:
always be considered when an open circuit is indicated J 35689-A Terminal Remover
while diagnosing. Intermittent problems may also be
caused by oxidized or loose connections.
1. Primary lock (121) by lifting.
2. Connector body (137).
METRI-PACK CONNECTORS
3. Connector seal (120) by pulling the seal back onto the
The Metri-Pack connectors use a pull-to-seat type ter­ wires away from the connector body (137).
minal, as shown in Figure 17. The special tool required to
remove the terminal is J 35689-A terminal remover. If 4. Terminal (136) by inserting J 35689-A (139) into the
removal is attempted with an ordinary pick, there is a connector body (137) to depress the locking tang (138),
good chance that the terminal will be bent or deformed. then push the wire and terminal through the connector
Refer to Figure 17. body (Figure 17).
• Snip off the old terminal unless the terminal is to
be reused, reshape the locking tang.
Weather-Pack Connector Replacement 5. 5 mm (0.2 inch) of the wire insulation (130).
+«- Remove or Disconnect (Figure 17)
Tool Required: Clean
J 28742-A Terminal Remover (Figure 18) • Terminal cavity of the connector body.
1. Primary lock (121) by lifting.
+ 4-
2. Connector sections. Install or Connect (Figure 17)
WEATHER-PACK CONNECTORS 3. Secondary lock (125) by spreading the sides of the
1. Terminal (136) on the wire.
hasp, thus clearing the staples and rotating the hasp
Special connectors known as Weather-Pack connec­ • Crimp and solder the terminal.
(127).
tors (Figure 17) require a special tool J 28742-A (Figure 2. Terminal (136) into the connector cavity by pulling the
18) for servicing. This special tool is required to remove 4. Terminal (136) by using J 287842-A (128, 139).
wire on the seal side of the connector until the locking
the pin and sleeve terminals. If removal is attempted with • Snip off the old terminal assembly.
tang (138) is fully seated.
an ordinary pick, there is a good chance that the terminal 5. 5 mm of the wire insulation (130).
will be bent or deformed. Unlike standard blade-type ter­ 3. Seal (120) by pressing the seal into the connector body
minals, these terminals cannot be straightened once they (137) until it is fully seated.
are bent. 4. Connector sections until the primary lock (121)
Clean
Make sure that the connectors are properly seated and • Terminal Barrel (124). engages.
all of the sealing rings ( 120) are in place when connecting
the leads. The hinge-type flap (123) provides a back-up, or
secondary locking feature for terminals. They are used to
improve the connector reliability by retaining the terminals
if the small terminal lock tangs (138) are not positioned
properly.

8
 J 22727

1. Weather-Pack II Terminal Remover

2. Electrical Terminal Remover
3. Signal Generator and Instrument Panel Tester

F-02438

Figure 18 — Special Tools

133 138
VIEW B
120. Connector Seal 130. 5 mm (0.2 inch)
121. Primary Lock 131. Terminal
122. Secondary Lock Staple 132. Roll Crimp
123. Secondary Lock 133. Roll Crimp
124. Terminal Barrel 134. Terminal Insulator
125. Secondary Lock 136. Metri-Pack Series 150 Female Terminal
126. Lock Opened 137. Connector Body
127. Lock Opened 138. Locking Tang
128. J 28742-A Terminal Remover 139. J 35689-A Terminal Remover
129. Wire

F -02349

Figure 17 — Weather-Pack and Metri-Pack Connectors

9
REGULAR PRODUCTION OPTION (RPO) LIST
Use this page as a reference to determine the DISC - Discrete LO - Low
AU3 — Power Side Door Locks meaning of an abbreviation if necessary. DIST - Distributor LP - Lamp
A31 — Power Side Windows DIV - Diverter LPS -- Lamps
B3D - School Bus Equipment A -- Ampere DM - Dome LT - Light
C36 - Auxiliary Heater A/C -- Air Conditioner DR -- Door LTR - Lighter
C60 - Air Conditioning AC -- Alternating Current DRAC - Digital Ratio Adapter Controller
C65 - Auxiliary Air Conditioning ACC -- Accessory DRL - Daytime Running Lamps M - Motor
C69 - Roof Mounted Air Conditioner AIR -- Air Injection Reaction MAN - Manual
C7P — 16.000LB GVW Rating AIR/COND - Air Conditioner ECM - Electronic Control Module MAP - Manifold Absolute Pressure
D48 — Electric Remote Control Outside Mirror ALDL -- Assembly Line Diagnostic Link EFE - Early Fuel Evaporation MAX - Maximum
E63 — Fleetside Body ALT - Alternator EGR - Exhaust Gas Recirculation MED - Medium
K34 — Cruise Control AMP -- Ampere ELEC -- Electric MRKR - Marker
K68 — Generator-105 AMP ANTI - Anticipate ENG - Engine MULT - Multiple
LB4 — Engine, 4.3L (262 CID) V 6 Gasoline ASM -- Assembly EPR - Exhaust Pressure Regulator
Engine, VIN Z ASSY - Assembly ESC -- Electronic Spark Control NAT - Natural
LH6 — Engine, 6.2L (378 CID) V 8 Diesel Engine, VIN C AUD -- Audio EST - Electronic Spark Timing NEU - Neutral
LL4 — Engine, 6.2L (378 CID) V 8 HD Diesel Engine, AUTO -- Automatic ETR - Electronically Tuned Radio NO - Normally Open
VIN J AUX -- Auxiliary EVRV - Electronic Vacuum Regulator Valve NC - Normally Closed
L05 — Engine, 5.7L (350 CID) V 8 Gasoline EXC - Except
Engine, VIN K BAT -- Battery ORN - Orange
L19 — Engine, 7.4L (454 CID) V 8 Gasoline BATT -- Battery F-PUMP - Fuel Pump
Engine, VIN N BI-LEV - Bi-Level FLASH - Flasher PK - Park
M20 — Man Trans, 4-Spd. BLK - Black FRT - Front PLR - Puller
MD 8 — Auto Trans, 4-Spd., With Overdrive BLT - Belt 4WD - Four-Wheel Drive PNK - Pink
MT1 — Auto Tans, 5 Spd., With Overdrive BLU -- Blue PNL -- Panel
MT 8 — Man Trans, 5-Spd.. With Overdrive BOT - Bottom GEN - Generator PPL - Purple
MY 6 — Man Trans, 4-Spd. BRK - Brake GRA - Gray PRESS - Pressure
NA1 - Emission System, Less Than 8500 GVW BRN - Brown GRD -- Ground PWR - Power
NA4 — Emission System, Above 8500 GVW BU - Backup GRN -- Green
R05 - Dual Rear Wheels BUZZ - Buzzer RCVR - Receiver
TP2 - Auxiliary Battery HAND -- Handling REF -- Reference
TR9 - Auxiliary Lighting Package CID -- Cubic Inch Displacement HZ - Hazard RESIST - Resistance
TVR - Rear Dome and Reading Lamp CIR/BRK - Circuit Breaker HD -- Heavy Duty RH - Right Hand
T61 - Canadian Daytime Running Lamps CIRC -- Circuit HD LP -- Headlamp RPO - Regular Production Option
UJ1 - Brake Warning Indicator System CLSTR - Cluster HEI - High Energy Ignition RST - Rust
UM 6 — Radio, ETR AM/FM Stereo, Cassette CNTRL -- Control HI - High RWAL - Real Wheel Antilock
UM7 — Radio, ETR AM/FM Stereo, W/O Cassette COMP -- Compartment HTR -- Heater
UY1 - Wiring Harness, Camper COMP -- Compressor SEN - Sensor
UY7 - Truck Trailer Wiring Harness, HD CONN -- Connector IAC - Idle Air Control SEND - Sender
U89 - Trailer Wiring Harness CONV -- Convenience IGN - Ignition SIG -- Signal
V22 — Quad Halogen Headlamps CTSY - Courtesy ILLUM - Illumination SIL - Silver
CYL - Cylinder l/P -- Instrument Panel SKT - Socket
INC - Increased SOL - Solenoid
DC -- Direct Current IND - Indicator SPEEDO -- Speedometer
ABBREVIATION LIST DEF - Defrost INJ -- Injector STR - Stripe
DK - Dark INST - Instrument SW - Switch
The following is a list of abbreviations used in the
DIAG - Diagnostic INTER -- Interior
wiring diagrams. The abbreviations have been developed
DIM -- Dimmer TACH - Tachometer
in such a way that their meaning should be clear.
DIR -- Directional LD - Light Duty TBI - Throttle Body Injection
LH - Left Hand TCC -- Torque Converter Clutch

10 RPO CODES AND ABBREVIATION LIST

TEMP -- Temperature
TP -- Throttle Position
T/L -- Tail Lamp
TRANS -- Transmission
TYP -- Typical

V - Volt
VAC -- Vacuum
VLV - Valve
VSS -- Vehicle Speed Sensor

W/ -- With
W/O -- Without
W/S -- Windshield
W WASHER -- Window Washer
WDO -- Window
WHT - White
WGR -- Wiring

YEL -- Yellow

RPO CODES AND ABBREVIATION LIST 11

 SECTION A
R/V MODELS

SECTION A A-1
 LIGHTED
VANITY MIRROR
(SEE PAGE 119)

ECM/PCM/TCM
(SEE PAGES 59, 68, 72)

RH TAIL,
STOP AND TURN
LAMPS
(SEE PAGE 150)

&

BLOWER MOTOR
(SEE PAGE 98)

A-2 PHANTOM VIEW

 REAR A/C
DOME LAMPS BLOWER
ROOF MARKER (SEE PAGE 119) (SEE PAGE 95)
LAMPS
(SEE PAGE 40)

RADIO
(SEE PAGE 144)

COURTESY
LAMP
(SEE PAGE 119)

BATTERY
(SEE PAGES 10, 12)

RH HEADLAMP
(SEE PAGES 25, 26, 32)

LH REAR TAIL
STOP AND TURN LAMPS
(SEE PAGE 150)

AUXILIARY
POWER DOOR HEATER BLOWER
LOCK ACTUATOR (SEE PAGE 99)
(SEE PAGES 131, 132, 134)
RH TURN
LAMP
(SEE PAGES 44, 46)
WINDSHIELD
HORNS
WASHER MOTOR
(SEE PAGE 49)
(SEE PAGE 52)

LH HEADLAMP
(SEE PAGES 25, 26, 32) LH TURN LH SIDE
LAMP MARKER LAMP
(SEE PAGES 44, 46) (SEE PAGE 35)

PHANTOM VIEW A-3

 LIGHTED
VANITY MIRROR
(SEE PAGE 119)

ECM/PCM/TCM
(SEE PAGES 59, 68, 72)

RH REAR TAIL,
STOP AND TURN LAMP
(SEE PAGE 150)

POWER DOOR
LOCK ACTUATOR
(SEE PAGE 130)

POWER WINDOW BLOWER

MOTOR MOTOR
(SEE PAGE 139) (SEE PAGE 98)

A-4 PHANTOM VIEW

 DOME LAMP
(SEE PAGE 119)

RADIO
(SEE PAGE 144)

COURTESY
LAMP
(SEE PAGE 119)

BATTERY
(SEE PAGES 10, 12)
RH HEADLAMP
(SEE PAGES 25, 26, 32)

LH REAR TAIL
STOP AND TURN LAMPS
(SEE PAGE 150)

POWER DOOR
RH TURN LOCK ACTUATOR
LAMP (SEE PAGES 131, 132, 134)
(SEE PAGES 44, 46)

HORNS
(SEE PAGE 49)

LT TURN LH SIDE
LAMP MARKER LAMP
LH HEADLAMP (SEE PAGES 44, 46) (SEE PAGE 35)
(SEE PAGES 25, 26, 32)

PHANTOM VIEW A-5

 LIGHTED
VANITY MIRROR
(SEE PAGE 119)

ECM/PCM/TCM
(SEE PAGES 59, 68,

RH REAR TAIL,
STOP AND TURN LAMPS
(SEE PAGE 151)

-6 PHANTOM VIEW
 ROOF MARKER
RADIO LAMPS DOME LAMP CARGO LAMP
(SEE PAGE 14) (SEE PAGE 40) (SEE PAGE 119) (SEE PAGE 120) FUEL TANK
SENDING UNIT
(SEE PAGES 77, 78, 79, 87, 88)
COURTESY LAMP
(SEE PAGE 119)

BATTERY
(SEE PAGES 10, 12)

RH HEADLAMP
(SEE PAGES 25, 26, 32)

LH REAR TAIL,
STOP AND TURN LAMPS
(SEE PAGE 151)
RH TURN
LAMP
(SEE PAGES 44, 46)

HORNS POWER MIRROR

(SEE PAGE 49) WINDOW AND DOOR
LOCK SWITCHES
(SEE PAGES 129, 139)

LH TURN LH SIDE
LAMP MARKER LAMP WINDSHIELD
LH HEADLAMP (SEE PAGE 44, 46) (SEE PAGE 35) WIPER MOTOR
(SEE PAGES 25, 26, 32) (SEE PAGE 52)

PHANTOM VIEW A-7

 SYMPTOMS INDEX HEADLAMPS
Headlamps do not illuminate high or low beams -- both s id e s ......................................................................a -23
SYMPTOM PAGE Low beam lamp(s) do not operate .....................................................................................................................a -23
AIR CONDITIONING High beam lamps(s) do not o p e ra te .................................................................................................................. a -24
A/C compressor does not engage ...................................................................................................................... a -91 Daytime running lamps do not operate (Canada o n ly ).................................................................................... a -24
Blower motor does not operate in any m o d e ......................................................................................................A-92 Daytime running lamps stay on (Canada only) ............................................................................................... a -24
Blower motor does not operate in H I .................................................................................................................... A-92
Blower motor does not operate in M E D ............................................................................................................... A-92 HEATER, FRONT
Blower motor does not operate in L O ......................................................................... ....................................... A-92 Blower motor does not operate at all ................................................................................................................ a -96
Blower motor does not operate in HI but only in LO and/or M E D ................................................................. a -96
AIR CONDITIONING, REAR Blower motor does not operate in LO and/or MED but only in H I ................................................................. a -96
Blower motor does not operate at all ..................................................................................................................A-93
Blower motor does not operate in HI but only in LO ........................................................................................A-93 HEATER, AUXILIARY
Blower motor does not operate in LO but only in HI ....................................................................................... ..A-93 Auxiliary heater blower motor does not operate at all ....................................................................................a -96
Auxiliary heater blower motor does not operate in L O .................................................................................... a -96
AUDIO ALARMS
Key-in warning alarm does not o p erate............................................................................................................... A-111 HORNS
The safety belt warning buzzer does not operate ............................................................................................ A-111 Horn(s) will not operate ....................................................................................................................................... a -48
The safety belt warning buzzer operates when safety belt is buckled........................................................... A-111 Horn sounds continuously without depressing horn switch .......................................................................... a -48
Lamps-on warning alarm does not o p e ra te ........................................................................................................A-111 Cigarette lighter does not operate....................................................................................................................... a -48

AUXILIARY COOLING FAN INSTRUMENT PANEL: GAGES AND INDICATORS

Cooling fan does not run .......................................................................................................................................A-89 Fuel gage indicates full or beyond at all tim es..................................................................................................A-100
Cooling fan runs continuously............................................................................................................................... A-89 Fuel gage indicates empty when there is fuel in the ta n k ............................................................................... A-100
Fuel gage is inaccurate ....................................................................................................................................... A-100
BRAKE SYSTEMS Temperature gage indicates hot with engine coolant below operating temperature
Brake indicator remains on with ignition switch in run and park brake o ff.................................................... A-114 and ignition switch in R U N ................................................................................................................................ A-101
Brake indicator does not light during a warning condition or during the antilock system check ............A-114 Temperature gage indicates cold all the time .................................................................................................. a -101
Temperature gage is not accurate .....................................................................................................................A-101
CRUISE CONTROL Oil pressure gage indicates low pressure when oil pressure is g o o d .......................................................... A-101
Cruise control does not disengage when clutch or brake pedal is depressed .......................................... A-122 Oil pressure gage indicates high pressure at all tim es....................................................................................A-101
Cruise control does not o p e ra te .......................................................................................................................... A-122 Oil pressure gage is not accurate....................................................................................................................... A-101
Voltmeter is not accurate ..................................................................................................................................... A-101
DIESEL ENGINE FUEL CONTROL Speedometer is inoperative or inaccurate......................................................................................................... A-102
Fuel heater does not o p e ra te ............................................................................................................................... A-86 Low coolant indicator does not light with coolant level low (diesel only)......................................................A-102
Service fuel filter indicator lights with no water in fuel .....................................................................................A-86 Low coolant indicator is lit when coolant level is g o o d ....................................................................................A-102
Sen/ice fuel filter indicator does not light briefly with ignition switch turned to run ................................... A-86
COURTESY LAMPS,CARGO LAMPS AND UNDERHOOD LAMP
TURN SIGNAL LAMPS Courtesy lamps do not operate............................................................................................................................A-118
Turn signals do not work on one s id e .................................................................................................................A-42 Dome lamp does not work or stays on all the time .........................................................................................A-118
Turn signals do not operate ................................................................................................................................. A-43 Cargo lamp does not w o r k ...................................................................................................................................A-118
Turn signal lamps flash ra p id ly ............................................................................................................................ A-43 l/P compartment box lamp does not w o rk ......................................................................................................... A-118
UnderhOod lamp does not w o rk ......................................................................................................................... A-118
FRONT PARK, MARKER, ROOF AND HAZARD LAMPS
Front park and side marker lamps do not operate............................................................................................A-33 POWER DOOR LOCKS (WITH SWING OUT SIDE DOOR)
Roof marker lamps do not o p e ra te ..................................................................................................................... A-33 None of the door lock motors lock or u n lo c k .................................................................................................... A-128
Hazard warning lamps do ont operate .............................................................................................................. A-33 One door lock motor does not lock or unlock from a particular switch........................................................ A-128
One door lock motor does not operate from any switch ............................................................................... A-128
FOUR-WHEEL DRIVE INDICATOR LAMPS No door lock motors lock or unlock from any switches ................................................................................. A-128
Four-wheel drive indicator lamp will not turn o ff................................................................................................ A-125
Four-wheel drive engages but 4WD indicator lamp does not light (V100, V 2 0 0 ) ........................................ A-125 POWER WINDOWS
Four-wheel drive engages but 4WD indicator lamp does not light (V 3 0 0 )....................................................A-125
Power windows does not operate or only go in one direction ......................................................................A-136
Power windows only operate from driver’s side window switch ................................................................... A-137
Power windows do not operate from driver’s side window switch................................................................. A-137
Tailgate window does not operate from tailgate window s w itc h ................................................................... A-137
Tailgate window does not operate from key operated tailgate window switch.............................................A-138

A-8 SYMPTOM INDEX

GLOW PLUGS POWER WINDOWS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is below Power windows do not operate or only go in one direction ......................................................................... A-136
normal operating tem perature............................................................................................................................ A-82 Power windows only operate from driver’s side window switch .....................................................................A-137
Wait indicator stays on or flashes when engine is at normal operating temperature and ignition Power windows do not operate from driver’s side window switch.................................................................. A-137
switch in run position (6.2L diesel engine) ..................................................................................................... A-83 Tailgate window does not operate from tailgate window s w itc h .....................................................................A-137
Tailgate window does not operate from key operated tailgate window switch............................................. A-138
HEADLAMPS
Headlamps do not illuminate high or low beams - both s id e s .......................................................................A-23 POWER MIRRORS
Low beam lamp(s) do not operate ..................................................................................................................... A-23 Neither mirror is operational ..................................................................................................................................A-127
High beam lamps(s) do not o p e ra te ...................................................................................................................A-24 LH mirror will not adjust UP and DOWN .............................................................................................................A-127
Daytime running lamps do not operate (Canada o n ly ).....................................................................................A-24 LH mirror will not adjust LEFT and R IG H T .......................................................................................................... A-127
Daytime running lamps stay on (Canada only) ................................................................................................ A-24 RH mirror will not adjust UP and DOWN .............................................................................................................A-128
RH mirror will not adjust LEFT and R IG H T.......................................................................................................... A-128
HEATER, FRONT
Blower motor does not operate at all ................................................................................................................ A-96
Blower motor does not operate in HI but only in LO and/or M E D ..................................................................A-96 SYM PTOM PAGE
Blower motor does not operate in LO and/or MED but only in H I ..................................................................A-96

HEATER, AUXILIARY AM RADIO

Auxiliary heater blower motor does not operate at all .....................................................................................A-96
Radio does not appear to work (no display lights, no sound) .......................................................................A-143
Auxiliary heater blower motor does not operate in L O .....................................................................................A-96
Clock does not operate .........................................................................................................................................A-143
Panel lamp does not come on .............................................................................................................................A-143
HORNS Display dimming function will not o p e ra te .......................................................................................................... A-143
Horn(s) will not operate ....................................................................................................................................... A-48
No sound or distorted sound from a speaker ................................................................................................... A-143
Horn sounds continuously without depressing horn switch ........................................................................... A-48
Cigarette lighter does not operate....................................................................................................................... A-48
REAR DEFOGGER
Rear window defogger does not work and on indicator does not lig h t........................................................ A-146
INSTRUMENT PANEL: GAGES AND INDICATORS
On indicator works but rear window defogger does not defrost.................................................................... A-146
Fuel gage indicates full or beyond at all tim es...................................................................................................A-100
Rear defogger panel lamp does not w o r k ..........................................................................................................A-146
Fuel gage indicates empty when there is fuel in the ta n k ................................................................................A-100
Fuel gage is inaccurate ....................................................................................................................................... A-100
REAR EXTERIOR LAMPS
Temperature gage indicates hot with engine coolant below operating temperature
Backup lamps do not operate............................................................................................................................... A-149
and ignition switch in R U N ................................................................................................................................ A-101
Rear park, marker and license lamps do not operate .....................................................................................A-149
Temperature gage indicates cold all the time ...................................................................................................A-101
Temperature gage is not accurate ..................................................................................................................... A-101
START AND CHARGE
Oil pressure gage indicates low pressure when oil pressure is g o o d ...........................................................A-101
Engine does not crank and starter solenoid does not click ........................................................................... A-53
Oil pressure gage indicates high pressure at all tim e s .....................................................................................A-101
Starter solenoid clicks, engine does not crank or cranks slowly.................................................................... A-54
Oil pressure gage is not accurate....................................................................................................................... A-101
Battery is undercharged or overcharged...................................................................... - .................................. A-54
Voltmeter is not accurate ..................................................................................................................................... A-101
Speedometer is inoperative or inaccurate......................................................................................................... A-102
VACUUM SYSTEMS
Low coolant indicator does not light with coolant level low (diesel o n ly )...................................................... A-102
Little or no heat from auxiliary heater .................................................................................................................A-161
Low coolant indicator is lit when coolant level is g o o d .....................................................................................A-102
Improper air distribution from outlets................................................................................................................... A-161
Cruise control does not o p e ra te .......................................................................................................................... A-161
COURTESY LAMPS,CARGO LAMPS AND UNDERHOOD LAMP
Courtesy lamps do not operate............................................................................................................................A-118
WINDSHIELD WIPERS AND WASHERS (PULSE)
Dome lamp does not work or stays on all the time ......................................................................................... A-118
Wipers do not operate in any mode ................................................................................................................... A-50
Cargo lamp does not w o r k ...................................................................................................................................A-118
Wipers do not operate in HI ................................................................................................................................. A-50
l/P compartment box lamp does not w o rk ......................................................................................................... A-118
Wipers do not operate in LO or d e la y ................................................................................................................ A-50
UnderhOod lamp does not w o rk ......................................................................................................................... A-118
Washer motor does not o p e ra te ..........................................................................................................................A-51
Washer motor does not shut o f f .......................................................................................................................... A-51
POWER DOOR LOCKS (WITH SWING OUT SIDE DOOR)
None of the door lock motors lock or unlock..................................................................................................... A-128
One door lock motor does not lock or unlock from a particular sw itch........................................................ A-128
One door lock motor does not operate from any switch ................................................................................A-128
No door lock motors lock or unlock from any switches .................................................................................. A-128

SYMPTOM INDEX A-9

 RPO CODES

- AIR CONDITIONING
ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
1-32.0 BLK I ■GENERATOR-105 AMP
- AUTO TRANS, 4-SPD., WITH OVERDRIVE
- MAN TRANS, 4-SPD
- AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
I I 150*8.0 BLK I AUXILIARY BATTERY
- WIRING HARNESS, CAMPER
• TRUCK TRAILER WIRING HARNESS, HD

dcm
o 55
4“ —
CO p
AUXILIARY
BATTERY

.2-1.0 R S T ----
"(FUSIBLE LIN K)1

AUXILIARY S105
COOLING FAN
RELAY
(L19 AND C60)
(SEE PAGE 90) o
hi AUXILIARY BATTERY
CC
JUNCTION
BLOCK
BATTERY (TP2)
JUNCTION
BLOCK
S118 • I 2-8.0 RED I
I §
w

CM

g IN-LINE FUSE
3 30 AMP \
j 1 ^ 1 ^ - 1 2 - 5 . 0 RED

• S103 I J I i
I-Hi
CO - I
CC £Q
f- UJ
I I mm —0 O(/> (O -I

I
2-5.0 RED CC CD
CM

TRANSMISSION
I j A/C
♦ CONNECTOR
CC CO (SEE PAGE S C172
© CO
C3P 12084690
CAMPER AND TRAILER I
WIRING (SEE PAGE 160) I AUXILIARY
0 H i 2-8.0 RED ■ ■ BATTERY
S104 I RELAY
(TP2) C106
I ________ 12045896

I 6-3.0 PPL I
GENERATOR
1-32.0 BLK

--------- H —^ --------- fcH Hi

STARTER MOTOR
SHEET
METAL
ENGINE
GROUND
SHEET
METAL
vj
T++1++ -
-
'-------
k\ k
■ >h
|t J
<

..
■m
•
■
T t

GROUND -------' H I D
GROUND G112
G111 G109
A-10 POWER DISTRIBUTION
GASOLINE ENGINE
 RPO CODES

LH6 • ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C

COLD ADVANCE
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
TIMER RELAY
M20 * MAN TRANS, 4-SPD
(LH6 ONLY)
MT1 - AUTO TRANS, HD, 4-SPD. WITH OVERDRIVE
\ (SEE PAGE 64)
UY7 - TRUCK TRAILER WIRING HARNESS, HD
■ 1-32.0 BLK I

--------1-------- I1
3.0 B L K ^ H " ■ M M K

| 1-32.0 BLK M H H
COLD
ADVANCE FAST
IDLE TEMPERATURE EGR DUMP
1 39-.8 PNK/BLK I I 39-.8 PNK/BLK I i mmm (LH6 o n ly )
SWITCH
® 9 (SEE PAGE 87)
(SEE PAGE 64)

EPR SOLENOID
FUEL HEATER
3S-.8 PNK/BLK r I 39-.S PNK/BLK I (LH6 ONLY)
(SEE PAGE 87) '
(SEE PAGE 64)
WATER IN FUEL
l 39-.8 PNK/BLK I EGR SOLENOID
RH SENSOR 1 39-.S PNK/BLK I
PULSE WITH MODULATION
(SEE PAGE 87)
BATTERY (LH6 ONLY)
(SEE PAGE 64)
FUEL SHUTOFF
SOLENOID
(SEE PAGES 87, 88)
S109

GENERATOR
0106
12045896
C— n^ M 1 Hi ENGINE

-m
> r — • ---- i •
9 0 6 -.5 G R A ^ B B
(FUSIBLE LINK)
X / !I1 T \11t
> —-n--- I -m •
L r r
5-
m

2-3.0 RED I

STARTER MOTOR

I 2-1.0 RST I I 2-3.0 RED I

(FUSIBLE LINK)

I 6-3.0 PPL I

BATTERY
JUNCTION
BLOCK 13-3.0 P N K * i
(LL4 ONLY)
sios i 906-1.0 PPL E
/
/ 12-1.0 RST1 I 2-3.0 RED I
(FUSIBLE LINK) S106
12-8.0 BLK/REDI

C119

& 1
COLD ADVANCE
TIMER REL/Y

1
A/C 1906-1.0 PPL
i 2-5.0 R E D i S121 (LH6 ONLY) .* 5 3 1 - .8 LT G RN/BLKI
(SEE PAGE 94) (LH6 ONLY)
S130 (LL4 ONLY) (SEE PAGE)
COLD ADVANCE
■ 531-.8 LT GRN/BLK (LH6 ONLY)« I 531-.8 LT GRN/BLK CONTROL (LH6 ONLY)
LEFT BANK
GLOW PLUGS
RIGHT BANK
GLOW PLUGS
SHEET
METAL
* 12-5.0 DK BLU/WHT I
TRAILER WIRING
(SEE PAGE 160)
3*3.0 PNK (LL4 ONLY) (SEE PAGE 64)

GROUND GROUND GROUND IN-LINE FUSE GLOW PLUG C168 FUEL SOLENOID
12015982 13-3.0 PNK * (LL4 ONLY)
G113 G114 G111 30 AMP CONTROLLER (SEE PAGES 87, 88)

A-12 POWER DISTRIBUTION

D1ESEJLEN G IN E3_
COWL
 RPO CODES

LH6 - ENGINE, 6.2L <378 CID) VS DIESEL ENGINE, VIN C

LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
POWER CIRCUIT 76
30-A M P CIRCUIT BREAKER AUTO TRANS/CONV CLUTCH NOTE: L U ENGINES DO NOT USE THE CRANK, ECM I OR ECM B FUSES.
LH6 ENGINES DO NOT USE THE CRANK FUSE
M D 8 DIESEL ONLY
TAIL GATE POWER WINDOW NOTE: DRL ARE ONLY ON VEHICLES FOR SALE IN CANADA WITH T61.
AUXILIARY BATTERY
POWER WINDOW S FOUR WHEEL DRIVE ILL LP

PANEL LAMPS

REAR DEFOGGER REAR DEFOGGER LAMP

CRUISE CONTROL FOUR-WHEEL DRIVE IND. LP

DIESEL AUXILIARY FUEL

TANK SELECTOR SWITCH POWER CIRCUIT 6 0
30-A M P CIRCUIT BREAKER

REAR HEATER

CLOCK TAIL GATE-POWER W INDOW

REAR A/C
REAR DEFOGGER
2 5 0 -3 .0 B R N -A U X HEATER A/C
DOME & -CARGO LAMP POWER LOCKS 43-1.0 YEL - RADIO
250-3.0 BRN AUX HEATER A/C 7 6 -3 .0 PNK —IGN PWR W D O -
8 .5 GRA —INSTRUMENT LPS
2 4 0 -1 .0 O R N -B A T T FUSED HORN/DM
4 4 -1 .0 DK GRN —LT SW RHEOSTAT
2 5 0 -3 .0 B R N -A U X HEATER A/C 1 2 0 4 1 2 3 5 SHUNT
2 3 .0 R ED -B ATTER Y
1 4 0 . 8 O R N -H A Z A R D FLASHER 3 -3 .0 P N K -IG N SW —ENG-IGN
3 0 0 -3 .0 ORN —IGNITION
4 3 -1 .0 Y E L -R A D IO 39-.8 PNK/BLK - IGN - ON AND CRANK - FUSED
T U R N B /U PW RW DO W IPE R
4 3 -.5 YEL—RADIO 4 0 .8 ORN —TAIL LPS/CTSY LPS/PARK LPS
GiO K ]
ECM i DR L
o \ 1
5 0 -2 .0 B RN -HEA TER A/C 2 -3 .0 R E D -IG N S W -B A T T

D3 0 0
CRANK
D) /
4 3 .0 BRN —IGNITION S W -A C C
9 3 - 8 W H T - W /S WASHER
440 .8 ORN - ECM B
3 8 .8 DK B L U -D IR SIG FLASHER---------

------------------ — v ___ / 9 3 .8 W H T - W /S WASHER

7 5 - 8 DK B LU -BACKUP LP SW
16 .8 PPL —DIRECT SIG SW 4 3 9 .8 PNK/BLK-ECM-FUSED
FRONT ■38 .8 DK BLU —DIRECT SIG FUSE 3 -3 .0 PNK —IGN 1
1 2 0 3 4 3 5 9 BLOCK MOLD 340-.8 ORN DRL 6 3 .0 PPL-STARTER SOLENOID FEED
1 2 0 5 9 4 5 2 PRINTED BLOCK 2-3.0 RED - BATTERY
8 0 6 .8 PPL/WHT—ECM CRANK FUSED
CAUTION: Determine If non-cycling circuit 7 6 -3 .0 P N K -IG N PWR W D O ----------------
breakers are hot before removing them. REAR
Hot non-cycling circuit breakers can cause
personal injury.

COLOR MALE CONN

A NAT 12004888
B BRN 12004887
C BLK 12004886
D GRN 12004885
E RED 12004883
W BLU 12004884
F DK GRA 12004740

A-14 FUSE BLOCK

 LAMP BULB DATA
AC Type Guide Lamps are recommended when replacement becomes necessary.
Lamp Usage Quantity Trade Power Rating
No. at 12V, Watts
FUSE AND CIRCUIT BREAKER IDENTIFICATION Headlamps (2) Headlamp System 2 6025 66/65
FUSE FUSE COLOR HOT DESCRIPTION 2 H6054 35/65
LOCATION PART NO. AND CONDITION (Opt.)
AMPERE
AUXILIARY HEATER AND AIR
(4) Headlamp System - Lo 2 H4703 55
AUX HTR A/C 12004010 WHITE HOT IN
25 AMP RUN CONDITIONING
- HI 2 H4701 65
CRANK 12004003 VIOLET HOT IN ECM 2 H4651 50
3 AMP START CRANK CIRCUIT (Opt.)
DRL 12004008 LTBLU HOT AT DRL Candle Power
15 AMP ALL TIMES
RED HOT IN ECM 1
Dome Lamps 2 211-2 12
ECM 1 12004007
10 AMP RUN OR START Instrument Cluster Lamps 5 168 3
12004007 RED HOT AT ECM
ECM B
10 AMP ALL TIMES
Headlamp Beam Indicator Lamp 1 168 3
GAGE/IDLE 12004009 YELLOW HOT IN IGNITION Taillamp and Stoplamp1 2 2057 2-32
20 AMP RUN OR START CRANK
License Lamp 1 67 4
HORN/DM 12004009 YEL HOT AT HORN 4**
20 AMP ALL TIMES DOME AND CARGO LAMPS Turn Signal (Front Park Lamps)1 3057NA 1.5-24
CLOCK Turn Signal Indicator Lamp 2 168 3
HTR A/C 12004010 WHITE HOT IN HEATER AND AIR CONDITIONING
20 AMP RUN
REAR DEFOGGER
Park Lamps (W/4 Headlamps) 2 194NA 1.5
IGN 12004009 YELLOW HOT IN
20 AMP RUN OR START CRUISE CONTROL Front Side Marker Lamps 2 194 2
DIESEL AUXILIARY FUEL TANK
SELECTOR SWITCH Rear Side Marker Lamps 2 168 3
INST LPS 12004005 TAN HOT W/LIQHT SWITCH INSTRUMENT PANEL LAMPS Roof Marker Lamps 5 194 2
5 AMP IN HEAD OR PARK
Brake Warning Indicator 1 168 3
PWR ACC (CIRCUIT 30 AMP HOT AT TAIL GATE POWER WINDOW
BREAKER) ALL TIMES REAR DEFOGGER Backup Lamp 2 1156 32
POWER LOCKS
Heater or A/C Control 1 194 2
PWR WDO (CIRCUIT 30 AMP HOT IN POWER WINDOWS
BREAKER) FUN Cargo Lamp* 1 1142 21
RADIO 12004008 LT BLUE HOT IN RADIO Fender Clearance Lamp* 4 168 3
15 AMP ACC OR RUN AUXILIARY BATTERY RELAY
FOUR-WHEEL DRIVE INDICATOR Rear Identification* 5 Part of 3
LAMP Lens
AUTOMATIC TRANSMISSION
CONVERTER CLUTCH (MD8 ONLY) Radio Dial Lamp 1 1893 2
STOP HAZ 12004008 LTBLU HOT AT HAZARD FLASHER Four-Wheel Drive Indicator 1 161 1
15 AMP ALL TIMES
Courtesy Lamp 1 1003 15
T/L CTSY 12004009 YELLOW HOT AT TAILLAMPS
20 AMP ALL TIMES COURTESY LAMPS Low Coolant Lamp2 1 194 2
PARKING LAMPS
Clock 1 168 3
TURN/BU 12004008 LT BLUE HOT IN RUN TURN SIGNALS
15 AMP OR START BACKUP LAMPS Safety Belt Warning 1 168 3
WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS Glow Plugs Indicator2 1 194 2
25 AMP ACC OR RUN
Four-Wheel Drive Shift Lever 1 194 2
Water In Fuel2 1 194 2
“SERVICE ENGINE SOON" Lamp
(W/Gasoline Engine) 1 194 2
(W/LH6 Diesel) 1 1893 2
Underhood Lamp 1 19/10 9.9
Reading Lamp 2 906 6

2. Diesel only.
* Not used on Suburban and Utility.
** 2 Required with 4 headlamp system.

BULB DATA AND FUSE BLOCK A-15

 £ jn __
— ■+■ *— H~
A/C COMPRESSOR
I150-.8 BLK I
BATTERY AUXILIARY (L19) (SEE PAGE 94)
BATTERY

ECM/PCM

I 551 -.8 TAN/BLK ■ [ (FLEETSIDE, WIDESIDE, STEPSIDEJ

3
CD
(SEE PAGE 59)

LH PARK AND
I 150-.8 BLK TURN LAMP A/22)
(SEE PAGE 35)

LH PARK LAMP (V22)

150-.8 BLK
(SEE PAGE 35)
RWAL (W/O C60)

r
1150-.8 BLK I
(SEE PAGE 116)

I 1-32.0 BLK I
LH LOW BEAM
S113 • ■ ■ ■ 150-.8 BLK HEADLAMP (V22)
RH HIGH-LOW (SEE PAGE 32)
RWAL (W/C80)
151-.8 BLK I HEADLAMP I 150-.8 BLK I
(SEEPAGE 116)

L
(SEE PAGE 25)

RH PARK AND LH HIGH BEAM

151-.8 BLK I TURN LAMP 150-.8 BLK HEADLAMP (V22)
(SEE PAGE 34) (SEE PAGE 32)

RH PARK LAMP
151-.8 BLK (SEE PAGE 35)
LH PARK AND
I 150-.8 BLK TURN LAMP
AUXILIARY ENGINE
(SEE PAGE 34)
COOLING FAN ECM/PCM (W/O C60)
151-2.0 BLK« 551-.8 TAN/WHTr
(L19 WITH C60) (SEE PAGE 68)
(SEE PAGE 90) • S122

LH HIGH-LOW
S111 \ 150-.8 BLK HEADLAMP
(SEE PAGE 25)

RH HIGH BEAM
151-.8BLK HEADLAMP (V22)
(SEE PAGE 32) *- j
tu
RH LOW BEAM
LH PARK LAMP
151-.8 BLK HEADLAMP (V22) I 150-.8 BLK I
(SEE PAGE 34)
(SEE PAGE 32)

I 151-3.0 8LK

V / 1
G106 G107 G112 G109 G105

SHEET FRAME ENGINE SHEET ENGINE

METAL GROUND GROUND METAL GROUND
GROUND GROUND

A-16 GROUND DISTRIBUTION

GASOLINE ENGINE
 RPO CODES

L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K

L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
M20 - MAN TRANS, 4-SPD.
C60 - AIR CONDITIONING
C200 V22 - QUAD HALOGEN HEADLAMPS
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE

ECM/PCM DRL MODULE

1413- 8 TAN 150-.8 BLK I
(SEE PAGES 59, 68) (SEE PAGE 26)

(M20 ONLY)
. (M20 ONLY)
450-.8 BLK/WHT | 450- 8 BLK/WHT I LIGHT SWITCH
150-.8 BLK I
(SEE PAGE 25)
Mmm ^m m r 450-.8 b lk /w h T 450-.8 BLK/WHT « T

419/450 HEATER CONTROL

150-.8 BLK I LAMP

f 450-.8 BLK/WHT*
FUEL PUMP RELAY i (SEEPAGE 110)

(SEE PAGE 60)

4 450-.8 BLK/WHT *m m r *m m r mmm*

RADIO
1S0-.8 BLK '
(SEE PAGE 144, 145)

I 450-.8 BLK/WHT 1
ECM/PCM
(SEE PAGE 59) \
S117 WINDSHIELD
150-.8 BLK I WIPER SWITCH
FUEL PUMP (SEE PAGE 52)

r
ECM/PCM 450-.8 BLK/WHT CYCLE RELAY
450-.8 BLK/WHT
(SEE PAGE 59)
(SEE PAGE 79) S201

450-.8 BLK/WHT I
EVRV
S215
!• w/ 450-.8 BLK/WHT
ALDL
(SEE PAGE 60) (SEE PAGE 59)

486-.8 BRN I
ESC HYBRID
MODULE
<\ 450-.8 BLK/WHT
DRAC
[ (SEE PAGE 75)
150-.8 BLK I
l/P CLUSTER
(SEE PAGE 107)

(SEE PAGE 58)

r
Z
< 150-.8 BLK
CONVENIENCE CENTER
(SEE PAGE 21)
PARK/NEUTRAL
I _______ 450-.8 BLK/WHT SWITCH (L05 WITH MD8)
(SEE PAGE 59)

SAFETY BELT
l _ 1150:. 8 BLK m
150:.8BLK ^ RETRACTOR SWITCH
(SEEPAGE 112)

G200

ENGINE DASH PANEL

GROUND
I
IIP GROUND
GROUND

GROUND DISTRIBUTION A-17

GASOLINE ENGINE
 4
1*32.0 BLK I

i— i n n n
- -h — “h
RH LH
BATTERY BATTERY
TCM (LL4 WITH MT1)
(SEE PAGE 72)

1-32.0 BLK

FUEL HEATER
(SEE PAGE 87)

RH HIGH-LOW
WATER IN FUEL SENSOR
5 1-.8 B LK I HEADLAMP
(SEE PAGE 87)
(SEE PAGE 25)

RH PARK AND
151-.8 BLK | TURN LAMP
(SEE PAGE 34)

RH PARK LAMP
151-.8 BLK I (SEE PAGE 34)

RH HIGH BEAM
151-.8 BLK I HEADLAMP (V22)
(SEE PAGE 32}

RH LOW BEAM
151-.6 BLK I HEADLAMP (V22)
(SEE PAGE 32)

W/O C60

151-3.0 BLK

1 G107

y i
G114

0
G113

12020183
C100
SHEET FRAME RIGHT BANK LEFT BANK ENGINE
METAL GROUND GLOW PLUG GLOW PLUG GROUND
GROUND GROUND GROUND

A-18 GROUND DISTRIBUTION

DIESEL ENGINES
 RPO CODES

LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J

LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
V22 - QUAD HALOGEN HEADLAMPS

ALDL (LL4 ONLY)

■150-.8 BLK I
(SEE PAGE 73)

WINDSHIELD
■150-.8 BLK I WIPER SWITCH
(SEE PAGE 52)

DRL MODULE
ALDL 1150-.8 BLK 1
1151-.8 BLK (LH6 ONLY)l (SEE PAGE 26)
(SEE PAGE 63)

CHECK ENGINE LAMP

I150-.8 BLK I DRIVER MODULE (LH6 ONLY)
(SEE PAGE 105)

HEATER CONTROL LAMP

(SEE PAGE 110)

LOW COOLANT
1150*.8 BLK I WARNING MODULE
(SEE PAGE 106)

RADIO
1150-.8 BLK I
(SEE PAGES 144, 145)

GLOW PLUG LAMP

(SEE PAGE 105)

l/P CLUSTER
1150-. 8 BLK I
(SEE PAGE 107)

K150-.8BLKI

DRAC MODULE (LL4 ONLY)

1150-.8 BLK I
(SEE PAGE 75)

CONVENIENCE CENTER
I150-.8 BLK
(SEE PAGE 21)

SAFETY BELT
RETRACTOR SWITCH
(SEE PAGE 112)

COPPER BRAID ■

„ , G200
CO) i/p G102 __ G103
■=■ GROUND
ENGINE DASHPANEL
GROUND GRAND
GROUND DISTRIBUTION A-19
DIESEL ENGINES
 RPO CODES

R05 - DUAL REAR WHEELS

1150-.8 BLK I LH FRONT AND RH FRONT AND

REAR CLEARANCE CLEARANCE LAMPS (R05)
LAMPS (R05) (SEE PAGE 157)
1150-. 8 BLK I (SEE PAGE 157) I 150-.8 BLK I

LH SIDE RH SIDE
1150-.8 BLK I MARKER LAMP I 150-.8 BLK I MARKER LAMP
(SEE PAGE 156) (SEE PAGE 156)

LH BACKUP RH BACKUP
1150*.8 BLK I LAMP I150-.8 BLK 1 LAMP
(SEE PAGE 153) (SEE PAGE 153)

LH TAIL, STOP RH TAIL, STOP

I150-.8 BLK | AND TURN LAMP 1150-.8 BLK I AND TURN LAMP
(SEE PAGE 150) (SEE PAGE 150)

I 150-.8 BLK I 1150-.8 BLK I

1150-.8 BLK I
(FLEETSIDE, WIOESIDE ONLY) S402

G403 G402
G406 G405 G407
SHEET SHEET
METAL METAL LH TAIL, STOP, AND TURN RH TAIL, STOP, AND TURN
GROUND GROUND LAMP GROUND FRAME LAMP GROUND
GROUND
FLEETSIDE, WIDESIDE, SUBURBAN AND UTILITY

STEPSIDE

A-20 GROUND DISTRIBUTION

REAR LAMPS
 AUDIO ALARM

238. SAFETY BELT

RETRACTOR SWITCH

150' GROUND

SAFETY BELT
237'
INDICATOR LAMP
39' IGNITION KEY IN
STOP HAZ
SWITCH I 80-.5 LT GRN
(SEE PAGE 113) FUSE
(SEE PAGE 36)
80' KEY IN SWITCH

140' BATTERY

8' LIGHTS ON SWITCH

INSTR LPS
(SEE PAGE 110)
GAGE/IDLE
FUSE 39-.S PNK/BLK SAFETY BELT
(SEE PAGE 26) RETRACTOR
SWITCH
INSTRUMENT I 237-.8 YEL
(SEE PAGE 112)
PANEL
(SEE PAGE 105)

HORNS
(SEE PAGE 49)

HORN/DM
FUSE
(SEE PAGE 49)

HORN CIGARETTE
RELAY LIGHTER
(SEE PAGE 49)

HAZARD
FLASHER
SWITCH I 27-.8 BRN
(SEE PAGE 36)

HORN
SWITCH
(SEE PAGE 49)

CONVENIENCE CENTER D U

HAZARD
FLASHER

l/P
(Q ) GROUND
■=" G200

CONVENIENCE CENTER A-21

 RPO CODES

TP2 - AUXILIARY BATTERY

1-32.0 BLK

£
o
+ - o
GT 105
BATTERY 8911214

I I 141-.8 BRN/WHT 11
£■

z
CC
m

I HTR

i
¥ 1T11V11
VrTa1
V11Tni i'
AUXILIARY (Aj ® IS [D] U m
BATTERY RELAY t^BAT-t
(cj (g b ® in ® m
WDO
m
/ y1
[c ] [c ] ra ra no Ei tu ° ii n i | u M ii
M gnJ ACC LPS PWR
30
SHUNT SHUNT
A » 4 L s in i In i
INSTR LPS PWR ACC

BIGN__AUX_HTR
d B 3* “ D dHAi iL s Ik 0 i p l a m
................... .. _A/C STOP HAZ
20AJ j^25A^ | r~15A
I 15A L kS I k 0 ( kS
T/L CTSY GAGE/tDLE H TR A/d _RADlO
RADIO

KWIPERl W3 I k fi I kS
ECM B TURN B/U PWR WDO
S105 S118
• ■ I 2-8.0 RED ■ I■ ■ 2-8.0 RED ■ ■ ^
ECM 1 DRL
a B^S o'
150-8.0 BLK
K J □ 0 0 □ □ |
REAR

FUSE
<S> BLOCK
12103404

w
SHEET SHEET AUXILIARY SHEET
METAL METAL BATTERY METAL
GROUND AUXILIARY GROUND JUNCTION GROUND
G111 BATTERY G109 BLOCK G108

A-22 AUXILIARY BATTERY

CIRCUIT OPERATION LOW BEAM LAMP(S) DO NOT OPERATE
TEST RESULT ACTION
HEADLAMPS
Voltage is applied to the Light Switch at all times. becomes the ground wire when the Headlamps are 1. Turn light switch ON and Test lamp does not light. GO to step 5.
The Light Switch includes a Self-Resetting Circuit operated normally. Voltage is applied to the DRL headlamp dimmer switch to LOW
BEAM position. Connect a test Test lamp lights. GO to step 2.
Breaker. The Circuit Breaker opens when the Headlamp Module when the Ignition Switch is in RUN through the
lamp from TAN (12) wire at
circuit draws too much current. When the Circuit PNK/BLK (39) wire from the GAGE/IDLE Fuse. inoperative lamp(s) to
Breaker opens, it interrupts the current flow. With no ground.
current flow the Circuit Breaker cools off and resets When the Ignition Switch is placed in RUN the DRL
automatically. When the Light Switch is in HEAD, the Module energizes the DRL Relay connecting the ORN 2. Connect test lamp from TAN Test lamp does not light. LOCATE and REPAIR open in BLK
Dimmer Switch directs voltage to either the Low Beams (240) circuit (hot at all times) with the DK BLU/ORN (593) (12) to BLK (150 or 151) (150 or 151) wire(s) from
or the High Beams. The High Beam Indicator also circuit, turning on the Headlamps. wire(s) at headlamp headlamp connector(s) C138 or
receives voltage along with the High Beams. When the connectors C138 or C144 C144 (Base), C149 or C154 (Quad
When the Headlamps are turned on manually, or the (Base), C149 or C154 (Quad Halogen) to ground terminal(s)
Light Switch is in PARK or HEAD, voltage is directed to
Halogen) to ground. (For G105, G106 or G107. (For
parklamps. Ignition Switch is turned OFF, the DRL Module de­
Canadian vehicle w/o quad, DK Canadian vehicles w/o Quad
energizes the DRL Relay connecting the DK BLU/ORN BLU/ORN (593) is used in place Halogen, GO to step 3.)
CANADIAN DAYTIME RUNNING LAMPS (593) circuit to the BLK (150) ground circuit. This allows of BLK (150) wire at connector
Voltage is applied to the Daytime Running Lamp normal operation of the Headlamps. C138). Test lamp lights. REPLACE headlamp(s).
(DRL) relay at all times through the ORN (240) wire from
the DRL Fuse and when the Ignition Switch is in RUN If the dimmer switch is put into the High Beam
Position, the DRL Module will supply voltage through the 3. Connect a test lamp from BLK Test lamp lights. GO to step 4.
through the PNK/BLK (39) wire from the GAGE/IDLE
WHT (629) wire, to the Instrument Panel Cluster to turn (150) wire at DRL relay
Fuse. The DRL Relay provides voltage to the LH High connector C126 to ground. Test lamp does not light.
on the High Beam Indicator bulb. LOCATE and REPAIR open in BLK
Beam through the DK BLU/ORN (593) wire. This wire also (150) wire from DRL relay to
ground G105.
4. Connect a self powered test Test lamp lights. LOCATE and REPAIR open in DK
DIAGNOSIS - HEADLAMPS lamp from DK BLU/ORN (593) at BLU/ORN (593) wire from
DRL relay connector C126 to headlamp connector C138 to DRL
PRELIMINARY CHECKS: ground. relay C126.
Check condition of T/L CTSY fuse. If fuse is blown, fuse. If fuse is in good condition, use the following
LOCATE and REPAIR source of overload, then REPLACE diagnostic procedures. Test lamp does not light. REPLACE DRL relay.
5. Connect a test lamp from TAN Test lamp does not light. GO to step 6.
(12 ) wire at headlamp dimmer
switch connector C201 to Test lamp lights. LOCATE and REPAIR open in TAN
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS—BOTH SIDES ground. (12 ) wire from headlamp dimmer
switch to headlamp.
TEST RESULT ACTION
6. Connect a test lamp from YEL Test lamp does not light. LOCATE and REPAIR open in YEL
1. Connect a test lamp from RED Test lamp lights. GO to step 2. (10) wire at headlamp dimmer ( 10) wire from headlamp dimmer
(2) wire at light switch switch connector C201 to switch to light switch.
connector C202 to ground. Test lamp does not light. LOCATE and REPAIR open in RED ground.
(2) wire from light switch to Test lamp lights. REPLACE headlamp dimmer
junction block. switch.
2. With the light switch on and Test lamp lights. GO to step 3.
the headlamp dimmer switch to
HIGH BEAM, connect a test lamp Test lamp does not light. REPLACE light switch.
from YEL (10) wire at light
switch connector C202 to
ground.

3. Connect a test lamp from LT GRN Test lamp lights. REPAIR open in LT GRN (11) wire
(1 1 ) wire at headlamp dimmer from headlamp dimmer switch to
switch connector C201 to headlamps.
ground.
Test lamp does not light. REPLACE headlamp dimmer
switch.

HEADLAMPS A-23
 HIGH BEAM LAMP(S) DO NOT OPERATE DRL DOES NOT OPERATE

TEST RESULT ACTION TEST RESULT ACTION

1. Place light switch to ON and Test lamp does not light. GO to step 5. 1. Check condition of DRL fuse. Fuse is not blown. GO to step 2.
dimmer switch to HIGH BEAM
position. Connect a test lamp from Test lamp lights. GO to step 2. Fuse is blown. LOCATE and REPAIR source of
LT GRN (11) wire at inoperative overload. Then, REPLACE fuse.
lamp(s) to ground. 2. Connect a test lamp from ORN Test lamp lights. GO to step 3.
(240) wire at DRL relay connector
2. Connect test lamp from LT GRN Test lamp does not light. LOCATE and REPAIR open in BLK C126 to ground. Test lamp does not light. LOCATE and REPAIR open in ORN
(11) wire to BLK (150 or 151) (150 or 151) wire(s) at headlamp (240) wire from DRL relay
wire(s) at headlamp connectors connector(s) C138 or C144 (Base), connector C126 to C125 and/or
C138 or C144 (Base), C150 or C150 or C155 (Quad Halogen) to ORN (340) wire between C125 to
C155 (Quad Halogen). (For ground connection(s) G105, G106 fuse block.
Canadian vehicles, DK BLU/ORN or G107. (For Canadian vehicles:
3. Check condition of GAGE/IDLE Fuse is not blown. GO to step 4.
(593) wire is used in place of BLK GO to step 3).
fuse.
(150) wire at connector C138 or Fuse is blown. LOCATE and REPAIR source of
C155). Test lamp lights. REPLACE headlamp(s).
overload. Then, REPLACE fuse.
3. Connect a test lamp from BLK Test lamp lights. GO to step 4.
4. Place ignition switch to run. Test lamp lights. GO to step 5.
(150) wire at DRL relay connector Connect a test lamp from
C126 to ground. Test lamp does not light. LOCATE and REPAIR open in BLK
PNK/BLK (39) wire at DRL relay Test lamp does not light. LOCATE and REPAIR open in
(150) wire from DRL relay
connector C126 to ground. PNK/BLK (39) wire between DRL
connector to ground G105.
relay and fuse block.
4. Connect a self powered test lamp Test lamp lights. LOCATE and REPAIR open in DK
5. Connect a test lamp from Test lamp lights. GO to step 6.
from DK BLU/ORN (593) wire to BLU/ORN (593) wire at headlamp
PNK/BLK (39) wire at DRL module
ground to DRL relay connector connector C138 or C150 to DRL
connector C221 to ground. Test lamp does not light. LOCATE and REPAIR open in
C126 to ground. relay C126.
PNK/BLK (39) wire between DRL
module and fuse block.
Test lamp does not light. REPLACE DRL relay.
6. Using a jumper wire, apply ground Daytime Running lamps light. GO to step 7.
5. Connect a test lamp from LT GRN Test lamp does not light. GO to step 6.
to LT GRN/BLK (592) wire at DRL
( 1 1 ) wire at headlamp dimmer module connector C211. Daytime Running Lamps do not GO to step 9.
switch connector C201 to ground. Test lamp lights. LOCATE and REPAIR open in LT light.
GRN (11) wire from headlamps to
headlamp dimmer switch. 7. Connect a self-powered test lamp Test lamp lights. GO to step 8.
from LT GRN/BLK (592) wire to
6. Connect a test lamp from YEL (10) Test iamp does not light. LOCATE and REPAIR open in YEL
BLK (150) wire at DRL module Test lamp does not light. LOCATE and REPAIR open in BLK
wire at headlamp dimmer switch ( 10) wire headlamp dimmer switch
connector C211. (150) wire between DRL module
connector C201 to ground. to light switch.
connector C 2 1 1 and ground G 200.
Test lamp lights. REPLACE headlamp dimmer 8. Connect a self-powered test lamp Test lamp lights. REPLACE DRL relay.
switch. from LT GRN/BLK (592) wire at
DRL relay connector C 126 to Test lamp does not light. LOCATE and REPAIR open in LT
PRELIMINARY CHECKS: ground. GRN/BLK (592) wire between DRL
Before checking the DAYTIME RUNNING LAMPS Lamp(s) are inoperative, refer to the HIGH BEAM relay connector C126 and DRL
system, do the following: LAMP(S) DO NOT OPERATE test procedures. If the module connector C211.
1. Place Park Brake in the OFF position. High Beam Lamp(s) are operative, use the following
9. Connect a test lamp from DK Test lamp lights. LOCATE and REPAIR open in DK
2. Place Light Switch to ON and Headlamp Dimmer diagnostic procedures, after placing the Light Switch
BLU/ORN (593) wire at DRL relay BLU/ORN (593) wire between DRL
Switch to HIGH BEAM position. If the High Beam to OFF position. connector C126 to ground. relay connector C126 and LH
DRL STAY ON headlamp connector C138 or
TEST RESULT ACTION C150.

1. Disconnect DRL module Battery voltage. REPLACE DRL module. Test lamp does not light. REPLACE DRL module.
connector C211. Place
ignition switch to RUN and No voltage. LOCATE and REPAIR open in YEL
light switch to ON position. (10) wire from DRL module to
Connect a J 34209-A multimeter light switch.
(or equivalent) to YEL (10)
wire from module connector to
ground. Measure voltage.

A-24 HEADLAMPS
 RPO CODES

C60 - FRONT MANUAL AIR CONDITIONING

L05 - 5.7L (350 CU. IN.) V8 GAS ENGINE VIN K
(SEE POWER DISTRIBUTION)
pJ=U . L19 - 7.4L (454 CU. IN.) V8 GAS ENGINE VIN N
(SEE POWER DISTRIBUTION) LH6 - 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN C
r^inr^i
□
LL4 - 6.2L (378 CU. IN.) HD V8 DIESEL ENGINE VIN J
BATTERY 0 M20 - MANUAL 4-SPEED TRANSMISSION

JUNCTION QDUCZJ
BLOCK B nB C203
12066261
S nS
tz fe l/P CLUSTER
□n O CONNECTOR
(SEE PAGE 103)
QDu
„ClI
m um

J Z r
■ ■2-1.0 R S T B H
(FUSIBLE LINK)

12-1.0 RST I I 2-3.0 RED I

(FUSIBLE LINK)
5100 (LH6, LL4)
5101 (L05, L19)

420 440 2
439 806 39
AUXILIARY
ENGINE COOLING FAN -
L 140 120
■151-2.0 BLK ■
(L19 AND C60) 31 3

(SEE PAGE 90) D ] 50 436

35 2
PARK AND 120 r
TURN LAMPS - ■151-.8 B L K i
: 18
30
• I 93 97 422 :
: 24 19 I
(SEE PAGE 34) 91 92 6

C100 l/P
12020184

■11-1.0 L T G R N l

| 12-.8 TAN

lA L
GENERATOR
(SEE PAGE 10)

151-.8 BLK

151-3.0 BLK

HEAD
. OFF
''P A R K
C138
40-
C144
12034372 12034372
HEAD
RH SHEET FRAME LH SHEET
LIGHT
HIGH-LOW METAL GROUND HIGH-LOW METAL SWITCH
HEADLAMP GROUND G107 HEADLAMP GROUND
G106 G105
HEADLAMPS A-25
BASE
 HOT IN START
OR RUN

GAGE/
IDLE
20 AMP

V22

t~ ...-J

ni 2 | 440 I 420 HI

r ii ^ a r a s m
h y
LH [ 1 2 0 | 140 | | [ ] | |

HIGH-LOW i 3 ! 31
HEADLAMP | 436 | 50 | ^ i p

( " 2 1 35 i l m

I , | 422 | 97 | 93 |

SHEET SHEET FRAME

METAL METAL GROUND
. | 6 | 92 | 91 |
* n
1 2 3 C3 c = i
GROUND GROUND G107
C100
A-26 HEADLAMPS G105 G106 12020183

W/DRL 5.7L, 7.4L V 8 GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL W/MAN TRANS
FLEETSIDE, WIDESIDE, CREW-BONUS CAB
 RPO CODES

060 - AIR CONDITIONING

DIODE L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN E
ASSEMBLY L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
DIODE C291 LL4 - ENGINE, 6.2L (378 CID) V8, HD DIESEL ENGINE, VIN J
P t V22 - QUAD HALOGEN HEADLAMPS
DRL ASSEMBLY 12040549
s
m _ MODULE (FLEETSIDE, WIDESIDE (UTILITY ONLY)
O Z * i ifl h = CREW/BONUS CAB)
==o5m=32'- RWAL PARK BRAKE
^: P; Qi
o < d ° :5Z nO
m w j (UTILITY ONLY)
< ^ S 2
c l S x x
clq
^ o
o c c
o o (SEE PAGE 116)
WARNING SWITCH
A l I I I I inn (CLOSED WITH PARK BRAKE APPLIED)

* T.

592-.8 LT GRN/BLK I

_ J
C293
33-.5 TAN/WHT 12004267
sc
m
5 33-.5 TAN/WHT 33-.5 TAN/WHT __________ I
33-.5 TAN/WHT 33-. 5 TAN/WHT
m

I i 33-.5 TAN/WHT (UTILITY ONLY)

&
l/P
CLUSTER
CONNECTOR
■onifpEi
I z
G»]nljD
(SEE PAGE)

131 lir a
I 11-.8 LT GRN
i ■ r j t a 592-.a l t g r n / b lk M r - jm m r jm m r j h t 4 OH[][II] n
_ ——.=»»«'-------------------------—"L _ L I_iHoili
f ____ _____ CONVENIENCE CENTER I I ,= ^ r = j
I 39*.8 PNK/BLK | (SEE PAGE 21) z

_____________________ U 39-.S PNK/BLK I

FUEL PUMP CYCLE RELAY
(SEE PAGE 78)
•IS n O D
□ dt=M
UdI d
S202 WATER IN FUEL LAMP . 2 X
J V-’ | P 7
I 11-1.0 LT GRN
i i 1 \ V
^ 1 3 9 -1 PNK/BLK I ■ ■ H ■ ■ H ■ ■
(SEE
(SEE PAGE
PAGE 105)
105) I (L| 4 0 N | Y)
£
.
»
r
I
1 1-------------------------------^
RWAL ......... ..... - - - ......r LOW COOLANT WARNING MODULE i I I U --------- 39-.S PNK/BLK
(SEE PAGE 116)
* 33-.5 TAN/WHT .

- I _ J ^

\ ^ a r 39-. 5 p n k /b lk m w M r
(SEE PAGE 104)

m um r
J

« a r ^
I I

-.m I * I r-
12066261 I
(LL4 ONLY)

12-.8 TAN w
\
I 11-1.0 LT GRN I

I
m m 1 jm 39-.S PNK/BLK 1 ^ ^
S201
110-1.0 YEL I
(SEE PAGES 17, 19)

LIGHT I 150-.8 BLK I

SWITCH

150- 156 I 12-.8 TAN

I 2—
DIMMER
SWITCH
CIRCUIT
BREAKER
25 AMP
G2O0
l/P '
GROUND
IGNITION
SWITCH 10-1.0 YEL

HEADLAMPS A-27
W/DRL 5.7L, 7.4L V8 GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL W/MAN TRANS
FLEETSIDE, WIDESIDE, CREW-BONUS CAB_____________________________________
 W/LL4

■ 50-2.0 BRN I
/
vMWMAMM
< HOT AT ALL TIMES <

HTR/AC
25
AMP
m w w vw s
DRL
15
AMP
\ GAGE/IDLE
20 AMP

L ______ J
592-.8 LT GRN/BLK .
I PNK/BLK

DRL GT105
RELAY 12020457
RH
HIGH-LOW —jLoxmju—
HEADLAMP 592-.8 LT GRN/BLK .
I
340-,8 ORN I

12052641
592-.S LT GRN/BLK

RH LOW BEAM
HEADLAMP

RH HIGH BEAM 11-.8 LT GRN I

HEADLAMP

V22
ONLY

11-1.0 LT GRN
11
39-.5 PNK/BLK
LH HIGH BEAM J t 39 14
HEADLAMP r 1 29 15
1

12-.8 TAN ■

C102
39-.8 PNK/BLK I
12020100
GENERATOR ^
(SEE PAGE 12)

LH LOW BEAM
HEADLAMP

I 151-3.0 BLK
LH
HIGH-LOW
HEADLAMP
(Q ) (q )

L _ 593- 8 DK BLU/ORN^
___________________________ i SHEET SHEET FRAME
METAL METAL GROUND
GROUND GROUND G107
G105 G106
A-28 HEADLAMPS
W/DRL 5.7L DIESEL ENGINES AND 4-SPD., AUTO TRANS SUBURBAN/UTILITY
 RPO CODES
S203 ___ W/LL4
DIODE

TTl
I 50-2.0 BRN I DIODE L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
ASSEMBLY
5 £ _3 ASSEMBLY (EXCEPT LL4)
LL4 - ENGINE, 6.2L (378 CID) V8, HD DIESEL ENGINE, VIN J
LH6 - ENGINE, 6.2L (370 CID) V8 DIESEL ENGINE, VIN C
DRAC I (W/LL4)
MD8 - AUTO TRANS, 4 SPD.pWITH OVERDRIVE
“ £ 2 5 i DRL
(SEE PAGE 75) ■ a n 50-1.0 BRN ■ ■ m I £ <£fl I- kO 5
g h tc
V22 - QUAD HALOGEN HEADLAMPS
MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
03 l 2 111 3 O MODULE RWAL
aa:*S(/>i-00
; 0 5 « 3 3 i uZ (SEE PAGE 116)

HTR SW
f^ r Ps rQ f i Wo - °i ZI go RWAL PARK BRAKE
(SEE PAGE 9 6 )' (SEE PAGE 116) WARNING SWITCH
{CLOSED WITH PARK BRAKE APPLIED)

592-.8 LT GRN/BLK
o ^
33-. 5 TAN/WHT

I W/MD8
C293

I 12004267

% mmmr m 33 -. 5 t a n / w h t w a rn k.^1 jm m w ja m m ^ 33 -. 5 TAN/WHT

33-. ta n /w h t I jm m w

I _____________ 39 -.8 p n k /b lk r Mmm

33-.5 TAN/WHT I 33-. 5 TAN/WHT I
l/P
133-.8 TAN/WHT .___ , ~ l CLUSTER
33-. 8 TAN/WHT
fcJ I CONNECTOR
629-.8 w h t mm
(SEE PAGE 103)

111-,8 IT GRN
150-.8 BLK G»]n[jD
| 31 I U [ 4 1 9 |

HGilnljD
5Q DnS
LH
6 J 592 | U | 2 3 t [

U n ra
39-.S PNK/BLK - 'r a t e
r ~ WATER IN FUEL dDuQD
I 11-1.0 LT GRN
I V V 39' 8 PNK/BLK 1 ™ L A M P (SEE PAGE 105) (LH6 ONLY) J J ^ 1 = 1 ^ 1
\ ............... t ^ ^ N T WARNING MODULE I I C203 |

J % ^ (SEE PAGE 104) I I 12066261 I

39-.5 PNK/BLK b t j v j w jm m r J H T m am l ^ I r
I 12-,8 TAN I

I 39-,8 PNK/BLK __ J 12,8 TAN

1 11-1.0 LT GRN I

S201
I 150-1.0 BLK ■
I I

110-1.0 YEL (SEE PAGES 17, 19)

I 150-.8 BLK I
LIGHT
SWITCH

150- I 12-. 8 TAN

1 2—
DIMMER
SWITCH
CIRCUIT
BREAKER
25 AMP

G200
IGNITION
SWITCH 10-1.0 YEL
l/P
GROUND

HEADLAMPS A-29
W/DRL 5.7L DIESEL ENGINE AND 4-SPD., AUTO TRANS SUBURBAN/UTILITY
 HOT IN RUN '

HTR
A/C a
25 |
AMP !

RH LOW BEAM
HEADLAMP

RH HIGH BEAM
HEADLAMP

V22
ONLY

LH HIGH BEAM
HEADLAMP

LH LOW BEAM
HEADLAMP

LH
HIGH-LOW
HEADLAMP

C 100
12020183
SHEET SHEET FRAME
METAL METAL GROUND
GROUND GROUND G107
A-30 HEADLAMPS G105 G106
W/DRL 5.7L, 7.4L GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL ENGINE W/HEAVY DUTY AUTO
TRANS, SUBURBAN, FLEETSIDE, WIDESIDE, CREW-BONUS CAB
 39*. 8 PNK/BLK I
S202>k
I 11-1.0 LT GRN I

39-.8 PNK/BLK ■
Ovv m 3 9 - 8 p n k /b lk ■ m m m m b l o w c o o l a n t w a r n in g m o d u le I I
—
0203 k
| % (SEE PAGE 104) (LL4 ONLY) I I 12066261 I
^ r 1 m k 39- 5 p n k /b lk v I ^ I v' ^ m r

■ ■ ■ » ■ ■ ■ ■ ■ ■ 1 2,8 TAN I I

I 11-1.0 LT GRN I

S201
I 10-1.0 YEL I (SEE PAGES 17, 19)

44

(L05/L19 W/O RWAL BRAKES)

LIGHT
L _ y _ _ SWITCH

150- X I 12-. 8 TAN

DOME DIMMER

IL/
2 -

OFF SWITCH
CIRCUIT '•P A R K
BREAKER
¥
25 AMP i HI 1
i *- I 11 r l*°jf G200
HEAD
OFF
12^ l/P ^
10
IGNITION
SWITCH
T\ 'P A R K GROUND

HEAD
t 10-1.0 YEL

HEADLAMPS A-31
W/DRL 5.7L, 7.4L GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL ENGINE W/HEAVY DUTY AUTO
TRANS, SUBURBAN, FLEETSIDE, WIDESIDE, CREW- BONUSCAB
 RPO CODES
(SEE POWER DISTRIBUTION)

C60 - AIR CONDITIONING

BATTERY L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, V1N K
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL-ENGfNE, VIN C
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
M20 - MAN TRANS, 4-SPD.

DIMMER
SWITCH

LIGHT
GROUND GROUND SWITCH
G105 G106

A-32 QUAD HALOGEN HEADLAMPS

CIRCUIT OPERATION ROOF MARKER LAMPS DO NOT OPERATE
TEST RESULT ACTION
HAZARD LAMPS 1. Connect test lamp from ORN (40) Test lamp lights. GO to step 2.
Voltage is applied at all times, through the STOP/HAZ they flash on when the Hazard Lamps are off and off wire at light switch connector
Fuse and the Hazard Flasher to the normally open when the Hazard Lamps are on. C202 to ground. Test lamp does not light. LOCATE and REPAIR open in ORN
contact of the Hazard Switch in the Turn Signal Switch (40) wire between light switch and
Assembly. With the Hazard Switch in HAZARD FLASH, In Hazard, this circuit is always open, and the Hazard fuse block or REPLACE (T/L CTSY)
voltage is applied to both Front and Rear Turn Lamps. Flasher control the Lamps. fuse.
All of the Turn Lamps and both Turn Indicators flash on 2. Connect test lamp from BRN (9) Test lamp lights. GO to step 3.
and off. PARK AND MARKER LAMPS wire at light switch connector
Voltage is applied through the T/L CTSY Fuse to the C202 to ground. Test lamp does not light. REPLACE light switch.
The Front Marker Lamps flash in HAZARD FLASH just Light Switch at all times. With the Light Switch in PARK
as they do in RIGHT TURN and LEFT TURN. If the Lamp or HEAD, voltage is applied to the Park, Tail, Marker, 3. Connect test lamp at WHT (45) Test lamp lights. GO to step 4.
Switch is in OFF, they flash on when the Hazard Lamps License Lamp and Roof Marker Lamps (if so equipped). wire at LH marker lamp terminal to
are on. If the Light Switch is in either PARK or HEAD, ground. Test lamp does not light. LOCATE and REPAIR open in
WHT (45) and BRN (9) wires from
marker lamp to light switch.
4. Connect test lamp from WHT (45) Test lamp lights. CHECK condition of light socket.
wire to BLK (150) wire at LH
DIAGNOSIS - FRONT PARK, MARKER marker lamp. Test lamp does not light. LOCATE and REPAIR open in BLK
(150) wire from marker lamps to
ROOF AND HAZARD LAMPS bus bar ground.
FRONT PARK AND SIDE MARKER LAMPS DO NOT OPERATE
TEST RESULT ACTION HAZARD WARNING LAMPS DO NOT OPERATE
1. Place light switch in PARK Test lamp lights. GO to step 2. TEST RESULT ACTION
position. Connect a test lamp from 1. Place ignition switch in RUN and Turn signal lights operate.
LOCATE and REPAIR open in ORN GO to step 2.
ORN (40) wire at light switch Test lamp does not light. position turn signal lamps as if
connector C202 to ground. (40) wire between light switch and making a turn. Turn signal lights do not operate. GO to step 3.
fuse block or REPLACE T/L CTSY
fuse. 2. Turn off turn signal lamps and put Test lamp lights. REPLACE turn signal switch.
hazard warning lamps on.
2. Connect test lamp from BRN (9) Test lamp lights. GO to step 3. Connect a test lamp from BRN
wire at light switch connector Test lamp does not light. CHECK condition of fuse
(27) wire at turn signal switch
C202 to ground. Test lamp does not light. REPLACE light switch. connector C205 to ground. (STOP/HAZ) and an open in ORN
(140) wire and BRN (27) wire. If
3. Connect a test lamp at BRN (9) Test lamp lights. CHECK conditions of bulb sockets fuse and wiring are good,
wire at LH park lamp connector and BLK (150 and 151) wires from REPLACE hazard flasher.
C140 to ground. park lamps to ground terminals 3. Place hazard lamps on. Connect Test lamp flashes. LOCATE and REPAJR open in
G106 and G107. test lamp from LT BLU (14) wire at wires from turn signal switch to
turn signal switch connector C205 convenience center.
Test lamp does not light. LOCATE and REPAIR open in BRN to ground.
(9) wire from park lamps to light Test lamp does not light. REPLACE turn signal switch.
switch.

FRONT, PARK AND MARKER LAMPS A-33

 RPO CODES

40-.8 O B N I RADIO/CLOCK
wvwwwww/ (SEE PAGES 144, C60 - AIR CONDITIONING
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
> HOT A T ALL TIM ES < 145)
T61 - CANADIAN DAYTIME RUNNING LAMPS
^wwwwwv^T

T/L CTSY
20 AMP

AUXILIARY ENGINE
COOLING FAN (L19 WITH C60)
(SEE PAGE 90)
RH PARK AND
TURN LAMP
♦ 1S6

I ■151-2.0 B LKl

RH HIGH-LOW
HEADLAMP 151-.8 BLK ■
(SEE PAGE 25)

LIGHT
SWITCH

RH PARK AND RADIO/CLOCK

(SEE PAGES 144, 145)
TURN LAMP

115-. 8 DK BLU I
TURN LAMPS SWITCH
(SEE PAGE 45)
I1 4 -.8 L T B L U I

LH PARK AND
TURN LAMP
420 440 2
\ 94 29
15 806 39
I 9 39 14 140 120
33 12 J
X r 31 3

~7)
: 93 11
1 (© ] SO 436

i r 35 2
LH HIGH-LOW
— - i i^ "s'
m z
^
m
93 97 422 :

t
HEADLAMP J eq O co 92
91 6
(SEE PAGE 25)
8g £
i
1 1 50-.8 B LK l

C100
D 1202184
m
b
CO

LH PARK AND C137

12077765
TURN LAMP

SHEET SHEET J FRAME

- METAL METAL GROUND
LH SIDE GROUND GROUND G107
MARKER LAMP G105 G106

A-34 FRONT, PARK AND MARKER LAMPS

BASE
 RPO CODES

< HOT AT ALL TIMES <

<W yVVVWWWs*
T/L CTSY
20 AMP

RH PARK
AND TURN
LAMP

RH PARK
LAMP

RH LOW BEAM
HEADLAMP
(SEE PAGE 32)

RH HIGH BEAM
HEADLAMP
(SEE PAGE 32)

LH HIGH BEAM
HEADLAMP
(SEE PAGE 32)

LH LOW BEAM
HEADLAMP
(SEE PAGE 32)

LH PARK
LAMP

LH PARK
AND TURN
LAMP

LH SIDE
MARKER

FRONT, PARK AND MARKER LAMPS A-35

W/QUAD HALOGEN HEADLAMPS
 yvwwwwvVf
> HOT AT ALL TIMES <
>V V W V W V V W N

STOP HAZ
15 AMP

RH PARK AND
TURN LAMP

RH PARK AND
TURN LAMP

LH PARK AND
TURN LAMP

LH PARK AND
TURN LAMP

A-36 HAZARD LAMPS

BASE
 HAZARD LAMPS A-37
_________________ BASE________
 vjViMWWVvV* 140-.8 0RN
S HOT AT ALL TIMES <
“Vw m w v w n 140-.8 0RN
(L0S/L19 WITH M20 FLEETSIDE, WIDESIDE,
STOP HAZ CREW/BONUS CAB)

15 AMP

RH PARK AND
TURN LAMP

C153
12077753
SHEET SHEET FRAME
METAL METAL GROUND
GROUND GROUND G107
G105 G106

A-38 HAZARD LAMPS

W/QUAD HALOGEN HEADLAMPS
 vAAWMAAAM
< HOT AT ALL TIMES <
> W W V W V \W S
T/LCTSY *)
CTSY LAMPS
20 AMP Ui I 40-.8 ORN I I 40-.8 ORN |
S204 (SEEPAGE 119)

40-.8 ORN | RADIO/CLOCK

(SEE PAGES 144, 145)
RH
MARKER
LAMP

( «5 )

FRONT
IDENTIFICATION /
LAMPS

M
m g

G *D

LH
r r t u f
MARKER
LAMP
I 45-. 8 W H TI

A-40 ROOF MARKER LAMPS

BLANK

BLANK A-41
CIRCUIT OPERATION DIAGNOSIS — TURN SIGNAL LAMPS

TURN SIGNAL LAMPS PRELIMINARY CHECKS:

With the Ignition Switch in RUN or START, voltage is ground. The Marker Lamp will flash with the Turn 1. Check condition of TURN/BU fuse. If fuse is blown, PARK AND SIDE MARKER LAMPS DO NOT OPERATE
applied through the TURN/BU Fuse and Turn Signal Lamps. The Lamps used for the ground path will not LOCATE and REPAIR source of overload, then diagnostic procedure in this manual. If the park or
Flasher to the normally closed contact of the Hazard flash, however, since the voltage drop across the Marker REPLACE fuse. marker lamps are operative, use the following
Flasher Switch in the Turn Signal Switch Assembly. Lamp is much higher than that across the other Lamps. 2. Place Headlamp Switch in PARK position. If any park diagnostic procedure.
or marker lamps do not operate, refer to FRONT
With the Turn Signal Switch in LH Turn position, When the Light Switch is in either PARK or HEAD,
TURN SIGNALS DO NOT WORK ON ONE SIDE
voltage is applied to both the LH Turn Indicator and the voltage is applied through the T/L CTSY Fuse, Lamp
LH Front Park/Turn Lamp (LT BLU wires). Voltage is Switch and splice S112 to the Marker and Park Lamps. TEST RESULT ACTION
applied to the LH Rear Turn Lamp (YEL wire). If the Turn Signal Switch is in LEFT TURN, the LH Front 1. Turn hazard warning system ON. Lights flash. CHECK for improper bulb.
Marker Lamp will have voltage at both connections and Observe lights on side of turn REPLACE if necessary.
The Lamps go on immediately. They begin to flash will go out. When the flasher removes voltage to the signals that did not work.
when the current flow heats up the timing element in the Turn Lamp, the Marker Lamp will be grounded through Lights do not come on. GO to step 2.
flasher and it repeatedly opens and closes the circuit. the Turn Lamp and will go on. In this way, the LH Front
Marker Lamp will flash on when the LH Front Park and 2. Turn hazard warning system off. Test lamp lights. GO to step 4.
Turn Lamp goes off, and off when the Turn Lamp goes Place ignition switch to RUN and
The voltage applied to the LH Front Park and Turn
turn signal to side that does not lamp does not light. GO to step 3.
Lamp will also be applied to the LH Front Marker Lamp. on.
work. Connect test lamp from LT
If the Light Switch is in the OFF position, the LH Front BLU (14) or DK BLU (15) wire
Marker Lamp will find a path to ground through splice With the Turn Signal Switch Assembly in RIGHT (depending on which side does
S112 and the many Lamps connected in parallel to TURN, voltage will be applied to the RH Lamps in a not work) at turn signal switch
ground. These Lamps provide low resistance paths to similar manner. connector C205 to ground.
3. Connect a test lamp from PPL (16) Test lamp lights. REPLACE turn signal switch.
at turn signal switch connector
C205 to ground. Test lamp does not light. REPLACE turn signal flasher.
4. Connect a test lamp from LT BLU Test lamp lights. GO to step 5.
(14) or DK BLU (15) wire
(depending on which side did not Test lamp does not light. LOCATE and REPAIR open in
work) at park and turn lamp either LT BLU (14) or DK BLU (15)
connector C137, C140, C145, wires.
C146, C147 (Base) or C151, C152,
C153, C156, C157, C158 (Quad
Halogen) to ground.
5. Connect a test lamp from LT BLU Test lamp lights. CHECK condition of bulb sockets.
(14) or DK BLU (15) wire to BLK
(150 or 151) wire at park and turn Test lamp does not light. LOCATE and REPAIR open in BLK
lamp connector C139, C140, (150 or 151) wire.
C146, C147 (Base) or C151, C156
(Quad Halogen).

A-42 TURN SIGNAL LAMPS

 TURN SIGNALS DO NOT OPERATE
TEST RESULT ACTION

1. Place hazard warning lamps to Hazard lamps operate. GO to step 2.

ON position.
Hazard lamps do not operate. GO to step 3.

2. Connect a test lamp from PPL (16) Test lamp flashes. REPLACE turn signal switch.
wire are turn signal switch
connector C205 to ground. Test lamp does not light. CHECK condition of fuse
(TURN/BU) and an open in PPL
(16) wire, DK BLU (38) wire, or BLK
(150) wire. If fuse and wiring are
good, REPLACE turn signal
flasher.

3. Place ignition switch in RUN Test lamp flashes. LOCATE and REPAIR open in
position and put turn signal switch wires from turn signal switch to
as if making a LH turn. Connect a convenience center.
test lamp from LT BLU (14) wire at
turn signal switch connector C205 Test lamp does not light. REPLACE turn signal switch.
to ground.

TU R N S IG N A L LAM PS FLASH RAPIDLY

TEST RESULT ACTION

Turn hazard lamp switch ON. One side of turn signal lamps flash REPLACE inoperative turn signal
Check front signal lamps and rear rapidly. bulb.
taillamps. Only one side of turn signals light REFER to “Turn Signals Do Not
but do not flash rapidly. Operate On One Side" symptom.

TURN SIGNAL LAMPS A-43

 I 16-.8 PPL I

i/P
CLUSTER
CONNECTOR
(SEE PAGE 103)

C203
12026261

D u n a

|lSO|U|~39~]
Q iln E H l
U D T3
rn n U r^
I 15-. 8 D K B LU I
p 420 440
B n C ID p 94 29 15 y
439 806 / 39
N 14
E 3 n l3 D
M
9
33
39
12
I 140 120
I1 4 -.8 L T B IU I
QDUE3
14-.8 LT BLU I
L 93 11 II (i 31
50 436

r
93
35
97
2
422

RH SIDE 91 92 6

MARKER LAMP
RH PARK AND
TURN LAMP

19-.8D KG R N I

18-.8YEL^H

RH PARK AND
TURN LAMP 15-.8 DK BLUi

151-.8 BLK
AUXILIARY
ENGINE COOLING
■■■■ M 151-2.0 B L K M
RH HIGH/LOW FAN (L19 WITH C60)
HEADLAMP (SEE PAGE 90)
(SEE PAGE 25)

LH PARK AND
TURN LAMP

LH PARK AND
TURN LAMP
SHEET SHEET FRAME
METAL METAL GROUND
LH SIDE GROUND GROUND G107
MARKER LAMP G105 G106
|A-44 t u r n s ig n a l l a m p s
base
 RPO CODES

E63 ■ FLEETSIDE BODY

R05 - DUAL REAR WHEELS
T61 - CANADIAN DAYTIME RUNNING LAMPS
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
C60 • AIR CONDITIONING

17 - 17-.8 WHT
19-.8 DK GRN
- 18-.8 YEL
16 16-.8 PPL
27 27-.S BRN
- 15-.5 DK BLU

14-.5 LT BLU
28-.5 BLK
- 80-. 5 LT GRN
- 159-.8 TAN

SHEET
SHEET METAL
METAL GROUND C412
GROUND G402 8911035 (SUBURBAN)
G403 (SURBURBAN/UTIUTY ONLY) (SURBURBAN ONLY)

TURN SIGNAL LAMPS A-45

_______________________ BASE________
 HTR
! 16-.8 PPL I
m
II © a m id hi id I! [I
^BAT-1 FUSE BLOCK
m 12103404
B @ E i 1 ^ y 1 111111A111111

° t i [ ] A in i ] ei i i
WDO

ID [c] B 0 i 1 1
MGNJ ACC LPS PWR

SHUNT SHUNT
m \ Jhi LH PARK AND 15-.8 DK BLU
.NSTR LPL __ TURN LAMP
K L D I lL d O n m

LsJ UE
T/L CTSY
15-.8 DK BLU
K l
ECM B AUXILIARY
ENGINE COOLING
KECM l1 KDRL] c d B 'f l'x o FAN (L19 WITH C60)
(SEE PAGE 90)

cCRANK
*a □ □
RH PARK
LAMP 151-.8 BLK

Ai
FRONT (SEE PAGE 40)

RH LOW BEAM S111

HEADLAMP ■ 1 151-2.0 BLK

J\
(SEE PAGES 25, 32) '

RH HIGH BEAM
TURN SIGNAL HEADLAMP ]
(SEE PAGES 25, 32)
FLASHER

LH HIGH BEAM
HEADLAMP
(SEE PAGES 25, 32)

LH LOW BEAM
HEADLAMP 1150-.8 BLK
(SEE PAGES 25, 32)

LH PARK
LAMP I150-.8 BLK 150-.8 BLK I
(SEE PAGE 40)

150-.8 BLK

RH PARK AND
TURN LAMP 14-.8 LTGRN I

151-.8 BLK I

14-.8 LTGRN I

a fl
SHEET SHEET FRAME
METAL METAL GROUND
GROUND GROUND G107
G105 G106
A-46 TURN SIGNAL LAMPS
W/QUAD HALOGEN HEADLAMPS
15-.8 DK BLU
RPO CODES
 CIGARETTE LIGHTER DOES NOT OPERATE
CIRCUIT OPERATION
TEST RESULT ACTION
When the Horn Switch is depressed, one side of the energized. The relay contacts close and battery voltage 1. Connect a test lamp at cigarette Test lamp lights. REPLACE cigarette lighter.
cojl of the Horn Relay is grounded. The relay is is applied to the horns. lighter connector C299 from ORN
(240) wire to ground. Test lamp does not light. LOCATE and REPAIR open in ORN
(240) wire between fuse block and
DIAGNOSIS - HORNS cigarette lighter connector C299.

PRELIMINARY CHECKS:
Check condition of HORN/DM fuse. If fuse is blown, fuse. If fuse is in good condition, use the following
LOCATE and REPAIR source of overload, then REPLACE diagnostic procedure.

HORN(S) WILL NOT OPERATE

TEST RESULT ACTION

1. Connect a test lamp from BLK/LT Test lamp lights. REPLACE horn.
GRN (29) wire at horn connector
(C142, C143) to ground. Press Test lamp does not light. GO to step 3.
horn switch.
2. Remove horn relay. Connect a Test lamp lights. GO to step 3.
test lamp from ORN (240) wire at
convenience center to ground. Test lamp does not light. LOCATE and REPAIR open in ORN
(240) wire between convenience
center and fuse block.

3. Disconnect turn signal switch Horn does not sound. GO to step 4.

connector C205. Use a jumper
wire to ground BLK (28) wire at Horn sounds. REPLACE turn signal switch.
turn signal switch connector C205.

4. Disconnect horn relay. Install a Horn sounds. REPLACE horn relay.

jumper wire from ORN (240)
terminal to DK GRN (29) terminal Horn does not sound. LOCATE and REPAIR open in DK
at convenience center. GRN (29) wire from convenience
center to C100 and/or LT
GRN/BLK (29) wire between C100
and horn(s).

HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSING HORN SWITCH

TEST RESULT ACTION

1. Disconnect turn signal switch Horn stops. REPLACE turn signal switch.
connector C205.
Horn continues to sound. GO to step 2.

2. Disconnect horn relay. Check for No shorts found. REPLACE relay.

a short to ground in DK GRN (29)
and BLK (29) wires. Short(s) found. REPAIR or REPLACE as required.

A-48 HORNS
 v/AAAW W W W
S HOT AT ALL TIMES <
m A /w W W V S

HORN/DM J)
20 AMP C 1240-1.0 ORN I CONVENIENCE
CENTER

RH
HORN
(STEERING C O L SW ITCHES)

C143
12004267 y <
-* z
o
<75
— 17-.0 WHT -
19-.8 DK GRN -
— 18-.8 YEL -
— 16-.8 PPL -
— 27-. 8 BRN - -C -J
15-.5 DK BLU-

I
*_ l
14-.5 LT BLU
I
a: 2S-.5 BLK
o 80-.5 LT GRN
159-.8 TAN

TURN
SIGNAL SWITCH

LH
HORN

C142
12004267

m
z

C102
12020100

HORNS A-49
 WIPERS DO NOT OPERATE IN ANY MODE
CIRCUIT OPERATION
TEST RESULT ACTION
1. Place ignition in RUN or ACC and Test lamp does not light. LOCATE and REPAIR open in
PULSE WIPERS PULSE turn wipers to HI. Connect a test WHT (93) wire between wiper
In addition to MIST, LO and HI speed operation the With the Wiper/Washer Switch in PULSE (Delay), lamp from WHT (93) wire at wiper motor connector C188 and fuse
pulse-type Wiper/Washer System includes an operating voltage is applied to the GRA (91) wire, the Wiper Motor motor connector C188 to ground. block.
mode in which the wipers make single strokes with an Module, and the Solid-State Control Board. Voltage is
Test lamp lights. GO to step 2.
adjustable time interval between strokes. The time applied to Park/Run Relay coil which is momentarily
interval is controlled by a Solid-State Pulse/Speed/Wash grounded by the Pulse/Speed/Wash Control circuit and 2. Connect a fused jumper from BLK Wiper motor runs. LOCATE and REPAIR open in BLK
Control in the Wiper Motor Module. The duration of the the relay closes. Battery voltage is supplied through the (150) wire at pulse wiper module (150) wire between pulse wiper
relay interval is determined by the Pulse Delay closed contacts of the relay to the run Wiper Motor. The connector C207 to ground. module connector C207 and
Resistance in the Wiper/Washer Switch. relay remains energized as long as the contacts of the ground G200.
Park/Run Switch remain closed. When the wiper blades
have reached PARK, the Park/Run Switch opens, de­ Wiper motor does not run. REPLACE wiper motor.
LOW SPEED
In the LO position, the Wiper/Washer Switch supplies energizing the Park/Run Relay. The wiper blades remain
voltage in the GRA (91) wire and the Pulse/Speed/Wash in PARK until the Control Board grounds the Park/Relay
Control. The Pulse/Speed/Wash Control provides coil to start another sweep. The delay time between WIPERS DO NOT OPERATE IN HI
ground to the Park/Run Relay which is energized and sweeps is controlled by the pulse delay resistors. The TEST RESULT ACTION
supplies voltage to the brushes of the Wiper Motor. The delay can be adjusted from 0 to 43 seconds.
1. Place ignition in RUN or ACC and Wiper motor does not run. LOCATE and REPAIR open in PPL
wipers run at low speed until they are turned off.
wipers to HI. Connect a fused (92) wire between wiper motor
WASHER jumper from PPL (92) wire at connector C188 and pulse wiper
HIGH SPEED When the Washer Switch is depressed, voltage is pulse wiper module connector module connector C207. If no
With the Wiper/Washer Switch in the HI position, applied to the Solid-State Control Board. The Control C207 to ground. open is found, REPLACE wiper
battery voltage is supplied from the PPL (92) wire directly Board supplies a ground to the washer motor through motor.
to a second armature terminal of the Wiper Motor. The the PNK (94) wire. It also starts the wiper cycle through
wipers run at high speed. When the Wiper/Washer the low speed brushes of the Wiper Motor. The washer Wiper motor runs. GO to step 2.
Switch is turned to OFF, the wipers complete the last continues to run as long as the switch is held down.
2. Connect a fused jumper from PPL Wiper motor does not run. LOCATE and REPAIR open in PPL
sweep at low speed and park. The Solid-State Control Board keeps the wipers on for (92) wire at pulse wiper switch (92) wire between pulse wiper
approximately six seconds after the washer goes off. If connector C204 to ground. switch connector C204 and pulse
PARK the washer is switched on during the PULSE operation, wiper module connector C207. If
When the wipers are turned off, the Wiper Motor runs the wipers run in low speed for six seconds. The wash no open is found, REPLACE pulse
at low speed until the wiper blades reach the PARK cycle is completed before the wipers return to the wiper control module.
position. At that time the Park/Run Relay opens and delayed pulse operation.
shuts the Wiper Motor to stop it immediately. The wiper Wiper motor runs. REPLACE wiper, washer switch.
blades remain in the PARK position. The Wiper Motor is equipped with a circuit breaker
which protects the motor when the wipers are blocked.
MIST The resulting high current will open the circuit breaker WIPERS DO NOT OPERATE IN LO OR DE LAY
When the control is moved to MIST and released, the which will reset upon cooling.
TEST RESULT ACTION
wipers make one sweep at low speed and return to
PARK. The circuit operation is the same as low speed. 1. Place ignition in RUN or ACC and Wiper motor does not run. LOCATE and REPAIR open in GRA
wipers to LO. Connect a fused (91) wire between wiper motor
jumper from GRA (91) wire at connector C188 and pulse wiper
pulse wiper module connector module connector C207. If no
C207 to ground. open is found, REPLACE wiper
DIAGNOSIS — WINDSHIELD WIPERS AND motor.
WASHERS (PULSE)
Wiper motor runs. GO to step 2.
2. Connect a fused jumper from GRA Wiper motor does not run. LOCATE and REPAIR open in GRA
PRELIMINARY CHECKS: (91) wire at wiper switch (91) wire between pulse wiper
CHECK condition of WIPER fuse. If fuse is in good connector C204 to ground. switch connector C204 and pulse
condition, use the following diagnostic procedure. wiper module connector C207. If
no open is found, REPLACE pulse
wiper control module.

Wiper motor runs. REPLACE pulse wiper/washer

switch.

A-50 WINDSHIELD WIPERS AND WASHERS

PULSE
 WASHER MOTOR DOES NOT OPERATE

TEST RESULT ACTION

1. Place ignition to RUN or ACC and Test lamp does not light. LOCATE and REPAIR open in
pulse wiper/washer switch to WHT (93) wire between washer
WASH. Connect a test lamp from pump connector C187 and fuse
WHT (93) wire at washer pump block.
connector C187 to ground.
Test lamp lights. GO to step 2.

2. Connect a test lamp from WHT Test lamp lights. REPLACE washer pump.
(93) wire to PNK (94) wire at
washer pump connector C187. Test lamp does not light. GO to step 3.

3. Connect a fused jumper from PNK Washer motor does not pump. LOCATE and REPAIR open in PNK
(94) wire at pulse wiper control (94) wire between washer pump
module connector C207 to connector C187 and pulse wiper
ground. control module connector C207.

Washer motor pumps. GO to step 4.

4. Connect fusible jumper from PNK Washer motor does not pump. LOCATE and REPAIR open in PNK
(94) wire at wiper switch (94) wire between pulse wiper
connector C204 to ground. control module connector C207
and pulse wiper switch connector
C204.

Washer motor pumps. GO to step 5.

5. Connect a fusible jumper from Washer motor does not pump. REPLACE wiper switch.
BLK (150) wire at wiper switch
connector C204 to ground. Washer motor pumps. LOCATE and REPAIR open in BLK
(150) wire between wiper switch
connector switch and ground
G200.

WASHER MOTOR DOES NOT SHUT OFF

TEST RESULT ACTION

1. Place ignition in RUN or ACC and Washer motor stops pumping. REPLACE wiper switch.
wiper switch to WASH.
Disconnect wiper switch connector Washer motor pumps. GO to step 2.
C204.

2. Disconnect wiper control module Washer motor stops pumping. REPLACE pulse wiper control
connector C207. module.
Washer motor pumps.
LOCATE and REPAIR short to
ground in PNK (94) wire between
pulse wiper control module
connector C207 and washer pump
connector C187.

WINDSHIELD WIPERS AND WASHERS A-51

PULSE
 HOT IN ACCY OR RUN

193-.8 WHT I

WIPER
25 AMP 193-.S WHT I

WINDSHIELD PULSE WIPER,

WIPER PULSE WIPER WASHER SWITCH
MOTOR CONTROL MODULE (COLUMN MOUNTED)

C188 C189
8917544 8917548

WINDSHIELD
WASHER
PUMP

l/P

_ S201
(SEE PAGE 17)
420 440
: 94 29 15
439 806 39
9 39 14
33 12 J
93 11

: 18
: 24
120
30
919 I1n _J
m
o
g

A-52 WINDSHIELD WIPERS AND WASHERS

PULSE
CIRCUIT OPERATION DIAGNOSIS - START AND CHARGE
START PRELIMINARY CHECKS:
When the Ignition Switch is moved to the START Drive Assembly to disengage and Solenoid Switch Turn headlamps and dome lamps ON and place insufficient, refer to Section 6D of the 1991 R/V,P Light
position, battery voltage is applied to the Starter contacts to open simultaneously. As soon as the ignition in START. If lamps go dim or go out, check Truck Service Manual. If battery has sufficient charge,
Solenoid. Both solenoid windings are energized. The contacts open, the starter circuit is turned off. battery for correct charge. If battery charge is use the following procedures.
circuit through the Pull-In Winding is completed to
ground through the Starter Motor. The windings work CHARGE ENGINE DOES NOT CRANK AND STARTER SOLENOID DOES NOT CLICK
together magnetically to pull in and hold in the Plunger. The Generator provides voltage to operate the
TEST RESULT ACTION
The Plunger moves the Shift Lever. This action causes vehicle’s electrical system and to charge its Battery. A
the Starter Drive Assembly to rotate as it engages the magnetic field is created when current flows through the 1. Place transmission in PARK (auto) Battery voltage. GO to step 2.
Flywheel ring gear on the engine. At the same time, the Rotor. This field rotates as the Rotor is driven by the or depress clutch pedal for man.
Plunger also closes the solenoid switch contacts in the engine, creating an AC voltage in the Stator windings. trans. Connect a voltmeter from No voltage. GO to step 3 for man. trans. GO
Starter Solenoid. Full battery voltage is applied directly The AC voltage is converted to DC by the rectified bridge PPL (6) wire at starter solenoid to to step 5 for auto, trans.
to the Starter Motor and it cranks the engine. and is supplied to the electrical system at the Battery ground. Turn ignition switch to
terminal. START position.
As soon as the Solenoid Switch contacts close, This Generator’s regulator uses digital techniques to 2. Connect a voltmeter from PPL (6) Battery voltage. REPLACE starter solenoid
voltage is no longer applied through the Pull-In Winding, supply the Rotor current and thereby control the output wire to starter mounting bolts.
since battery voltage is applied to both ends of the voltage. The Rotor current is proportional to the width of Less than battery voltage. CLEAN starter motor mounting
windings. The Hold-ln Winding remains energized, and bolts, starter motor, and mounting
the electrical pulses supplied to it by the Regulator.
its magnetic field is strong enough to hold the Plunger, surface.
When the Ignition Switch is placed in RUN, narrow width
Shift Lever, and Drive Assembly Solenoid Switch pulses are supplied to the Rotor, creating a weak 3. Disconnect clutch start switch Battery voltage. GO to step 4.
contacts in place to continue cranking the engine. connector C237. Connect
magnetic field. When the engine is started, the
Regulator senses Generator rotation by detecting AC voltmeter from YEL (5) wire at No voltage. LOCATE and REPAIR open in YEL
When the Ignition Switch is released from the START clutch start switch connector C237 (5) wire between the clutch start
voltage at the Stator through an internal wire. Once the
position, battery voltage is removed from the PPL (6) wire engine is running the Regulator varies the field current to ground. Ignition switch must switch and the ignition switch. If
and the junction of the two windings. Voltage is applied by controlling the pulse width. This regulates the be in START position. wire is in good condition, GO to
from the Motor contacts through both windings to step 5.
Generator output voltage for proper battery charging and
ground at the end of the Hold-ln Winding. However, the
electrical system operation. 4. Depress clutch and put Engine cranks. REPLACE clutch start switch.
voltage applied to the Pull-In Windings is now opposing
transmission in neutral. Apply
the voltage applied when the winding was first energized.
parking brake. Connect a fused Engine does not crank. LOCATE and REPAIR open in PPL
The magnetic fields of the Pull-In and Hold-ln Windings jumper from YEL (5) to PPL (6) at (6) wire from clutch start switch to
now oppose one another. This action of the windings, clutch start switch connector starter solenoid.
with the help of the Return Spring, causes the Starter C237. Turn ignition switch to
START position.
5. With ignition switch OFF, connect Battery voltage. REPLACE ignition switch.
a voltmeter from RED (2) wire at
ignition switch connector C209 to No voltage. REPLACE and REPAIR open in
ground. Repeat step except RED (2) wires and fusible link at
connect from RED (3) wire at junction block.
ignition switch connector C210 to
ground.

START AND CHARGE A-53

 STARTER SOLENOID CL CKS, ENGINE DOES NOT CRANK OR CRANKS SLOWLY
TEST RESULT ACTION

1. Remove CRANK and ECM 1 fuses. Voltage reading greater than 9.6 GO to step 2.
Connect a voltmeter to positive volts after 15 seconds cranking.
and negative battery terminals.
Turn ignition switch to Voltage less than 9.6 volts after 15 PERFORM a Battery Load Test.
START. seconds cranking. Refer to Section 6D in 1991 R/V, P
Light Truck Service Manual.

2. Connect a voltmeter from negative Less than .5 volts. GO to step 3.

battery terminal to engine block.
More than .5 volts. REPLACE negative battery cable.

3. Connect a voltmeter from positive Less than .5 volts. REPAIR starter motor.
battery terminal to starter solenoid
terminal at BLK (2) wire. More than .5 volts. REPLACE positive battery cable.

B A T T E R Y IS U N D ER C H A R G E D O R O V ER C H A R G E D

TEST RESULT ACTION

1. Connect voltmeter from RED (2) Battery voltage. GO to step 2.

wire at generator to ground.
No voltage. LOCATE and REPAIR open in RED
(2) wire and fusible link from
generator to junction block.

2. Reconnect generator connector Reading of 13-16 volts. PERFORM Generator Bench Test.
C106 and terminal. Have all Refer to Section 6D in the 1991
accessories turned off and engine R/V, P Light Truck Service Manual.
running at fast idle. Connect
voltmeter from battery terminal on Reading of less than or greater REPAIR generator.
generator to ground. than 13-16 volts.

A-54 START AND CHARGE

 RPO CODES

L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, ViN K

L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
M20 - MAN TRANS, 4-SPD
MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE

C203
12066261

2-8.0 BLK/RED

START AND CHARGE A-55

GASOLINE ENGINE
 RPO CODES

LH 6. 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN C

LL4 - 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN J
M20 - MANUAL 4-SPEED TRANSMISSION
MT1 - AUTOMATIC 3-SPEED TRANSMISSION

E D fp E I
OS] QT)
firiU j 4i91
H r iQ O

-f~ —
I 25-.8 BRN |
s is

LH ’J O O
BATTERY ODnCD
m llD D
C203
STARTER MOTOR 12066261

o l/P CLUSTER
o CONNECTOR
(SEE PAGE 103)

l/p

ID

5 } 2
94 29 15 31
39 1 820 :
9 39 14
33 12 J L 4 ) 508
3
93 11
3»] 25 50

18 r
93
35
97
2
439
||
:
24 30
91 92 6 I

V
12020184
C100

12045896
C106

START
r----- N— ■ -■

'! * >j
/f * ' !■ • Q: GLOW PLUGS
i----- -m • CONTROLLER
SHEET RIGHT BANK LEFT BANK a -i (SEE PAGE 84)
vS= -< )
METAL GLOW PLUGS GLOW PLUGS
GROUND GROUND GROUND 2-3.0 BLU
(FUSIBLE LINK)
m | 2-.8 RED — eT c) ^
CLUTCH
CLUTCI
G111 G114 G113 START
I 2-.8 BLK/RED I SWITCH
(MAN TRANS ONLY)

A-56 START AND CHARGE

DIESEL ENGINE
 RPO CODES

L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN N

L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
NA4 - EMISSION SYSTEM, ABOVE 8500 GVW

CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
465 .8 DK G R N /W H T A1 FUEL P U M P RELAY DRIVE C1 N O T USED
A2 N O T USED C2 N O T USED
A3 N O T USED 444 .8 LT G R N /B LK C3 S TEPPER C O IL B LO W
435 .8 GRA A4 EGR S O LEN O ID (L 0 5 ) 443 .8 LT G R N /W H T C4 S TEPPER C O IL B H IG H
EVRV (L 0 5 W ITH NA4, L 0 5 441 .8 LT B L U /W H T C5 S TEPPER C O IL A H IG H
CAN ADIAN A N D L19) 4 42 .8 LT BLU/BLK C6 S TEPPER C O IL A LO W
419 .8 B R N /W H T A5 SYSTEM C H E C K LAMP *4 46 .8 LT BLU C7 A /C C O N T R O L (4TH GEAR
439 .8 PNK/BLK A6 12V IG N ITIO N FUSED D IS C R E TE (L05 W IT H M D 8)
*4 2 2 .8 TAN/BLK A7 T O R Q U E C O N V E R TE R C LU TC H C8 N O T USED
(M D8) 806 .8 PPL7WHT C9 C R A N K SIG N A L (FU SED)
461 .8 ORN A8 SER IA L DATA 410 .8 YEL C 10 C O O L A N T TE M P E R A TU R E
451 .8 W H T/B LK A9 A SSEM BLY LINE D IA G N O S TIC LINK 432 .8 LT G RN C11 M AP S E N S O R
437 .8 BRN A10 SPEED S EN SO R (L 0 5 , L19 C 12 N O T USED
W IT H O U T RW AL) 417 .8 DK BLU C 13 TP S E N S O R
DRAC M O D U LE (L 0 5 , L19 416 .8 GRA C 14 5V S E N S O R R E FE R E N C E
W ITH RW AL) C 15 N O T USED
452 .8 BLK A11 5V R E TU R N B 440 .8 O RN C 16 12V BATTERY FUSED
450 .8 BLK/W HT A12 SYSTEM R ETURN 551 .8 TA N /W H T D1 SYSTEM G R O U N D
440 .8 ORN B1 12V BATTERY FUSED 455 .8 PPL D2 5V R E TU R N A
120 .8 TA N /W H T B2 ELEC FUEL PU M P FUSED FEED D3 N O T USED
453 .8 BLK/RED B3 DIS TR IB U TO R REF LOW 423 .8 WHT D4 HEI S PA R K T IM IN G
B4 N O T USED 4 24 .8 TA N /B L K D5 HEI BYPASS
430 .8 PPL/W HT B5 DIS TR IB U TO R REF H IG H 413 .8 TAN D6 OXYG EN S E N S O R LO W (G R O U N D )
B6 N O T USED 412 .8 PPL D7 OXYG EN S E N S O R HIG H
485 .8 BLK B7 SPA RK RETARD C O N TR O L D8 N O T USED
59 .8 DK G RN B8 AIR C O N D ITIO N D9 N O T USED
B9 N O T USED D10 N O T USED
*4 3 4 .5 O RN /B LK B10 PARK /N EU TR A L S W ITC H D11 N O T USED
B11 N O T USED D12 N O T USED
B12 N O T USED D13 N O T USED
468 .8 DK GRN D14 IN JE C TO R B (2) DRIVE
*A U T O TRA NS ONLY D15 N O T USED
ELEC TR O N IC C O N TR O L M O DULE C O N N E C T O R 467 .8 DK BLU D16 IN JE C TO R A (1) DRIVE
*A U T O TR A NS O NLY
E LE C TR O N IC C O N T R O L M O D U LE C O N N E C T O R

ELECTRONIC CONTROL MODULE PINOUTS A-57

GASOLINE ENGINE
 43S-.8 PNK/BLKI

ECM B
10 AMP

A-58 ELECTRONIC CONTROL MODULE (ECM)

INPUTS - GASOLINE ENGINE
 RPO CODES
439-.8 PNK/BLK
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
L19 - ENGINE 7.4L (454 CID) V8 GAS ENGINE, VIN N
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE

I419-.8 BRN/WHT I

♦
SERVICE
ENGINE
SOON
LAMP
(SEE PAGE 104)

ECM
CONNECTORS

CRANK SIGNAL
(FUSED)
(SEE PAGE 55)

ALDL

ENGINE
C206
12020043
GROUND
G110
ELECTRONIC CONTROL MODULE (ECM) A-59
INPUTS - GASOLINE ENGINE
 v A A W A A /W W f 422-. 8 TAN/BLK I

< HOT AT ALL TIMES <

439-.S PNK/BLK .
J,W W V W V W V S

ECM B
10 AMP

EVRV
(L19)

ENGINE
GROUND
G115
A-60 ELECTRONIC CONTROL MODULE (ECM)
OUTPUTS - GASOLINE ENGINE
 RPO CODES

| 439-.S PNK/BLK 444-.S LT GRN/BLK | L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
M20 - MAN TRANS, 4-SPD.
I 440-.8 ORN 119 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N

820-.8 PPL/WHT

HANDLING MODULE +

12064770
E

w m ' j i ^ 4 1 9 |4 5 0 | 451 | 4 3 7 |4 6 l]
j |434|822] 821|696| 33

SERVICE ENGINE G H J

SOON LAMP 12064769

(SEE PAGE 105)

A 422-.S TAN/BLK

ELECTRONIC CONTROL MODULE (ECM) A-61

OUTPUTS - GASOLINE ENGINE
 C IR C U IT W IR E C O LO R CAVITY D E S C R IP T IO N CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
4 32 .8 LT G RN A1 M AP S E N S O R 452 .8 BLK C1 SYSTEM G RO UND
4 17 .8 D K BLU A2 TP S E N S O R 150 .8 BLK C2 SYSTEM G RO UND
4 10 .8 YEL A3 C O O L A N T T E M P E R A T U R E S W ITC H C3 NOT USED
A4 N O T USED C4 NOT USED
A5 N O T USED *4 2 2 .8 T A N /B L K C5 TO RQ UE CO N VER TER C LU TC H
451 .8 W H T/B LK A6 A S S EM B LY LINE D IA G N O S T IC LINK 421 .8 D K B LU /W H T C6 COLD ADV A N C E /G LO W PLUG
CONNECTOR TIM ER IN H IB IT RELAY
A7 N O T USED C7 NOT USED
121 .8 W HT A8 E N G IN E SPE E D S E N S O R C8 NOT USED
4 37 .8 BRN A9 V SS FR O M D R A C M O D U L E C9 NOT USED
4 88 .8 LT G RN A 10 A S S EM B LY LINE D IA G N O S T IC LIN K 435 .5 GRA C 10 EGR DIAG NO STIC C O N N E C T O R
CONNECTOR 697 .8 LT BLU C11 EGR DUM P S O LEN O ID
A11 N O T USED 538 .8 D K G RN C12 EPR VALVE SO LEN O ID
4 16 .8 G RA A 12 TP S E N S O R A N D M AP S N E S O R C 13 NOT USED
5V R E FE R E N C E 439 .8 P N K /B LK C 14 12V IG NITIO N FUSED
C 15 NOT USED
B1 NOT USED
440 .8 ORN C 16 12V BATTERY FUSED
B2 NOT USED
B3 NOT USED D1 NOT USED
B4 NOT USED D2 NOT USED
B5 NOT USED D3 NOT USED
B6 NOT USED D4 NOT USED
B7 NOT USED D5 NOT USED
B8 NOT USED D6 NOT USED
B9 NOT USED D7 NOT USED
B 10 NOT USED D8 NO T USED
B11 NOT USED D9 NOT USED
B12 NOT USED D10 NOT USED
D11 NOT USED
E LE C TR O N IC C O N T R O L M O D U L E C O N N E C T O R D12 NOT USED
D13 NOT USED
D14 NOT USED
D15 NOT USED
D16 NOT USED
*A U T O TR A NS O NLY
E LE C T R O N IC C O N T R O L M O D U L E C O N N E C TO R

A-62 ELECTRONIC CONTROL MODULE PINOUTS

DIESEL ENGINE
GAGE/IDLE
20 AMP

39-.8 PNK/BLK

r
531-.8 LT GRN/BLK |

COLD 1531
ADVANCE 531-.8 LT GRN/BLK A • S121
CONTROL m
C167
2977253
LL 421-.8 DK BLU/WHT
538-.5 DK GRN I

1397-.8 LT BLU ■

I
)7 -.8 LT BLU I
------------------------ 1 -
150-1.0 BLK ■ 150-.8 BLK I

r
j q
S122
150-. 8 BLK ;
(SEE PAGE 18)
C193
I 531-.8LT GRN/BLK V

697 .8 LT BLU I

EGR DUMP ------------------------------i -

39-.s p n k /b lk m m r j^ m r 1 _

435-.8 GRA | 53S-.8 DK GRN

EGR VALVE - i = - r \
J H T ^ 39-.S PNK/BLK * i^ r J V I

CD CD CD CD
v
z
? S?
z
£
z
£
z
Q. CL CL a. 39-.S PNK/BLK
C194 CO 03 CO CO

39 / T \ 12015?Z6 vj w i'>

ERR VALVE
K V^/ 538 )
a 39-.8 p n k /b lk

538-.8 DK GRN
mht jm m J |r
WATER
IN FUEL
SENSOR
S109 _____
(SEE PAGE 87) • k r m aw 39-.s p n k /b lk r , l

COLD ADVANCE
FAST IDLE
TEMPERATURE SWITCH
(SEE PAGE 87)

531-.8LT GRN/BLK

ENGINE GLOW PLUG 150-.8 BLK

GROUND CONTROLLER

A-64 ELECTRONIC CONTROL MODULE (ECM)

OUTPUTS DIESEL ENGINE
439-.S PNK/BLK 439-.S PNK/BLK I

ELECTRONIC CONTROL MODULE (ECM) A-65

OUTPUTS DIESEL ENGINES
 CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
4 65 .8 D K G R N /W H T A1 FU E L P U M P RELAY D RIVE 439 .8 P N K /B LK C1 12V IG N ITIO N FUSED
1223 .8 YEL/B LK A2 S O LE N O ID B D R IV E R 450 .8 B LK /W H T C2 SYSTEM G R O U N D
1222 .8 LT G R N A3 S O LE N O ID A D R IV E R 551 .8 T A N /W H T C3 SYSTEM G R O U N D
422 .8 T A N /B L K A4 T C C D RIVER 4 16 .8 G RA C4 5V SEN SO R R E FE R E N C E
A5 N O T USED 417 .8 D K BLU C5 TPS
A6 N O T USED 441 .8 LT B LU /W H T C6 STEPPER C O IL A H IG H
419 .8 B R N /W H T A7 S YS TE M C H E C K LAM P 442 .8 LT B LU/BLK C7 STEPPER C O IL A LO W
A8 N O T USED 4 44 .8 LT G R N /B L K C8 STEPPER C O IL B LO W
A9 N O T USED 443 .8 LT G R N /W H T C9 STEPPER C O IL B H IG H
A 10 N O T US E D 432 .8 LT G RN C 10 MAP
435 .8 GRA A11 EVR V S O LE N O ID 461 .8 ORN C11 SERIAL DATA
4 20 .8 PPL A 12 BRAKE S IG N A L C 12 N O T USED
B1 N O T USED 413 .8 TAN C13 OXYGEN SEN SO R G R O U N D
1226 .8 RED B2 P R E S S U R E S W ITC H M A N IF O L D C 412 .8 PPL C14 OXYGEN SEN SO R
1225 .8 D K BLU B3 P R E SS U R E S W ITC H M A N IF O L D B 468 .8 D K G RN C15 INJEC TO R B DRIVER
1224 .8 PNK B4 P R E SS U R E S W IT C H M A N IF O LD A 467 .8 D K BLU C16 INJEC TO R A DRIVER
1232 .8 LT BLU B5 O U T P U T S P E E D H IG H 440 .8 ORN D1 12V BATTERY FUSED
1233 .8 D K G R N /Y EL B6 O U T P U T S P E E D LO W 455 .8 PPL D2 S ENSO R G R O U N D
1229 .8 LT B LU /W H T B7 FO R C E M O T O R LO W 452 .8 BLK D3 SEN SO R G R O U N D
1228 .8 B LK /R ED B8 FO R C E M O T O R H IG H 474 .8 GRA D4 5V SEN SO R RE FE R E N C E
1230 .8 D K B LU /W H T B9 IN P U T S PE E D H IG H 4 96 .8 D K BLU D5 K N O C K SIGNAL
1231 .8 G R A /R E D B10 IN P U T S PE E D LO W 451 .8 W H T/B LK D6 ALDL
4 37 .8 BRN B11 V SS (W /O RW AL) D R A C (W / RW AL) 1 20 .8 T A N /W H T D7 ELECTRIC FUEL P U M P FEED
59 .8 D K G RN B 12 AIR C O N D IT IO N IN G FUSED
D8 N O T USED
P O W E R TR A IN C O N T R O L M O D U L E C O N N E C T O R D9 NO T USED
D 10 NO T USED
423 .8 WHT D11 HEI SPA RK T IM IN G
424 .8 TA N /B LK D 12 HEI BYPASS
4 53 .8 BLK/RED D 13 DISTRIBUTO R R E FE R E N C E LO W
4 30 .8 P P L /W H T D 14 DISTRIBUTO R R E FE R E N C E H IG H
1 22 7 .8 BLK/YEL D 15 TR A N SM IS S IO N TE M P E R A TU R E
410 .8 YEL D 16 CO O LANT TE M P E R A TU R E

P O W E R TR A IN C O N T R O L M O D U LE C O N N E C TO R

A-66 POWERTRAIN CONTROL MODULE PINOUTS

CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
A1 N O T USED 150 .8 BLK C1 SYSTEM G R O U N D
A2 N O T USED 150 .8 BLK C2 SYSTEM G R O U N D
1 224 .8 PNK A3 P R E SS U R E S W ITC H M A N IF O LD A 4 52 .8 BLK C3 SENSOR GROUND
1 225 .8 DK BLU A4 P R E SS U R E S W ITC H M A N IF O LD B 4 16 .8 G RA C4 5V S E N S O R R E FE R E N C E
1 226 .8 RED A5 P R E SS U R E S W ITC H M A N IF O LD C C5 N O T USED
1 223 .8 YEL/BLK A6 S O LE N O ID B D R IV E R C6 N O T USED
1 22 2 .8 LT G R N A7 S O LE N O ID A DR IVER C7 N O T USED
451 .8 W H T/B LK A8 ALDL C8 N O T USED
A9 N O T USED C9 N O T USED
A 10 N O T USED C 10 N O T USED
A11 N O T USED C11 N O T USED
440 .8 O RN A 12 12V BATTERY FUSED C 12 N O T USED
B1 C 13 N O T USED
N O T USED
C 14 N O T USED
B2 N O T USED
1 22 8 .8 R E D /B LK C 15 F O R C E M O T O R H IG H
59 .8 DK G R N B3 A IR C O N D IT IO N IN G
439 .8 P N K /B LK C 16 12V IG N IT IO N FUSED
4 20 .8 PPL/BLK B4 BRAKE S IG N A L
4 22 .8 TA N /B LK B5 TCC D1 N O T USED
B6 N O T USED 4 37 .8 BRN D2 VSS
B7 N O T USED 1231 .8 DK B LU /W H T D3 IN P U T S PE E D LO W
B8 N O T USED 1232 .8 LT BLU D4 IN P U T SPE E D H IG H
B9 N O T USED D5 N O T USED
488 .8 LT G R N B10 SER IA L DATA 121 .8 WHT D6 E N G IN E SPEED
1 23 3 .8 DK G R N /Y E L B11 O U TP U T SPE E D S E N S O R LO W 452 .8 BLK D7 SENSOR GROUND
1232 .8 LT BLU B12 O U TP U T SPE E D S E N S O R H IG H 4 17 .8 D K BLU D8 TP S E N S O R
D9 N O T USED
TR A N S M IS S IO N C O N T R O L M O D U L E C O N N E C T O R D 10 N O T USED
D11 N O T USED
1 227 .8 BLK/YEL D12 T R A N S M IS S IO N TE M P E R A TU R E
4 32 .8 LT G RN D13 M AP S E N S O R
D14 N O T USED
D 15 N O T USED
1229 .8 LT B LU /W H T D 16 FO R C E M O T O R H IG H

T R A N S M IS S IO N C O N T R O L M O D U LE C O N N E C T O R

TRANSMISSION CONTROL MODULE (TCM) A-67

DIESEL ENGINES
 W W W W W W \yf WSAAAW^WWVW
S HOT AT ALL TIMES < J ^ HOT IN START OR RUN ^

W w w vvw s
ECM B
10 AMP

COOLANT
TEMPERATURE
SENSOR

OXYGEN
SENSOR

OUTPUT
SPEED
SENSOR
(4WD ONLY)

INPUT
SPEED
SENSOR TRANSMISSION
G110 ENGINE
ENGINE GROUND
GROUND G115
A-68 POWERTRAIN CONTROL MODULE (PCM)
INPUTS - GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
iv - jm w jm m r 450-.8 b lk / w h t ' mmmr

^ * r m m r m m ar ^m w m tm ' jm m r M m m r ^ 551 -.8 t a n / w h t m m r ®i

A/C
(SEE PAGE 94)

POWERTRAIN CONTROL MODULE (PCM) A-69

INPUTS - GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
 439-.8 PNK/BLX I

ECM B
10 AMP

EVRV

ELECTRONIC
SPARK
TIMING

INJ-2

INJ-1

FUEL PUMP
OIL PRESS
SWITCH

FUEL
PUMP
C100
RELAY 12020183

I 440-1.0 ORN

A-70 POWERTRAIN CONTROL MODULE (PCM)

OUTPUTS ■ GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
 k /W V W W W 'M k /W W W W W «, WvVVWWVVWVW
< HOT AT ALL TIMES < \ HOT IN START > / S HOT IN START OR RUN <
r
Ir
r439*.8 PNK/BLK ■
I a A/WWWWVn W W V W W V ' ECM 1 - 'W V W W V W V V n
ECM B CRANK 439-.8 PNK/BLK

r. 1223-.8 YEL/BLK

10 AMP

TP SENSOR
3 AMP
439-.8 PNK/BLK I

1440*1.0 ORN I
_ i
r 1440*1.0 ORN

11226-.8 RED I

11225-.8 DK BLU ■
_ c
439-.8 PNK/BLK |

-452 C 1 1224- 8 P N K H
1452-.S BLK I

■ 1 2 1 -.8 W H T H I
•417 B I417-.8 DK BLU

1416-.8 GRA I 1452-.8 BLK I

416
| 420-.8 PPL/BLK m

C134
12052843
r - 422-.S TAN/BLK r

I 417-.8 DK B L U M

1229-.8 LT BLU/WHT I

^ 1233-.8 DK GRN/YEL I

11232-.8 LT BLU I

11222-.8 LT GRN I

I 416-.8 GRA I

• ■ I 452- 8 BLK I
S122
(SEE PAGE 18)
| 150-.8 BLK |
• 1230

■ I 150-.8 BLK I

' 1227-.8 BLK/YEL m

-1231

C173 M230-.8 DK BLU/WHT i a 1230-.8 GRA/RED M

INPUT 12078084
11231-.8 GRA/REDBT ■ 1231-.8 DK BLU/WHT F
SPEED
SENSOR

r 1228-.8 RED/BLK
452 A
I452-.8 BLK I

0 m
1121-.8 W H Tl
B
121
C175 LU

n
12015792
ENGINE 3
m 5
O
SPEED H
-j- *
Q
SENSOR ® CO

•1233
j I
11233-.8 DK GRN/YEL ■

C172
-1232 11232-.8 LT BLU I
12084690
| i-139 h r
Ul s I 92 I 91 I
TRANSMISSION
CONNECTOR
OUTPUT
12084435 ENGINE
SPEED C100
439-.S PNK/BLK • 12020183 GROUND
SENSOR
G110
A-72 TRANSMISSION CONTROL MODULE (TCM)
DIESEL ENGINE
 RPO CODES
W sM AW M VW Vf
S HOT IN START OR RUN Z MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
"w w v w v w w v v a *

GAGE/IDLE GT101
12064740
20 AMP

422-.8 TAN/BLK

446-.S LT BLU i
B A
©01 1 14651
D »1 2 1'" “ 1
BRAKE
14531 3 |___ | SWITCH
1------ 1 4 P»35l
|430l 5 14191 (M D 8 ONLY)
L 1 6 14 39 1 £
z
CL
f4 8 5 l 7 [4 2 2 *
S O 8 f46T1
1 1 9 f4 5 fl
[434110 |4 3 7|
£
I I 11 I452I
I___ | 12 [450J ECM
______i________ i CONNECTORS

(SEE PAGE 116)

139-.8 PNK/BLK
S202
(SEE PAGE 27)

e D C B A

01 <D O
I RWAL O CN to
*
(*)
*
to
*

I -
DIODE ARRAY
MODULE
C215
12045575
ILJ
G H J K |
(SEE PAGE 116)
C203

( 12020043

ALDL

I
420 440 2
439 806 39 :
L 140 120
31 3

I : 18 120
3>
r
50
35
436
2
9 I 93 97 422 V
I 422-.S TAN/BLK I
: 24 30 19 |
91 92 6

o
o

A-74 TRANSMISSION CONVERTER CLUTCH (TCC) DETENT SOLENOID

5.7L V8 GASOLINE ENGINE
 RPO CODES
YAAAWVW C216 I/P CLUSTER
S hot in run < 12047946 (11/629) CONNECTOR L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
(SEE PAGE 103) LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
Tw w vw * ECM M20 - MAN TRANS, 4-SPD.

CONNECTOR I 440 l 1 1 4651

HTR A/C [ ISO 1 2 n n

25 AMP I I 50-2.0 BRN |

1453 1 3 n
□ 4 14351
[430'1 5 1 419<
DRAC
E 14391
□
1485 1 7 14221 DEncm
HTR A/C SELECTOR <
[ 59 1 B 1 4611 □ D n H ( 419/489/1234 ) < 5 H
50-2.0 BRN I CONTROL SWITCH z c D
0
1592]ui z371
.
[ = □ 9 1451 1
0 0 Z
(SEE PAGE 94) t- _i
f<34l 10 1 4371 s IX
"69 <z 0 2_.
1— 1 U t452l Ui
0 z § 8
0 z UI CO f
50-2.0 BRN I RWAL MODULE t = n 12 1 4S0l HDnCim 0 0 0 Q 4
(SEE PAGE 116) UI Ui H Ui UJ Q
□ d Ud d Ui
Q. Q.
LU O
§5 w
g a.
(0 (/) Ui
Ui Ui O ui
Z
0
I 50-1.0 BRN I X z § O
AC
z
UJ Ui Ui
VSS S211
> > 0 >

IT
C289
* 822-.8 LT GRN/BLK I
12066130
A 821-.8 PPL/WHT

□SDH
GT101
12064740

I 437-.S BRN

RWAL CONTROLLER I 696*.8 WHT H i

(SEE PAGE 116)

i (L05 WITH M20)

C200

CRUISE CONTROL
(SEE PAGE 124)

150-.8 BLK (LL4 ONLY)

fc S215 (SEE PAGE 17)

I ______

CD 422
696 461
S122
(SEE PAGE 116)
436 j c
____ 436 450/151)
^ (450/151
• 150-.8 BLK

ALDL CONNECTOR
____ 451
mgr ^450-.8
45o-.seBLK/WHT * \
C206 FUEL PUMP
CD 12020043 CYCLE RELAY
C100
12020183 f (SEE PAGE 79)

ENGINE
ENGINE GROUND
GROUND G115
G110
DIGITAL RATIO ADAPTER CONTROLLER (DRAC) MODULE A-75
 RPO CODES

yvwwwwwvv/ ^w w w vw w w
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
< HOT IN START OR RUN < S HOT IN START OR RUN ^
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
m w v v w v v v w ^ ECM 1 ^ ^MVVNAVWWV^A

?
GAGE/IDLE
20 AMP 10 AMP
439-.8 PNK/BLK I I 439-.S PNK/BLK

f 39-.S PNK/BLK

423-.8 WHT I o | —
430-.8 PPL/WHTI

424-.S TAN/WHT

453-.B PPL/WHT
_ _

i ^
i _

( )

T
C133

424-.8 TAN/WHT GT101

12064740

121-.8 WHT

3-3.0 PNK

TACHOMETER °?

139-.8 PNK/BLK ■

EVRV SOLENOID (L19)

(SEE PAGE 60) IGNITION
SWITCH
AIR SWITCH SOLENOID (SEE PAGE 11)
(UTILITY ONLY)
(SEE PAGE 60)

EGR SOLENOID
(L05 ONLY)
(SEE PAGE 60)

HYBRID FUNCTION ESC

439-.Q PNK/BLK
(SEE PAGE 58)

■ 439-.B PNK/BLK I I 439-.8 PNK/BLK I

A-76 IGNITION
GASOLINE ENGINE
ECM 1
10 AMP

ECM
CONNECTORS

THROTTLE BODY INJECTOR A-77

GASOLINE ENGINE
 RPO CODES
440-1.0 ORN I

vAW AM AM M L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K

< HOT AT ALL TIMES < L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
. HOT IN START O R RUN 39-.8 PNK/BLK*
>VVVW\AMMN
FUEL PUMP
ECM
CYCLE RELAY
CONNECTOR B A (HOT FUEL HANDLING
ECM B GAGE/IDLE 1465 Ip
r f l2 0 l 2 1------ 1 MODULE)
10 AMP 20 AMP 14531 3 L Z 3
□ 4 [435]
[4301 5 14191-
IDLER AIR IGNmON SW ito G E l C Z 3 e
□ 6 1439] FUEL PUMP FUSED
CONTROL f4 8 5 l 7 E H ]
GROUND
450 | cQ D
1 59 1 8 J461 | b C D i— | g
FRAME 120-.8 GRA (SUBURBAN ONLY)
[~ 1 9 I 451J
iv n v r (LI 9)
[434110 14371
AI 12° I i Ih 120-1.0 TAN/WHT JM

I I 11 i 452J
I___ I 12 I 450 h C194
12045688
C161
ALDL
12078082 J 450*.8 BLK/WHT.
(SEE PAGE 59)
I 440-.8 ORN I
S215
I 465-.8 DK GRN/WHT , % (SEE PAGE 79)
120-.8 GRA I
441-.8 LT BLU/WHT | 441-.8 LT BLU/WHT I
443-.8 LT GRN/WHT" 443-.S LT GRN/WHT
IDLE AIR 442-.8 LT BLU/BLK A 442-.8 LT BLU/BLK ■ DRAC
* 450-.8 BLK/WHT
(SEE PAGE 75)
CONTROL 444-.S LT GRN/BLK I 444-.8 LT GRN/BLK .
ACTUATOR
0-05)
551-.8 TAN/WHT
STEPPER 441 ENGINE
MOTOR GT100
12064740

442 413-.8 TAN I

: 94 29 15
I 420 440 2
439 806 39
fYYY^ 443 806 | 439 9 39 14
444 33 12 J L 140 120 |
I.. 120 140 I
31 3
93 11 (
C161
12015796
436 50
3»rJ 50
35
436
2
: 18 120
FUEL PUMP
9I 93 97 422 :
: 24 30 19 |
422 97 1 93 | 91 92 6
OIL PRESSURE
SWITCH
3 GE3 \
«*S139
C100 C100
1120-1.0 G R A i 440-.8 ORN I 12020183 12020184
ECM
CONNECTOR FUEL GAGE
120-1.0 GRA I ’ (SEE PAGE 108)

C115
440-1.0 ORNI 120-1.0 TAN/WH1 I
12065401

FUEL C409
RWAL 12059473
PUMP (SEEPAGE 116)
120-1.0 TAN/WHT

PRIME ELECTRIC FUEL PUMP

30-.8 PNK I
C160 S140 . FUEL GAGE SENDING UNIT
2977253
450-.8 BLK/WHT I

C101

FUEL
12020099 J
PUMP BLU OR PPL^ FRAME
RELAY 450-.8 BLK/WHT I v ^Jl
ENGINE ENGINE OR LT GRN
GROUND
C148 GROUND O GROUND G409
12052287
G110 ^ G115

A-78 FUEL CONTROL AND IDLE AIR CONTROL

GASOLINE ENGINE
 39-. 8 PNK/BLK 3Q-.8 PNK/BLK

(FUEL PUMP CYCLE

RELAY HOT FUEL
GAGE/IDLE HANDLING MODULE)
20 AMP ________I

GROUND.- c
a o o
c r ---------------------------------

I
=!
450

S117
GT
IGNITION SWITCH - 4 39
FUEL PUMP FUSED - • 120
9

bCZI CI3
M
S T r - ' -
I □ O f T ’ <~ r
« l----- 1 I----- 1SI
-t-, I
cziH
1
(SEE PAGE 17) 101
12064740 n l _____________
v:
12047886
12045688

h r450-.8 BLK/WHT V . 1450-.8 BLK/WHT I

pm rm
§ i

c
jir—r
120-.8 G RAI

------------------------------------ \ \
M I 450-.8 BLK/WHT
w ------------ I - I l ______
^ S139 || _ L —i |
| i r ^ ■ 120-1 .O G R A M B ^ -
FUEL PUMP OIL
PRESS SWITCH
0
tar TBt
\
»-

^ l
(SEE PAGE 60)
12064770
C200
I I I
I
| I 120-1.0 GRA FUEL PUMP
RELAY B A
(SEE PAGE 60) 14401 1 14651
2I I I ^m ^ ■ 4 5 0 - . 8 BLK/WHT (SEE PAGE 27) ^
[4531 3 C D
\ S215 ^ ^
I I 4 [4351 ALDL
[430l 5 E H } • m m ^ 1 4 5 0 - 8 BLK/WHT
I I 6 [Ml ECM (SEE PAGE 59) ?*
H r
I \ r r- m
CONNECTOR DRAC
I
n
H \ f~59~l 8 [4611 ^45 0 -.8 BLK/WHT i
(SEE PAGE 75) ELECTRIC FUEL PUMP
I I 9 IW l mO
_____________ [4341 10 14371 ” CO FUEL GAGE SENDING UNIT
I I 11 [4521 I450-.8 BLK/WHT I PARK/NEUTRAL
I I 12 [ 450)1 SWITCH
l/P (SEE PAGE 59)
T

ENGINE
i - Z 450-.8 BLK/WHT
—13
k i „
IS 1 r
420 440 2

[LiJ
94 29 15
112 440 | 420 | H
Cl 9 39 14
439 806 39 | jm w a w m jm 39-.s p n k /b lk FRAME
1 ( 39 306 | 439 J G
L 140 120 I GROUND
J
_______ ___ i
33 12

i T
F
i 1120 140 |
II "1 31 3
G409
: 93 11
T (3 >I50 436 39-.S PNK/BLK
I3 31 |
y))}DE
(50/130>
| 436 | 50 | ♦N 8g-p / 5 0 /2 5 ] : 18 120 9 r 9735
93
2
422 :
I2 35j m C 24 A 19
91 92 6
1 |422 97 | 9 3 1 B I ______________________________________________
120-.8 TAN/WHT
d 120-.8 GRA“(SUBURBAN ONLY)
■1 6 92 | 91 |

2 3 S
A

v = i
P K
CO \
120-.8 GRA (SUBURBAN ONLY) WIRE COLOR

C100 C100 CAN BE BLU,

12020183 120-1.0 TAN/WHT 12020184 PPL OR LT GRN

G110 A 120-1.0 TAN/WHT d

ENGINE 18 120 9 I 30-.8 PNK I

C101
GROUND 24 30 19
12020094
FUEL GAGE
30-.5 PNK I
(SEE PAGE 108)
I 30-.8 PNK I

HOT FUEL HANDLING A-79

GASOLINE ENGINES
 39-.8 PNK/BLK

ENGINE

GAGE/IDLE
20 AMP
$___ I FUEL
IG NITIO N SW
FUEL PUM P FUSED
GROUND 450

U U
o I 4S0~1 (
C I

B[
a Q
39

I I
|
Ie

)0
| H
39-.8 PNK/BLK
1

PUMP
V ------------------- I
RELAY
— j
(HOT FUEL HANDLING
MODULE) I r
39-.S PNK/BLK [/
S202
39-,8 PNK/BLK a • (SEE PAGE 27)
l/P

p
N
94
5*
Dk
Ml 15
6
420
439
440
806
2
39
r ELECTRIC
9 39 14
M 33 12 J L 140 120 I FUEL PUMP
31 3
L 93 11 ASSEMBLY
m 50 436
(AUXILIARY
, r 35 2 RIGHT SIDE)
93 97 422
91 92 6

30-.8 PNK *

120-1.0 TAN/WHT _ _ ^ Q |

120-1.0 TAN/WHT

FUEL TANK
SELECTOR
VALVE
♦ C304
AND METER
FUEL GAGE
(SEE PAGE 108)
SWITCH
FUEL TANK
SELECTOR S329
*| LEF
9 2 1 -1 .0 G R A 921-1.0 GRA 921-1.0 GRA 1 • I 921-1.0 GRA IM cT
rJ
SWITCH
920-1.0 TAN 920-1.0 TAN ■ ■ 920-1.0 TAN H p ? i
930-.8 PNK/WHT 3
120-1.0 TAN/WHT
w m m 30-. 8 PNK ■ ■ ■
8 £ I VALVE
12010973 C302 12015792 931-.8 PNK/BLK

BUS
RIGHT
15
C305
BAR 12020089
GROUND
G201 ELECTRIC
to
FUEL PUMP
E (PRODUCTION
LEFT SIDE) WIRE CAN BE

L*
BLU, PPL OR
C409
DK GRN COLOR
E 12059473

C203A FRAME FRAME

8911256 GROUND GROUND
G409 G410

A-80 AUXILIARY FUEL TANK AND FUEL TANK SELECTOR SWITCH

GASOLINE ENGINE
 FUEL GAGE
(SEE PAGE 108)

G201
BUS
BAR
GROUND
G410 r\ G409
FRAME (Q) (Q) FRAME
GROUND ■=" •= ■ GROUND
AUXILIARY FUEL TANK AND FUEL TANK SELECTOR SWITCH A-81
DIESEL ENGINE
CIRCUIT OPERATION WAIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME WHEN
ENGINE IS BELOW NORMAL OPERATING TEMPERATURE
The heating of the Glow Plugs is controlled by the After the initial time period the relay will de-energized for
five seconds then will cycle ON/OFF for approximately 10 TEST RESULT ACTION
Glow Plug Relay in the Glow Plug Controller. Battery
voltage is applied to the relay contacts through the RED seconds. NOTE: For 6.2L V8 diesel Test lamp lights. GO to step 2.
wire from the Junction Block. The relay is operated by engines, ground DK BLU/WHT
a Solid-State Controller. The Controller responds to When the Glow Plug Controller receives the Start (421) wire at cold advance glow
engine temperature and also to an Ignition Switch Start Input, the Glow Plugs and WAIT Indicator will cycle plug inhibit relay connector C108.
input. ON/OFF after the Ignition Switch is returned to RUN.
1. Place ignition switch in RUN Test lamp does not light. LOCATE and REPAIR open in RED
When the Ignition Switch is turned to RUN, battery After approximately 25 seconds the Controller will position. Connect test lamp from (2) wire and fusible link from glow
open the Glow Plug Relay and the heating of the plugs RED (2) wire at glow plug plug controller to junction block.
voltage is applied to the Enable Input of the Controller.
controller to ground.
The Glow Plug Relay within the Controller will be stops. If the engine is restarted while the engine is at
energized for approximately five seconds during which it normal operating temperature, the ECM will keep the 2. Connect a test lamp from LT Test lamp lights. GO to step 5.
applies voltage to the Glow Plugs and WAIT Indicator. relay contacts open so that no plug heating takes place. GRN/BLK (531) wire for 6.2L or
PNK (3) wire for 6.2L HD engines Test lamp does not light. GO to step 3 for 6.2L engines.
at glow plug controller connector
DIAGNOSIS - GLOW PLUGS C168 to ground. For 6.2L HD engines, LOCATE and
REPAIR open in PNK (3) wire from
glow plug controller to ignition
PRELIMINARY CHECKS: switch.
A check of the glow plug system should be Turn ignition switch to OFF and then momentarily to
performed before diagnostic procedures. START and return to RUN position. The WAIT indicator
should flash for approximately 25 seconds and then go 3. Connect a test lamp from each Test lamp lights. GO to step 4.
With engine below normal operating temperature, turn out. PNK/BLK (39) wire at cold
ignition switch to RUN. The WAIT indicator should light. advance glow plug inhibit relay Test lamp does not light. CHECK condition of GAGE/IDLE
After approximately 10 seconds, the WAIT indicator must With engine at normal temperature, turn ignition connector C108 to ground. fuse. If fuse is good, LOCATE and
begin to flash for an additional 10 seconds and then go switch to RUN. The WAIT indicator should not flash for REPAIR open in PNK/BLK (39) wire
an 6.2L engine, but should flash for an 6.2L HD engine. from inhibit relay to fuse block.
out.
4. Connect a 10 amp fused jumper Test lamp lights. CHECK for open in DK BLU/WHT
from DK BLU/WHT (421) wire at (421) wire from inhibit relay to
cold advance glow plug inhibit ECM. If wire is good, problem is
relay connector C167 to ground. with ECM. Refer to Section 6E in
Connect test lamp from LT the 1991 R/V, P Light Truck
GRN/BLK (531) wire at inhibit relay Service Manual.
connector C108 to ground.
Test lamp does not light. CHECK for open in LT GRN/BLK
(531) wire. If good, REPLACE cold
advance glow plug inhibit relay.
5. Connect a test lamp from LT Test lamp lights. GO to step 6.
GRN/BLK (531) wire for 6.2L
engines or PNK (3) wire for 6.2L Test lamp does not light. LOCATE and REPAIR open in BLK
HD engines to BLK (150) wire at (150) wire from glow plug
glow plug controller connector controller to ground terminal G110.
C168.

A-82 GLOW PLUGS

 WAIT INDICATOR STAYS ON OR FLASHES WHEN ENGINE IS AT NORMAL OPERATING
WAIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME WHEN TEMPERATURE AND IGNITION SWITCH IN RUN POSITION (6.2 L DIESEL ENGINE ONLY)
ENGINE IS BELOW NORMAL OPERATING TEMPERATURE ______________
TEST RESULT ACTION
TEST RESULT ACTION
1. Connect test lamp from each Test lamp lights. GO to step 2.
6. Connect test lamp from PPL/WHT Test lamp lights. GO to step 7. PNK/BLK (39) wire at cold
(806) wire at glow plug controller advance glow plug inhibit relay Test lamp does not light. CHECK condition of GAGE/IDLE
connector C168 to ground. Move Test lamp does not light. LOCATE and REPAIR open in connector C108 to ground. fuse. If fuse is good, LOCATE and
ignition switch to START position. PPL/WHT (806) wire from glow REPAIR open from inhibit relay to
plug controller to starter motor. fuse block.
7. Place ignition switch to OFF Test lamp lights. REPLACE glow plug controller. 2. Connect a fused jumper from DK Test lamp lights. CHECK for open in DK BLU/WHT
position. Connect test lamp from BLU/WHT (421) wire at cold (421) wire from inhibit relay to
ORN (503) wires at glow plug Test lamp does not light. GO to step 8. advance glow plug inhibit relay ECM. If wire is good, problem is
controller to ground. connector C108 to ground. with ECM. Refer to Section 6E in
Connect test lamp from LT 1991 R/V, P Light Truck Service
8. Disconnect glow plug controller Reading of 2 ohms or less. GO step 9.
GRN/BLK (531) wire at inhibit relay Manual.
connector C168. Using a positive connector C108 to ground.
polarity ohmmeter, check Reading greater than 2 ohms. LOCATE and REPAIR open in GRA
Test lamp does not light. REPLACE cold advance glow plug
continuity between ORN (503) or (503)and (509) wires from glow
plug controller connector C117 to inhibit relay.
(509) wires and BLK (150) wires.
glow plug harness splices S198
and S199.

9. Connect glow plug controller Test lamp cycles on and off for GO to step 11.
connector. Connect test lamp from approximately 25 seconds then
ORN (503) wires at glow plug goes off.
controller to connector C168 to
ground. Turn ignition switch Test lamp does not light or cycles REPLACE glow plug controller.
momentarily to START and then for the incorrect time.
release to RUN position.

10. Remove all connectors from glow Test lamp lights for all glow plugs. LOCATE and REPAIR open in ORN
plugs. Connect one lead of test (503) or ORN/BLK (509) wires and
lamp to battery voltage and other fusible links from glow plug to
lead to each glow plug. controller.

Test lamp does not light for one or REPLACE glow plug(s) where test
more glow plugs. lamp did not light.

GLOW PLUGS A-83

 3108
11-32.0 BLK I 906-1.0 P P Li

I 2-.Q BLK/RED ■ 2- 8 BLK/RED I

RIGHT BANK GLOW PLUGS

3-3.0 PNK I

FUEL SHUTOFF
+ - 1 + ~ SOLENOID

RH BATTERY LH BATTERY

FUSIBLE LINKS S198

509-5.0 ORN/BLKI H 509-2.0 GRA m
(FUSIBLE UNK)
■ i 503-2.0 GRA ■ ■
^ S199 FUSIBLE UNK)

FUSIBLE UNKS

S103

S197 503-1.0 ORN I

503-1.0 ORN I
LEFT BANK GLOW PLUGS

LEFT BANK SHEET RIGHT BANK 6-3.0 PPL I

GLOW PLUGS METAL GLOW PLUGS
GROUND GROUND GROUND 2-3.0 RED ■

G113 G111 G114 • ■ 12-3.0 RED 1

S106

A-84 GLOW PLUGS

 RPO CODES

1806-1.0 PPL/WHTl LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
COLD ADVANCE GLOW PLUG LH6 • ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
531-.8 LT GRN/BLX M20 • MAN TRANS, 4 SPD.
" TIMER INHIBIT RELAY
(LH6) (SEE PAGE 64)

COLD ADVANCE CONTROL

(LH6) (SEE PAGE 64)

CLUTCH START SWITCH

(M20 ONLY)
(SEE PAGE 56)

i/P
ENGINE GROUND GROUND (0 1
G110 G200 ^

GLOW PLUGS A-85

CIRCUIT OPERATION DIAGNOSIS —DIESEL ENGINE FUEL CONTROLS
The Diesel Fuel Filter System combines five functions the fuel. When the switch is closed, battery voltage is PRELIMINARY CHECKS:
into a single package: applied to the heater form the GAGE/IDLE Fuse. CHECK condition of GAGE/IDLE fuse. If fuse is If fuse is in good condition, use the following
blown, LOCATE and REPAIR source of overload, then diagnostic procedures.
1. Heats diesel fuel to prevent wax-plugging of the filter. The fuel then passes through the Primary and REPLACE fuse.
2. Combines very small droplets of water in the fuel into Secondary filters. Next the fuel flows through the water
FUEL HEATER DOES NOT OPERATE
larger drops and separates the water from the fuel. coalescer. Here the droplets of water in the fuel are
3. Filters the diesel fuel. combined into larger drops, the drops fall to the water TEST RESULT ACTION
4. Detects the presence of excess water in the fuel and reservoir in the filter. When the fuel flows from the Fuel
1. Disconnect fuel heater connector Battery voltage. GO to step 2.
5. Provides a means to drain the water it has separated. Filter Assembly to the injection pump, it is clean and free
C196. Place ignition switch to
of water. RUN position. Connect a No voltage. LOCATE and REPAIR open in
The Fuel Filter Assembly consists of the Fuel Heater, voltmeter from PNK/BLK (39) PNK/BLK (39) wire from fuel heater
the Water In Fuel Sensor and a Filter. The Filter contains The Solid-State Water In Fuel Sensor applies voltage wire at fuel heater connector to fuse block.
the "coalescer" (the device that combines small droplets to a Probe. When the Probe touches water, the Module C196 to ground.
of water into larger ones) and the filter/separator. closes a switch. This completes a circuit to ground to
light the SERVICE FUEL FILTER indicator. 2. Connect a voltmeter from Battery voltage. REPLACE fuel filter.
An electric fuel pump delivers diesel fuel from the tank PNK/BLK (39) wire to BLK (150)
wire at fuel heater connector No voltage. LOCATE and REPAIR open in BLK
to the fuel filter. As fuel enters the filter, it passes first A time delay circuit in the Water In Fuel Module
C196. (150) wire from fuel sensor to
through the Fuel Heater. The heater contains a grounds the indicator bulb briefly to test the bulb each ground terminal G110.
thermostatic switch. The switch opens or closes, to turn time the system is turned on.
the heater off or on, depending on the temperature of SERVICE FUEL FILTER INDICATOR DOES NOT LIGHT BRIEFLY WITH IGNITION SWITCH TURNED TO RUN
TEST RESULT ACTION
1. Disconnect water in fuel sensor Battery voltage. GO to step 2.
connector C197 and place ignition
switch in RUN. Connect a No voltage reading. LOCATE and REPAIR open in
voltmeter from PNK/BLK (39) PNK/BLK (39) wire from fuel'sensor
wire at fuel sensor connector to fuse block.
C197 to ground.
2. Connect a voltmeter from Battery voltage. GO to step 3.
PNK/BLK (39) to BLK (150) wire at
water in fuel sensor connector No voltage. LOCATE and REPAIR open in BLK
C197. (150) wire from fuel sensor to
ground terminal G110.
3. Connect a voltmeter from YEL Battery voltage. REPLACE fuel filter.
(508) wire at water in fuel sensor
connector C197 to ground. No voltage. CHECK Service Fuel Filter lamp. If
lamp is good, LOCATE and
REPAIR open in YEL (508) wire.

SERVICE FUEL FILTER INDICATOR LIGHTS WITH NO WATER IN FUEL

TEST RESULT ACTION
1. Place ignition switch in RUN SERVICE FUEL FILTER indicator LOCATE and REPAIR short to
position. Disconnect water in fuel stays on. ground in YEL (508) wire.
sensor connector C197.
SERVICE FUEL FILTER indicator REPLACE fuel filter.
goes out.

A-86 DIESEL ENGINE FUEL CONTROLS

yvw w w w vw /
< HOT IN START OR RUN ?

m w vvvw w w ^
39 COLD

I / . 534
ADVANCE
FAST IDLE
GAGE/IDLE TEMPERATURE
20 AMP * #1 B SWITCH
C102A
a 2977373
534-.S DK GRN I

39-. 8 PNK/BLK
FAST IDLE
EGR DUMP VALVE
SOLENOID (SEE PAGE 64)
C100A EGRVALVE
(SEE PAGE 6 4 )' 39-.8 PNK/BLK r . k M
COLD ADVANCE TIMER
EPR VALVE .
39- 8 p n k /b lk jm m '• b a 39-.s p n k /b lk
I RELAY (SEE PAGE 64)
|
(SEE PAGE 64) '

39" 8 PNKyBLKWr S | ^ 39 e PNK/BLK ^ GENERATOR

(SEE PAGE 12)

I V

i I
S I 22
(SEE PAGE 18)

I U
I
\ *
CD
CD
£ £
2
S202
WATER (SEE PAGE 27)
IN FUEL
n o
SENSOR

39- 8 PNK/BLK V
r §
z

I 150-.8 BLK ■ ■

139-.8 PNK/BLK J P
N
M
L
94
9
33
93
29
39
12
11
15
14

J
I
420 508 1508-.8 YEL

50

Inr
35 1
FUEL WATER IN FUEL
HEATER
18
24
120
30
9
19 ||
97 150
LAMP (SEE PAGE 105)

I 3-3.0 PNK I

C199 ENGINE
FUEL SHUTOFF
SOLENOID
12020274
(q\ GROUND C100
12020183
^ G110
DIESEL ENGINE FUEL CONTROLS A-87
6.2L V8 DIESEL ENGINE
 , HOT IN START OR RUN

GAGE/IDLE GENERATOR
20 AMP I _______ COLD (SEE PAGE 12)

COLD ADVANCE
FAST IDLE
SOLENOID
ADVANCE
CONTROL
FAST IDLE
TEMPERATURE r . i
SWITCH
(OPENS AS
TEMPERATURE A n B
INCREASES)
C198 z
2977373

C171
12004267

I 936-.8 LT GRN i

936-.0 LT GRN

S109
I 39-.8 PNK/BLK I

39 )

5 0 8 )
r
I
■ 39-.S PNK/BLK I

|
\
[
WATER m m 39-.8 p n k /b lk h f ^m m ^ m ^m m *m m ^m 39-.e p n k /b lk

IN FUEL
SENSOR \ S202
(SEE PAGE 27)

I
i RWAL
(SEE PAGE 116)
FUEL □
HEATER 39-.8 PNK/BLK

C196
12020397

39-.8 PNK/BLK ' m — W m m w ^

Q )

8 I2 503 31]
F * n * dl
13931 140
503 2
I 3-3.0 PNK | 420 140 39 jI 94 29 15 I

i
820 :
9 39 14 p i
■ | 508 440
Ui L 33 12 L 440 508
►
WATER IN FUEL
LAMP
68
■
I3 68
= U (t
: 93 11
i t
m 25
3 I
(SEE PAGE 105)
GLOW PLUG I 25 1 50

CONTROLLER I2
50
35 III 18 120
9 I
r
93
35
97
2
439 m • V 3 . 0 PNK
IGNITION
; SWITCH
: 24 30
I
| 439 97 93 | 191 91 92 6 S207 (SEE PAGE 13)

II 6 92 91 |
F\ (SEE PAGE 13)

a
ENGINE
GROUND
DM£ 3-3.0 PNK 1 2 3

12020183
G110 FUEL SHUTOFF SOLENOID 12020274 C100

A-88 DIESEL ENGINE FUEL CONTROLS

6.2L HD V8 DIESEL ENGINE
CIRCUIT OPERATION COOLING FAN RUNS CONTINUOUSLY
TEST RESULT ACTION
Battery voltage is applied to the Auxiliary Cooling Fan 107°C (225°F), the DK GRN (935) wire is grounded and
the Auxiliary Cooling Fan Relay energizes. Battery 1. Place ignition switch in RUN Auxiliary cooling fan runs. GO to step 2.
Relay at all times by the RED (2) wire and by the
position and with engine
PNK/BLK (39) wire through the GAGE/IDLE fuse, when voltage is applied across the Auxiliary Cooling Fan Motor
coolant temperature below Auxiliary cooling fan does no REPLACE auxiliary cooling fan
the Ignition Switch is in RUN or START. When the and the Auxiliary Cooling Fan runs. 107°C (225°F), disconnect run. temperature switch.
Auxiliary Cooling Fan Temperature Switch closes at auxiliary cooling fan
temperature switch connector
DIAGNOSIS - AUXILIARY COOLING FAN C170.

COOLING FAN DOES NOT RUN I. Disconnect auxiliary cooling Test lamp lights. CHECK for short in DK GRN (535)
fan relay connector C190. wire from fan relay to
TEST RESULT ACTION Connect a test lamp from auxiliary cooling fan
PNK/BLK (39) to DK GRN (535) temperature switch.
1. Disconnect auxiliary cooling fan Auxiliary cooling fan does not run. GO to step 2. wires at auxiliary cooling fan
temperature switch connector relay connector C190. Test lamp does not light. REPLACE auxiliary cooling fan
C170. Connect a fused jumper Auxiliary cooling fan runs. REPLACE auxiliary cooling fan relay.
from DK GRN (535) wire at temperature switch.
auxiliary cooling fan temperature
switch connector C170 to ground.

2. Disconnect auxiliary cooling fan Test lamp lights. GO to step 3.

relay connector C190. Connect
test lamp from PNK/BLK (39) wire Test lamp does not light. CHECK condition of fuse
at auxiliary cooling fan relay (GAGE/IDLE) and/or LOCATE and
connector C190 to ground. REPAIR open in PNK/BLK (39) wire
from auxiliary cooling fan relay to
fuse block.

3. Connect fused jumper from DK Test lamp lights. GO to step 4.

GRN (535) wire at auxiliary cooling
fan temperature switch connector Test lamp does not light. LOCATE and REPAIR open in DK
C170 to ground. Connect a test GRN (535) wire.
lamp from PNK/BLK (39) wire to
DK GRN (935) wire at auxiliary
cooling fan relay connector C190.
4. Connect a test lamp from RED (2) Test lamp lights. GO to step 5.
wire at auxiliary cooling fan relay
connector C190 to ground. Test lamp does not light. LOCATE and REPAIR open in RED
(2) wire and fusible link.

5. Connect a 30 amp fused jumper Auxiliary cooling fan does not run. GO to step 6.
from RED (2) wire to BLK/RED
(702) wire at auxiliary cooling fan Auxiliary cooling fan runs. REPLACE auxiliary cooling fan
relay connector C190. relay.

6. Leave 30 amp fused jumper Test lamp lights. GO to step 7.

connector. Disconnect auxiliary
cooling fan connector C191. Test lamp does not light. LOCATE and REPAIR open in
Connect a test lamp from BLK/RED (702) wires from auxiliary
BLK/RED (702) at auxiliary cooling cooling fan to auxiliary cooling fan
fan connector C191 to ground. relay.

7. Connect a test lamp from Test lamp lights. REPLACE auxiliary cooling fan.
BLK/RED (702) to BLK (151) wires
at auxiliary cooling fan connector Test lamp does not light. LOCATE and REPAIR open in BLK
C191. (151) wire from auxiliary cooling
fan to ground terminal G106.

AUXILIARY COOLING FAN A-89

7.4L V8 GASOLINE ENGINE
 .H O T IN S T A R T O R RUN

GAGE/IDLE
20 AMP

AUXILIARY COOLING FAN

TEMPERATURE SWITCH
(CLOSES WHEN COOLANT
TEMPERATURE EXCEEDS
2 2 5 °F (107°C) S i

I 2-.8 RST (FUSIBLE U NK)I S116

C193

a 1
UJ
CC

BATTERY JUNCTION
BLOCK

I 2*2.0 RED I C192 S202

12065171 12065172 (SEE PAGE 27)

935 I 935-.8 DK GRN I

AUXILIARY — r
COOLING l l 15 29 1 94 1 IP P—
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AUXILIARY m 436
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151-2.0 BLK I r 0 S 111 19
93 97 422

| (SEE PAGE 16) TT 91 92 6

V
151-3.0 BLK

C100
SHEET 12020184

METAL FRAME
GROUND GROUND
G106 G107
A-90 AUXILIARY COOLING FAN
7.4L V8 GASOLINE ENGINE
CIRCUIT OPERATION DIAGNOSIS - AIR CONDITIONING
BLOWER CONTROLS COMPRESSOR CONTROLS PRELIMINARY CHECKS:
Battery voltage is applied at all times to the HI Blower The Compressor for the A/C System is driven by the Outside temperature must be above 16°C (60°F) in order to properly diagnose system.
Relay, through the RED (2) wire. When the Blower engine by means of a belt drive and the A/C Compressor
A /C C O M P R E S SO R C LU TC H DO ES N O T ENGAGE
Switch is in the OFF, LO or MED positions, the HI Blower Clutch. The Clutch allows the Compressor to be
Relay is de-energized. disengaged when the A/C is not required.
TEST RESULT ACTION
With the Ignition Switch is in the RUN and ACC Operation of the Compressor depends on the 1. Place ignition switch in RUN, Battery voltage. GO to step 2.
position, voltage is supplied to the Selector Control by particular A/C Mode selected at the Heater and A/C selector control in MAX.
way of the BRN (50) wire through the HTR A/C Fuse. Controller. With A/C ON selected, battery voltage flows Connect voltmeter from BRN No voltage. LOCATE and REPAIR open in BRN
This voltage is supplied, through the Selector Control, through the Selector Control to the Evaporator Pressure (50) wire at selector control (50) wire from selector
and then through the BRN/WHT (64) wire to the Blower Control Switch by way of the LT GRN (66) wire. Voltage connector C233 to ground. control to fuse block. CHECK
Switch and Resistor Block. At the Resistor Block, voltage flows through the normally closed contacts of the HTR/AC fuse.
is dropped through three resistors. This reduced voltage Evaporator Pressure Control Switch to the A/C 2. Disconnect A/C compressor A/C clutch engages. GO to step 4.
flows through the DK BLU (101) wire to the de-energized, Compressor Clutch. The coil is energized and the A/C control switch connector C178
HI blower relay. Since the Hi blower relay is de­ Compressor Clutch engages. and place selector control to A/C clutch does not engage. CHECK for open A/C compressor
energized, circuits 101 and 65 are connected through MAX. Connect a fused jumper control switch. If A/C
the relay. This reduced voltage flows through the PPL If the refrigerant pressure drops to a point which may between LT GRN (66) wire and DK compressor control switch is
(65) wire to the Blower Motor and the Blower Motor will cause icing of the evaporator, the Evaporator Pressure GRN (59) wire at A/C open and refrigerant pressure
run at a slow speed. Control Switch opens, de-energizing the A/C Compressor compressor control switch is normal, REPLACE A/C
Clutch. When the refrigerant pressure rises to a point connector C178. compressor control switch.
When the Blower Switch is turned to LO, voltage flows where cooling is required again, the Evaporator Pressure 3. Connect voltmeter from DK GRN Battery voltage. GO to step 5.
through the Blower Switch, to the Resistor Block, through Control Switch closes to re-energize the A/C Compressor (59) wire at compressor clutch
the TAN (63) wire. Voltage flows through two resistors, Clutch. connector C165 to ground. No voltage. LOCATE and REPAIR open in DK
through the DK BLU (101) wire, through the contacts of GRN (59) wire from A/C
the de-energized HI Blower Relay to the Blower Motor by The A/C Compressor Clutch Diode is connected compressor clutch to A/C
way of the PPL (65) wire. across the terminals of the A/C Compressor Clutch. compressor control switch.
Whenever the clutch is de-energized, the magnetic field
4. Connect voltmeter from DK GRN Battery voltage. REPLACE A/C compressor clutch.
When the Blower Switch is turned to MED, voltage around it collapses, generating an induced voltage in the (59) wire to BLK (150) wire at
flows through the Blower Switch, to the Resistor Block, clutch coil. The Diode provides a path for the current A/C compressor clutch No voltage. LOCATE and REPAIR open in BLK
through the LT BLU (72) wire. Voltage flows through one resulting from the induced voltage so that other circuit connector C165. (150) wire from A/C compressor
resistor, through the DK BLU (101) wire, through the components are not damaged by it. clutch to ground terminal
contacts of the de-energized HI Blower Relay to the G110.
Blower Motor by way of the PPL (65) wire. REAR BLOWER CONTROL
Battery voltage is supplied to the Blower Switch
When the Blower is turn to HI, voltage flows through through the AUX HTR A/C Fuse and the BRN (50) wire.
the Blower Switch, to the HI Blower Relay, through the When the Blower Switch is turned to LO, voltage flows
ORN (52) wire. This voltage flows through the coil of the through the Blower Switch to the Resistors by way of the
HI Blower Relay. With the HI Blower Relay energized, YEL (51) wire. Voltage flows through two resistors,
battery voltage flows through the RED (2) wire, through through the ORN (52) wire to the Rear Blower Motor.
the contacts of the energized HI Blower Relay to the
Blower Motor by way of the PPL (65) wire. This allows When the Blower Switch is turned to HI, voltage flows
battery voltage to power the Blower Motor. through the Blower Switch directly to the Rear Blower
Motor through the ORN (52) wire.

AIR CONDITIONING A-91

 BLOWER MOTOR DOES NOT OPERATE IN ANY MODE BLOWER MOTOR DOES NOT OPERATE IN HI
TEST RESULT ACTION TEST RESULT ACTION

1. Place ignition switch to RUN, Battery voltage. REPLACE blower motor. 1. Place ignition switch to RUN, Battery voltage. GO to step 2.
selector control to VENT and selector control to VENT and
blower switch to HI. Disconnect No voltage. GO to step 2. blower switch to HI. Connect No voltage. LOCATE and REPAIR open in ORN
blower motor connector C180. voltmeter from ORN (52) wire (52) wire from HI blower relay
Connect voltmeter from PPL (65) at HI blower relay connector to blower switch.
wire at blower connector C180 to C177 to ground.
ground terminal G117.
2. Connect voltmeter to RED (2) Battery voltage. GO to step 3.
2. Connect voltmeter from BRN (50) Battery voltage. GO to step 3. wire at HI blower relay
wire at selector control connector connector C177 to ground. No voltage. LOCATE and REPAIR open in RED
C233 to ground. No voltage. CHECK condition of HTB/AC fuse. (2) wire or fusible link.
If fuse is good, LOCATE and
REPAIR open in BRN (50) wire 3. Connect voltmeter to RED (2) Battery voltage. REPLACE HI blower relay.
from selector control connector wire at HI blower relay
C233 to fuse block. connector C177 to BLK (150) No voltage. LOCATE and REPAIR open in BLK
wire. (150) wire to ground G115.
3. Connect voltmeter from BRN/WHT Battery voltage. GO to step 4.
(64) wire at blower switch
connector C234 to ground. No voltage. LOCATE and REPAIR open in BLOWER MOTOR DOES NOT OPERATE IN MED
BRN/WHT (64) wire between
blower switch connector C234 and TEST RESULT ACTION
selector switch connector C233. If
no open is found, REPLACE 1. Place blower switch to MED. Battery voltage. GO to step 2.
selector control. Connect voltmeter to LT BLU
(72) wire at blower switch No voltage. REPLACE blower switch.
4. Connect voltmeter from ORN (52) Battery voltage. GO to step 5. connector C234 to ground.
wire at HI blower relay connector
C177 to ground. No voltage. LOCATE and REPAIR open in ORN 2. Connect voltmeter to LT BLU Battery voltage. REPLACE blower resistor.
(52) wire between HI blower relay (72) wire at blower resistor
connector C177 and blower switch connector C179 to ground. No voltage. LOCATE and REPAIR open in LT
connector C234. If no open is BLU (72) wire between blower
found, REPLACE blower switch. resistor and blower switch.

5. Disconnect HI blower relay Battery voltage. GO to step 6.

connector C177. Connect BLOWER MOTOR DOES NOT OPERATE IN LO
voltmeter from ORN (52) wire at HI No voltage. LOCATE and REPAIR open in BLK
blower relay connector C177 to (150) wire between HI blower relay TEST RESULT ACTION
BLK (150) wire. connector C177 and ground
1. Place blower switch to LO. Battery voltage. GO to step 2.
terminal G115. Connect voltmeter to TAN (63)
6. Connect HI blower relay connector Battery voltage. LOCATE and REPAIR open in PPL wire at blower switch No voltage. REPLACE blower switch.
C177. Connect voltmeter from PPL (65) wire between HI blower relay connector C234 to ground.
(65) wire at HI blower relay connector C177 and blower motor Battery voltage.
2. Connect voltmeter to TAN (63) REPLACE blower resistor.
connector to ground. connector C180. wire at blower resistor
connector C179 to ground. No voltage. LOCATE and REPAIR open in TAN
No voltage. REPLACE HI blower relay. (63) wire between blower
resistor and blower switch.

A-92 AIR CONDITIONING

 DIAGNOSIS CHART - AIR CONDITIONING, REAR BLOWER MOTOR DOES NOT OPERATE IN LO BUT ONLY IN HI
PRELIMINARY CHECKS: TEST RESULT ACTION
CHECK condition of AUX HTR A/C fuse. If fuse is REPLACE fuse. If fuse is in good condition, use
1. Place blower switch in LO Test lamp lights. GO to step 2.
blown, LOCATE and REPAIR source of overload, then following diagnostic procedures.
position. Connect a test lamp
from YEL (51) LO wire at blower Test lamp does not light. REPLACE blower switch.
motor switch connector C281 to
BLOWER MOTOR DOES NOT OPERATE AT ALL ground.
TEST RESULT ACTION
2. Connect a test lamp from YEL Test lamp lights. GO to step 3.
1. Disconnect blower motor Test lamp lights. GO to step 2. (51) LO wire at blower
connector C410. Place resistor connector C181 to Test lamp does not light. LOCATE and REPAIR open in YEL
ignition switch in RUN Test lamp does not light. GO to step 3. ground. (51) wire from blower resistor
position. Connect a test lamp to blower switch.
from PPL (52) wire at blower
3. Connect a test lamp from ORN Test lamp lights. LOCATE and REPAIR open in ORN
motor connector C410 to
(52) wire at blower resistor (52) wire between blower
ground.
connector C181 to ground. resistor connector C181 and
2. Connect a test lamp from PPL Test lamp lights. REPLACE blower motor. splice S220. If no open is
(52) wire to BLK (2) wire at found, REPLACE resistor.
blower motor connector C410. Test lamp does not light. LOCATE and REPAIR open in
ground BLK (2) wire between
blower motor and ground
terminal G411.

3. Connect a test lamp from BRN Test lamp lights. GO to step 4.

(50) wire at blower switch
connector C281 to ground. Test lamp does not light. LOCATE and REPAIR open in BRN
(50) wire between blower
switch connector C281 and fuse
block connector C283. If no
open is found, CHECK AUX HTR
A/C fuse.

4. Place blower switch in LO or Test lamp does not light. REPLACE blower switch.
HI. Connect a test lamp from
blower switch connector C281 Test lamp lights. LOCATE and REPAIR open in wires
at wire that applies to to blower motor.
position of switch to ground.
LO is YEL (51) wire and HI is
ORN (52) wire.

BLOWER MOTOR DOES NOT OPERATE IN HI BUT ONLY IN LO

TEST RESULT ACTION

1. Connect a test lamp from ORN Test lamp lights. LOCATE and REPAIR open in ORN
(52) wire at blower switch (52) wire between blower
connector C281 to ground. switch connector C281 and
splice S220.

Test lamp does not light. REPLACE blower switch.

AIR CONDITIONING A-93

 50-5.0 BRN

f OFF
LO Q i
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SWITCH

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C281
12004101

S220
• ■■ 52-2.0 ORN m m m 52

2977253 C282
8900420
2977518
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RESISTOR GT103
8911215

REAR BLOWER
£ MOTOR
o
o

\Q) SHEET
■=■ METAL
GROUND
G405
AIR CONDITIONING A-95
REAR
CIRCUIT OPERATION BLOWER MOTOR DOES NOT OPERATE IN LO AND/OR MED BUT ONLY IN HI
TEST RESULT ACTION
FRONT HEATER AUXILIARY HEATER 1. Place blower switch in position Test lamp lights. GO to step 2.
The blower motor delivers air to the interior of the The Auxiliary Blower Motor delivers heated air to the where blower motor does not
vehicle. Its speed is controlled by the Blower Switch and rear of the vehicle. Its speed is controlled by a rear work. Connect a test lamp from Test lamp does not light. REPLACE blower switch.
Blower Resistors. When the Ignition Switch is placed in Blower Switch and Blower Resistors. When the Ignition either YEL (51) LO wire or LT BLU
RUN, battery voltage is applied to the Blower Switch Switch is placed in RUN, battery voltage is applied to the (72) MED wire (depending on
through the HTR A/C Fuse. With the Blower Switch in rear Blower Motor through the AUX HTR A/C Fuse. With switch position) at blower motor
LO, voltage is applied across both resistors to the Blower the rear Blower Switch in LO, a ground path through two switch connector C234 to ground.
Motor. With the Blower Switch in MED, voltage is applied resistors allows the voltage at the rear Blower Switch
2. Connect a test lamp from either Test lamp lights. REPLACE blower resistor.
across one resistor to the Blower Motor, and the Blower Motor to flow to ground. With the rear Blower in HI, a
YEL (51) LO wire or LT BLU (72)
runs faster. When the Blower Switch is in HI, battery ground path allows full voltage at the rear Blower Motor MED wire (depending on switch Test lamp does not light. LOCATE and REPAIR open in
voltage is applied directly to the Blower Motor and to flow to ground. position) at resistor blower wire(s) (51 or 72) from blower
Blower operates at its fastest speed. connector C183 to ground. resistor connector C183 to blower
switch connector C234.
DIAGNOSIS - FRONT HEATER
BLOWER MOTOR DOES NOT OPERATE AT ALL

TEST RESULT ACTION DIAGNOSIS - AUXILIARY HEATER

1. Check condition of HTR A/C fuse. Fuse is not blown. GO to step 2. AUXILIARY HEATER BLOWER MOTOR DOES NOT OPERATE AT ALL

Fuse is blown. LOCATE and REPAIR source of TEST RESULT ACTION

overload. Then, REPLACE fuse.
1. Check condition of AUX HTR A/C Fuse is not blown. GO to step 2.
2. Place ignition switch in RUN and Test lamp lights. CHECK blower motor screws for a fuse.
blower switch in HI. Disconnect good ground. If ok, REPLACE Fuse is blown. LOCATE and REPAIR source of
blower motor connector C180. blower motor. overload. Then, REPLACE fuse.
Connect a test lamp from ORN
Test lamp does not light. GO to step 3. 2. Place ignition switch in RUN and Test lamp lights. GO to step 3.
(52) wire at blower motor
connector C 180 to ground. blower switch in HI. Disconnect
blower motor connector C425. Test lamp does not light. LOCATE and REPAIR open in BRN
3. Connect a test lamp from BRN Test lamp lights. GO to step 4. Connect a test lamp from BRN (50) wire between blower motor
(50) wire at heater blower switch (50) wire to ground. connector C425 and fuse block
connector C234 to ground. Test lamp does not light. LOCATE and REPAIR open in BRN connector C285.
(50) wire between heater blower
3. Connect blower motor connector Test lamp lights. REPLACE blower motor.
switch connector C234 and fuse
C425. Connect a test lamp from
block.
BRN (50) wire at blower motor to Test lamp does not light. GO to step 4.
4. Place blower switch to LO, MED, Test lamp does not light. REPLACE blower switch. DK GRN (952) wire.
or HI. Connect a test lamp from
4. Connect a self-powered test lamp Test lamp lights. LOCATE and REPAIR open in DK
heater blower switch connector Test lamp lights. LOCATE and REPAIR open in
from DK GRN (952) wire at blower GRN (952) wire between blower
C234 at wire that applies to wires to blower motor between
switch connector C234 to BLK switch connector C284 and blower
position of switch to ground. LO is heater blower switch connector
(150) wire. motor connector C425.
YEL (51) wire, MED is LT BLU (72) C234 and blower resistor
wire, and HI is ORN (52) wire. connector C183.
Test lamp does not light. LOCATE and REPAIR open in BLK
(150) wire between blower switch
connector C284 and bus bar
BLOWER MOTOR DOES NOT OPERATE IN HI BUT ONLY IN LO AND/OR MED ground connector C296. If no
open is found, REPLACE blower
TEST RESULT ACTION switch.
1. Connect a test lamp from ORN Test lamp lights. GO to step 2.
(52) wire at blower switch
connector C234 to ground. Test lamp does not light. REPLACE blower switch.
2. Connect a test lamp from ORN Test lamp does not light. LOCATE and REPAIR open in ORN
(52) wire at resistor connector (52) wire from blower resistor
C183 to ground. connector C183 to blower switch
connector C234.

A-96 HEATER
 AUXILIARY HEATER BLOWER MOTOR DOES NOT OPERATE IN LO

TEST RESULT ACTION

1. Connect a self-powered test Test lamp lights. REPLACE blower resistor.

lamp from YEL (51) wire at
blower resistor connector Test lamp does not light. GO to step 2.
C426 to ground.
2. Connect a self-powered test Test lamp lights. LOCATE and REPAIR open in YEL
lamp from YEL (51) wire at (51) wire between blower
blower resistor connector resistor connector C426 and
C426 to BLK (150) wire. blower switch connector C284.

Test lamp does not light. REPLACE blower switch.

HEATER A-97
 RPO CODES

L05 - ENGINE, 5.7L (350 CIO) V8 GAS ENGINE, VIN K

L19 - ENGINE, 7.4L (454 CIO) V8 GAS ENGINE, VIN N

HOT IN RUN '

HTR A/C
25 AMP
I I 50-2.0 BRN I 50-2.0 BRN
H 53203

T I

X
t
05 a
° 5
T fi
ss \
DRAC
(SEE PAGE 75)

RESISTOR BLOWER
MOTOR
2

m CQ <3>

HEATER
si
C183
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2965010
BLOWER
El 52
OMEDO0FF SWITCH
C180
2977976
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GT104
8811217

52-2.0 ORN ■
51-2.0_YEL_|« | 51-2.0 YEL
52-2.0 ORN ■ 52-2.0 ORN 50-2.0 BRN

72-2.0 LT BLU 72-2.0 LT BLU

C235
12015952 12015987

A-98 HEATER
FRONT
 C311 51-2.0 YEL I

GT402
6268585 12015956

952-2.0 DK GRN

1 1 (M l
(A
0) | q>[
C312
50-2.0 BRN« I 50-2.0 BRN I 50 1 50 ]
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12004727 f
C425
2973781

BUS
BAR
EC
GROUND
G201
BLOWER
MOTOR

AUXILIARY HEATER A-99

CIRCUIT OPERATION DIAGNOSIS - INSTRUMENT PANEL: GAGES AND INDICATORS

FUEL GAGE PRELIMINARY CHECKS

The pointer of the Fuel Gage is moved by the directly and the other is grounded through the
magnetic fields of two coils. The coils are at right angles Temperature Sender. This has 55 ohms resistance at
Check condition of GAGE/IDLE fuse. If fuse is blown,
to each other. Battery voltage is applied to the E-coil 128°C (260°F) (hot coolant) and its resistance becomes
locate and repair source of overload, then replace fuse.
and the circuit divides at the opposite end of the coil. greater at low temperatures. It is approximately 1400
If fuse is in good condition, use the following diagnostic
One path continues to ground through the F-coil. ohms at 38°C (100°F). This causes the current through
procedures.
Another goes to ground through the variable resistor of the Sender and one coil to increase as the coolant
the Fuel Gage Sender. temperature increases. This moves the pointer.
FUEL G AG E IN D IC A TE S FU LL OR BEYOND AT A LL TIM E S
When the tank is low, the resistance of the Sender is TEST RESULT ACTION
low. A large flow of current passes through the E-coil VOLTMETER
and the Fuel Gage Sender resistor. This moves the The Voltmeter measures the electrical system’s 1. Disconnect fuel sender Fuel gage indicates full. LOCATE and REPAIR a short in
pointer toward E on the scale. When the tank is full, the voltage with the Ignition Switch in RUN or START. With connector C409 and place PNK (30) wire. If no short is
Sender resistance is high. More current now flows the engine stopped, the Voltmeter indicates Battery ignition switch to RUN. found, REPLACE fuel gage.
through the F-coil, moving the pointer toward F on the Connect a fused jumper from
condition. With the engine running, the Voltmeter
PNK (30) wire at fuel tank Fuel gage indicates empty. CHECK fuel gage ground. If
scale. indicates Charging System operation.
sender connector C409 to ground is good, REPAIR/REPLACE
ground. fuel gage sender.
With two coils operating the pointer, the Gage is not LOW COOLANT INDICATOR
affected by changes in the system’s battery voltage. The Low Coolant Indicator comes on to warn the
driver when a low level of coolant exists in the radiator.
OIL PRESSURE GAGE Battery voltage is applied to the Low Coolant Module. FUEL GAGE INDICATES EMPTY WHEN THERE IS FUEL IN THE TANK
The engine oil pressure is displayed by the Oil When a low coolant condition exists, a signal is sent to TEST RESULT ACTION
Pressure Gage. The pointer of the Gage is moved by the Low Coolant Module from the Low Coolant Sensor.
two coils, and its operation is similar to that of the Fuel The Low Coolant Module will provide a ground to the 1. Disconnect fuel tank sender Fuel gage indicates full. CHECK fuse gage ground. If
Gage. Low Coolant Indicator. connector C409 and place ignition ground is good, REPAIR/REPLACE
switch to RUN. fuel gage sender.
The Oil Pressure Sender is connected to the junction The Low Coolant Sensor is not a switch that opens
Fuel gage indicates empty. LOCATE and REPAIR a short in
of the two coils. It has low resistance when the oil and closes. It has a very high resistance to ground, more
PNK (30) wire. If no short is found,
pressure is low, and 90 ohms resistance when the oil than 50,000 ohms, when the engine coolant level is low. REPLACE fuel gage.
pressure is high. This changing resistance changes the This causes the Low Coolant Module to light the Low
current flow through the coils. The magnetic fields of the Coolant Indicator. With more of the Sensor covered by
coils move the pointer from low to high. coolant, its resistance decreases. When the fluid level is
good, the resistance will be less than 10,000 ohms. With FU EL G AG E IS INACCURATE
TEMPERATURE GAGE the Sensor resistance between 10,000 and 50,000 ohms, TEST RESULT ACTION
The Temperature Gage is also operated by two coils. the Sensor is partly covered and the fluid is not low
Battery voltage is applied to both coils. One is grounded enough to cause the warning to be displayed. 1. Disconnect fuel tank sender Gage responds correctly. CHECK fuel tank ground wire for
connector C409. Connect one high resistance. If ground is
RED lead of Tester J 33431-B to good, REPAIR/REPLACE fuel gage
PNK (30) wire and other to sender.
ground. Set resistance dials
to 0 ohms and then to 90 ohms. Gage does not respond CHECK for high resistance in
Fuel gage should indicate correctly. PNK (30) wire. If wire is good,
empty and then full. (Allow REPLACE fuel gage.
time for gage to reach full due
to anti-slosh device.)

A-100 INSTRUMENT PANEL

GAGES AND INDICATORS
 TEMPERATURE GAGE INDICATES HOT WITH ENGINE COOLANT OIL PRESSURE GAGE INDICATES HIGH PRESSURE AT ALL TIMES
BELOW OPERATING TEMPERATURE AND IGNITION SWITCH IN RUN
TEST RESULT ACTION
TEST RESULT ACTION
1. Disconnect oil pressure Oil pressure gage indicates REPLACE oil pressure sender.
Disconnect temperature sender Temperature gage indicates cold. REPLACE temperature sender. sender connector C115 low pressure.
connector C107 and place ignition (Gasoline) or C116 (Diesel)
Temperature gage does not LOCATE and REPAIR a short in
switch to RUN. and place ignition switch to Oil pressure gage indicates LOCATE and REPAIR open in TAN
indicate cold. DK GRN (35) wire. If no short is
found, PERFORM diagnostic RUN. Connect a fused jumper high pressure. (31) wire. If wire is good,
procedures under symptom from TAN (31) wire at oil REPLACE oil pressure gage.
“Temperature Gage Is Not pressure sender connector
Accurate.” C115 (Gasoline) or C116
(Diesel) to ground.

TEMPERATURE GAGE INDICATES COLD ALL THE TIME

TEST RESULT ACTION OIL PRESSURE GAGE IS NOT ACCURATE
1. Disconnect temperature sender Temperature gage indicates REPLACE temperature sender. TEST RESULT ACTION
connector C107. Ground the DK hot. Oil pressure gage indicates REPLACE oil pressure sender.
1. Disconnect oil pressure
GRN (35) wire at temperature LOCATE and REPAIR open in DK correctly.
sender connector C115
sender connector C107. Temperature gage does not GRN (35) wire. If wire is good, (Gasoline) or C116 (Diesel).
indicate hot. REPLACE temperature gage. Oil pressure gage does not LOCATE and REPAIR open in TAN
Connect one RED lead of
J33431-B tester to TAN (31) indicate correctly. (31) wire. If wire is good,
wire at oil pressure sender REPLACE oil pressure gage.
TEMPERATURE GAGE IS NOT ACCURATE connector C115 (Gasoline) or
C116 (Diesel) and other lead
TEST RESULT ACTION to ground. Set resistance
dials to 0 ohms and then to 90
Disconnect temperature sender Gage indicates correctly. REPLACE temperature sender.
ohms. The oil pressure gage
connector C107. Connect red lead Gage is not correct. LOCATE and REPAIR open in DK should indicate low pressure
from J 33431 -B tester to DK GRN GRN (35) wire. If wire is good, and then high pressure.
(35) wire and other lead to ground. REPLACE temperature gage.
Adjust resistance dials to 1400
ohms and then to 55 ohms.
Temperature gage should indicate VOLTMETER IS NOT ACCURATE
cold then hot.
TEST RESULT ACTION
Place ignition switch to RUN Voltage reading is same as Voltmeter is good.
position. Connect a voltmeter vehicle’s voltmeter.
OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN 0 L PRESSURE IS GOOD
between positive and negative LOCATE and REPAIR open in
RESULT ACTION Voltage reading is different from
TEST terminals of the battery.
vehicle’s voltmeter. PNK/BLK (39) wire and BLK (150)
1. Disconnect oil pressure Oil pressure gage indicates REPLACE oil pressure sender. wire at instrument cluster. If wires
sender connector C115 high pressure. are good, REPLACE voltmeter.
(Gasoline) or C116 (Diesel)
and place ignition switch to Oil pressure gage indicates no LOCATE and REPAIR short TAN
RUN. or low pressure. (31) wire. If wire is good,
REPLACE oil pressure gage.

INSTRUMENT PANEL A-101

GAGES AND INDICATORS
 SPEEDOMETER IS INOPERATIVE OR INACCURATE
TEST RESULT ACTION
1. Disconnect instrument cluster Battery voltage. GO to step 2.
connector C203 and place
ignition switch to RUN. No voltage. CHECK condition of HTR A/C
Connect voltmeter from LT fuse. If fuse is good, LOCATE
BLU/BLK (824) wire at and REPAIR open in LT BLU/BLK
instrument cluster connector (824) wire.
C203 to ground.

2. Connect voltmeter from LT Battery voltage. REFER to speed sensor in

BLU/BLK (824) wire to BLK Emissions Manual (Gasoline) or
(150) wire at instrument Service Manual (Diesel) for
cluster connector C203. further diagnosing.

No voltage. LOCATE and REPAIR open in BLK

(150) wire from instrument
cluster to ground.

LOW COOLANT INDICATOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLY)
TEST RESULT ACTION
1 . Disconnect low coolant probe Low coolant indicator lights. REPLACE low coolant probe.
connector C186 and place ignition
Low coolant indicator does not
switch to RUN. Observe low
light. GO to step 2.
coolant indicator light.
2. Disconnect low coolant module Battery voltage. GO to step 3.
connector C225. Connect
No voltage. LOCATE and REPAIR open in
voltmeter from PNK/BLK (39) wire
PNK/BLK (39) wire.
at low coolant module connector
C225 to ground.
3. Connect voltmeter from PNK/BLK Battery voltage. GO to step 4.
(39) wire to BLK (150) wire at low
No voltage. LOCATE and REPAIR open in BLK
coolant module connector C225.
(150) wire.
4. Connect voltmeter from GRA (69) Battery voltage. GO to step 5.
wire at low coolant module
No voltage. LOCATE and REPAIR open or
connector C225 to ground.
short to ground in GRA (69) wire
going from low coolant module to
low coolant indicator lamp.
5. Connect voltmeter from PNK/BLK Battery voltage. LOCATE and REPAIR short to
(39) wire to YEL/BLK (68) wire at ground in YEL/BLK (68) wire from
low coolant module connector low coolant module to low coolant
C225. probe.
No voltage. REPLACE low coolant module.

LOW COOLANT INDICATOR IS LIT WHEN COOLANT LEVEL IS GOOD

TEST RESULT ACTION
Connect a fused jumper from low Low coolant indicator goes out. REPLACE low coolant probe.
coolant probe connector C186 to
Low coolant indicator stays lit. LOCATE and REPAIR open in
ground. Place ignition switch to
YEL/BLK (68) wire. If wire is good,
RUN and observe low coolant
follow diagnostic procedures listed
indicator light.
under symptom “ Low Coolant
Indicator Does Not Light With
Coolant Level Low.”

A-102 INSTRUMENT PANEL

GAGES AND INDICATORS
ILLUM ILLUM ILLUM ILLUM ILLUM L05 - ENGINE, 5.7L (350 CIO) V8 GAS ENGINE, VIN K
L19 - ENGINE, 7.4L (464 CIO) V8 GAS ENGINE, VIN N
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
0 <0 0 0 0 LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE

FIBER OPTIC
CABLE

ASHTRAY
ILLUMINATION

CANADIAN
DAYTIME
RUNNING

INSTRUMENT CLUSTER A-103

 GLOW PLUG RELAY
AND CONTROLLER
(LL4, LH6)
(SEE PAGE 04)

LOW COOLANT
SENSOR (LL4)
(SEE PAGE 106)

I 33-.5 TAN/WHT 4

A-104 INDICATOR LAMPS

SUBURBAN/UTILITY
 419-.0 BRN/WHTl

I 33-. 5 TAN/WHT |

A-106 INDICATOR LAMPS

FLEETSIDE, WIDESIDE, CREW-BONUS CAB
 RPO CODES
wvwwwwww/
S HOT IN START OR RUN < L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
L19 - ENGINE, 7.4L (454 CID) V0 GAS ENGINE, VIN N
Ivw w w W V W V ^ A LL4 - ENGINE, 6.2L (378 CID) V0 HD DIESEL ENGINE, VIN J
LH6 - ENGINE, 6.2L (378 CID) V0 DIESEL ENGINE, VIN C
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
GAGE/IDLE MT1 - AUTO TRANS, HD 4-SPD., WfTH OVERDRIVE

20 AMP

12064770

135- 8 DKGRN

COOLANT
TEMPERATURE C107
SENDER 12015306

120
31

FUEL PUMP
OIL PRESSURE
t 440
31-.8 TAN

SWITCH
(L05, L19)

31-.5 TAN (LL4 WITH MT1)

OIL PRESSURE C116

SENDER 2977935
(LH6, LL4)

FUEL TANK
SENDER
(LH6, LL4)

I30-.BPNK

BUS BAR
GROUND
FRAME
G200
GROUND

G409
A-108 INSTRUMENT PANEL GAGES
SUBURBAN/UTILITY
 RPO CODES
VAAMiWvM/WVW
< HOT IN START OR RUN ? L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
L19 - ENGINE, 7.4L (454 CIO) V8 GAS ENGINE, VIN N
W vw w vw w ^ LL4 - ENGINE, 8.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C

GAGE/IDLE
20 AMP 39-.8 PNK/BLK T
S202
(SEE PAGE 27)

I 3 9-5 PNK/BLK V

\ DRAC
(SEE PAGE 75)
35-.8 DK GRN

COOLANT
C183
TEMPERATURE 12052644
SENDER

l/P CLUSTER
CONNECTOR
(SEE PAGE 103)

31-.5 T A N i

31-.8 TAN
FUEL PUMP
OIL PRESSURE
SWITCH
(L05, L19)

131-.8 TAN ■ ■ ■■■

31-.5 TAN (LL4 WITH MT1)

S201
OIL PRESSURE C185
(SEE PAGES 17, 19)

SENDER 2977935
(LH6, LL4)

■35-5 DK GRN1

ECM/PCM 20-1.0 TAN/WHT1 • S139

120-1.0 TAN/WHT ELECTRIC FUEL PUMP
(SEE PAGE 60) (SEE PAGE i FUEL GAGE SENDING UNIT
C 30 ) (L05, L19)

FUEL TANK
SENDER
(LH6, LL4)

30-.8 PNK I 130-.8 PNK I m tm t 30-.8 PNK ■ ■ w M

I 30-.5 PNK
BUS BAR
GROUND
FRAME
G200
GROUND ( Q
G409 -= r

INSTRUMENT PANEL GAGES A-109

FLEETSIDE
 HEATER A/C
CONTROL ASSEMBLY
INSTR LPS
5 AMP * LAMP

RADIO l/P CLUSTER

(SEE PAGES 144, 145) CONNECTOR
C203
12026261

GROUND
G200

A-110 INSTRUMENT PANEL LAMPS

 T H E S A F E T Y BELT W A R N IN G B U ZZER DO ES N O T O P ER A TE
CIRCUIT OPERATION
TEST RESULT ACTION
SAFETY BELT WARNING BUZZER 1. Connect test lamp from PNK/BLK Test lamplights. GO to step 2.
(39) wire at convenience center to
Test lamp does not light. CHECK condition of the
With the Ignition Switch in RUN or START, voltage is panel dimmer switch is not in the dimmest setting, ground.
GAGE/IDLE fuse. If fuse is not
applied through the GAGE/IDLE Fuse to the Audio Alarm voltage is applied through the INSTR LPS fuse to the blown, LOCATE and REPAIR open
at the Convenience Center. With the driver’s safety belt audio alarm module through the GRA (8) wire. With the in PNK/BLK (39) wire from
not buckled, terminal 39 of the Audio Alarm is grounded panel dimmer switch at its dimmest setting the voltage convenience center to fuse block.
through the Safety Belt Switch. The Fasten Belts may not be enough to activate the alarm. When the 2. Connect test lamp from WHT (238) Test lamp lights. GO to step 3.
Indicators always goes on for about five seconds when ignition switch is in RUN or START, voltage is applied wire and BLK (150) wire at
the Ignition Switch is turned to RUN or START. through the GAGE/IDLE fuse and the PNK/BLK (39) wire. Test lamp does not light. LOCATE and REPAIR open in BLK
convenience center.
These two voltage are sensed and the alarm is not (150) wire from convenience
center to bus bar ground.
IGNITION KEY WARNING BUZZER sounded.
3. Connect test lamp from WHT (238) Test lamplights. GO to step 4.
The alarm is activated when the ignition switch is wire at safety belt retractor switch
Whenever the key is in the ignition switch, the ignition Test lamp does not light. LOCATE and REPAIR open in
turned to LOCK, OFF, or ACC, the GAGE/IDLE fuse loses connector C306 to ground.
switch is in LOCK, OFF, or ACC and the driver’s door is WHT (238) wire from safety belt
open, terminal 80 or the audio alarm is grounded. This voltage. The audio alarm module senses this loss of retractor switch to convenience
sounds the buzzer. voltage and activates the alarm. If voltage is still center.
available from the INSTR LPS fuse. Voltage from the 4. Buckle safety belt. Connect test Test lamp lights. LOCATE and REPAIR open in BLK
LAM PS-ON WARNING BUZZER STOP HAZ fuse is applied to sound the alarm. The lamp from BLK (150) wire at safety (150) wire from safety belt retractor
alarm can be turned off by turning off the light switch. belt retractor switch connector switch to bus bar ground.
C306 to ground.
When the light switch is in HEAD or PARK and the Test lamp does not light. REPLACE safety belt retractor
switch.
DIAGNOSIS -- AUDIO ALARMS
TH E S A F E T Y B E LT W A R N IN G B UZZER O P E R A TE S W H EN S A FE T Y BELT IS BUC KLED
KEY-IN WARNING ALARM DOES NOT OPE RATE
TEST RESULT ACTION TEST RESULT ACTION

1. Turn ignition switch OFF. Leave Test lamp lights. GO to step 2. Disconnect safety belt retractor Safety belt buzzer stops. REPLACE safety belt retractor
key in ignition switch. Open left switch connector C306. switch.
door. Remove audio alarm Test lamp does not light. CHECK STOP/HAZ fuse. If fuse is Safety belt buzzer continues. CHECK for a short from WHT (238)
module. Connect a voltmeter from good, REPAIR open in ORN (140) wire to ground. REPAIR as
ORN (140) wire at convenience wire. Install audio alarm module. required.
center to ground.

2. Connect a self-powered test lamp Test lamp lights. REPLACE audio alarm module. LAMPS-0 J WARNING ALARM DOES NOT OPERATE
form LT GRN (80) at convenience TEST RESULT ACTION
center to ground. Test lamp does not light. GO to step 3.
1. Remove audio alarm module. Battery voltage. GO to step 2.
3. Connect a self-powered test lamp Test lamp lights. LOCATE and REPAIR open in LT Turn ignition switch to RUN.
from LT GRN (80) wire at turn GRN (80) wire from turn signal Turn lamps switch ON. Connect No voltage. CHECK GAGE/IDLE fuse. If fuse
signal switch connector C205 to switch connector C205 to voltmeter from PNK/BLK (39) is good, LOCATE and REPAIR open
ground. convenience center. Install audio wire at convenience center to in PNK/BLK (29) wire.
alarm module. ground.

Test lamp does not light. GO to step 4. 2. Connect voltmeter from GRA (8) Battery voltage. GO to step 3.
wire at convenience center to
4. Connect a self-powered test lamp Test lamp lights. REPLACE turn signal switch, ground. No voltage. LOCATE and REPAIR open in GRA
from TAN (159) wire at turn signal INSTALL audio alarm module. (8) wire.
switch connector C205 to ground.
Test does not light GO to step 5. 3. Connect ohmmeter from BLK Low resistance. REPLACE audio alarm module.
(150) wire at convenience
5. Connect a self-powered test lamp Test lamp lights. LOCATE and REPAIR open in TAN center to ground. High resistance. LOCATE and REPAIR cause of high
from TAN (159) wire at LH jamb (159) wire between LH door jamb resistance in BLK (150) wire.
switch connector C208 to ground. switch connector C208 and turn
signal switch connector C205.
INSTALL audio alarm module.

Test lamp does not light. REPLACE LH door jamb switch.

INSTALL audio alarm module.

AUDIO ALARM A-111

 RPO COOES

LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J

LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
L05 - ENGINE, 5.7L (454 CID) V8 GAS ENGINE, VIN K
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE

GAGE/IDLE CONVENIENCE
20 AMP CENTER

SAFETY BELT
RETRACTOR
SWITCH
(OPEN WHEN
SEAT BELT 55
CD
|5
ENGAGED)
co o

£ i

t
T
238
150
T“
]
C306
JJ
8911773 8911772
I 39-.8 PNK/BLK I U39-,8 PNK/BLK
i/p
CLUSTER ^ r
CONNECTOR
(SEE PAGE 105) 39-.8 PNK/BLK
I 39-.8 PNK/BLK |

^ ■ r S202
39-.8 PNK/BLK ■

WATER IN FUEL '/fils

FILTER LAMP .. } 39-.8 PNK/BLK I 39-.8 PNK/BLK
(SEE PAGE 105)
(RPO LH6, LL4)
LOW
COOLANT
WARNING
MODULE
(SEE PAGE 104)
I 39- 8 PNK/BLK |
J If 39*.8 PNK/BLK I

L 39-.8 PNK/BLK I

BUS
BAR
GROUND
G200

A-112 SAFETY BELT WARNING BUZZER

 RPO CODES

yvw w w w w f
LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
S HOT AT ALL TIMES < S HOT IN START OH RUN ^
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
TVWWWVWV'A m vw w w w m HORN/DM MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE

20 AMP a 240-1.0 ORN

INSTR LPS STOP HA2 GAGE/IDLE
5 AMP 15 AMP 20 AMP
L
[
140-.8 ORN I
HORN RELAY

140-.8 ORN I S210

SAFETY BELT SW -2 3 8
CONVENIENCE
CENTER
I 140-.8 ORN

I 80-.5 LT GRN I
L 14O-.0 ORN I RWAL MODULE
(SEE PAGE 116)

GROUND

FASTEN BELTS
-150
-2 3 7 o m 8 140 80

IGNITION - 39 I 39-.8 PNK/BLK I

238 150 237 39
IGN KEY SW -8 0
S202
BATTERY -1 4 0
(SEE PAGE 27)
LIGHTS ON SW - 8

-2 7
-1 4 0
r a °
HAZARD FLASH o i —I
HZ/F 2 “
z
cc

l
HORN O
AUDIO ALARM RELAY

% r
FRONT
<3
in
cb 3
CD
l/P CLUSTER
237-.8 Y E L I CONNECTOR
(SEE PAGE 105)

240-1.0 ORN I

S201
I 8-.5 GRA I S209 (SEE PAGES 17, 19)
y -f
17 -------.8 WHT -
19 ---- 8 DKGRN
18 ------- .8 YEL -
16 ------- .8 PPL -
RADIO 27 ------- .8 BRN -
(SEE PAGES 144, 145)
I S-.5 GRA I 3
cn 15 — .8 DK BLU
o
S
-.8LTBLU

l/P CLUSTER 28
CONNECTOR l 8 .5 GRA i

r
(SEE PAGE 105) 159-.8 TAN 159

HEATER, A/C
CONTROL ASSEMBLY
LAMPS (SEE PAGE 110)
8-.5 GRA I 0 TURN
LH DOOR SIGNAL
JAMB
BUS BAR SWITCH SWITCH
GROUND (SEE PAGE 118

G200 a
KEY-IN AND LIGHTS-ON WARNING BUZZER A-113
CIRCUIT OPERATION BRAKE INDICATOR DOES NOT LIGHT DURING A WARNING CONDITION
OR DURING THE ANTILOCK SYSTEM CHECK
Battery voltage is applied to the Brake Indicator when Indicator when there is low brake fluid pressure in one of
the Ignition Switch is in RUN or START. Two switches the two hydraulic brake systems. This could be caused TEST RESULT ACTION
are connected to the Brake Indicator. When either of by a leak in one of the brake lines. Refer to Section 5 in
these two switches close, ground is provided and the the 1991 R/V,P Light Truck Service Manual for Switch 1. Disconnect park brake switch Brake indicator lamp does GO to step 2.
indicator lights. The Brake Indicator is also connected to reset procedures. This can only be accomplished after connector C293. Connect a light.
the Electronic Rear Wheel Brake Control Module. the faulty system has been repaired. fused jumper from park brake CHECK adjustment of park brake
switch connector C293 to Brake indicator lamp lights. switch. If adjustment cannot
ground. be corrected, REPLACE brake
The Park Brake Warning Switch provides a ground The Electronic Rear Wheel Brake Control Module
switch.
when the Parking Brake is applied. The Park Brake grounds the Brake Indicator when the module senses a
Indicator lights to alert the driver. fault in the Antilock Brake System. For Electronic Rear 2. Disconnect brake pressure Brake indicator lamp does not GO to step 3.
Wheel Brake Control Diagnosis, refer to Section 5A in the warning switch connector light.
The Brake Pressure Switch closes to light the Brake 1991 R/V,P Light Truck Service Manual. C104. Connect a fused jumper
from TAN/WHT (33) wire at Brake indicator lamp lights. REPLACE brake pressure warning
brake pressure warning switch switch.
connector C 104 to ground.
DIAGNOSIS - BRAKE SYSTEMS
3. Disconnect electronic rear Brake indicator lamp does not CHECK wiring and in-line diode
BRAKE INDICATOR REMAINS ON WITH IGNITION SWITCH IN RUN AND PARK BRAKE OFF wheel brake control module light. (if equipped) between
connector C103. Connect a instrument cluster and each
TEST RESULT ACTION fused jumper from TAN/WHT (33) switch and module for an open.
wire at antilock module If wiring is good, the problem
1. Disconnect park brake switch Brake indictor lamp does not go GO to step 2.
connector C103 to ground. is in the instrument cluster.
connector C293. out.
Brake indicator lamp lights. CHECK for an inoperative
Brake indicator lamp goes out. CHECK adjustment of park brake
switch. If adjustment cannot be antilock brake system. Refer
corrected, REPLACE brake switch. to Section 5A of the 1991 R/V,
P Light Truck Service Manual
2. Disconnect brake pressure Brake indicator lamp does not go GO to step 3 if not equipped with for a diagnostic circuit
warning switch connector C104. out. Electronic Rear Wheel Brake check.
Control.

GO to step 4 is equipped with

Electronic Rear Wheel Brake
Control.

Brake indictor lamp goes out. CHECK for a possible leak or loss
of fluid in the brake system.

3. Connect a self-powered test lamp Test lamp lights. LOCATE and REPAIR short in
from TAN/WHT (33) wire at park TAN/WHT (33) wire.
brake warning switch C293 to
ground. Test lamp does not light. CHECK instrument cluster and
indicator lamp.

4. Disconnect Electronic Rear Wheel Brake indicator lamp does not go CHECK wiring between instrument
Brake Control module connector out. cluster and each switch and
C103. module for a short to ground. If
wiring is good, the problem is in
the instrument cluster.

Brake indicator lamp goes out. CHECK for an inoperative antilock

brake system. Refer to Section 5A
of the 1991 R/V, P Light Truck
Service Manual for a diagnostic
circuit check.

A-114 BRAKE WARNING SYSTEM

 [ 300 } A
[ BL_g_J f j [~36l p c
oldD 133-. 5 TAN/WHT |

C210 33-.5 TAN/WHT |

6294641

IGNITION SWITCH

S219

l/P
l\
Z
<
ID

: 94 29 15
420 440 2
439 806 39
9 39 14
.mI1—
± L —i 33 12 J L 140 120
I3 3 -.5 TAN/WHT I
115 !291941 31 3
93 11
1141391 9 I 50 436

\ l l r t 2 l3 3 | r 35 2
18 120 9
111 193 il
II : 24 30 19
93 97 422 :
91 92 6
C102
12020100

I 33-.S TAN/WHT I

PARK BRAKE
WARNING SWITCH
BRAKE SET
(CLOSED WITH

C° PARK BRAKE
APPLIED)

BRAKE I 33-.5 TAN/WHT I

PRESSURE
C293
WARNING 12004267
= SWITCH

BRAKE WARNING SYSTEM A-115

WITH RWAL
 VsMMA/WV/WW yw vw w w w w
S HOT AT ALL TIMES < > HOT IN ACCY OR RUN <
>VVV\VVVVVW'i ^W vvw vw w w vA
ECM 1
10 AMP

RWAL
CONTROLLER

ANTILOCK ENGINE
BRAKE VALVE (Q ) GROUND
G110
A-116 REAR WHEEL ANTILOCK BRAKES
CIRCUIT OPERATION DOME LAMP DOES NOT WORK OR STAYS ON ALL THE TIME
TEST RESULT ACTION
COURTESY DOME, VANITY, l/P CARGO LAMP 1. Connect a test lamp from ORN Test lamp lights. GO to step 2.
COMPARTMENT BOX, CARGO AND Voltage is applied at all times through the HORN/DM (40) wire at both dome lamps to
UNDERHOOD LAMPS Fuse to the Cargo Lamp Switch. When the Cargo Lamp ground. Test lamp does not light. LOCATE and REPAIR open in ORN
Voltage is applied at all times from the T/L CTSY Fuse Switch is turned on, voltage flows through the switch to (40) wire.
to the Courtesy Lamp, Dome Lamp, l/P Compartment the Lamp. On models with a tailgate, a ground path is
2. Open both doors and turn panel Test lamp lights. REPLACE bulb if dome lamp did
Box Lamp and Vanity Lamps. The Courtesy and Dome provided when the tailgate is opened.
lamp switch to ON. Connect a not work. If dome lamp stayed ON
Lamps turn on when a ground path is provided by the test lamp from ORN (40) wire to all the time, GO to step 3.
Panel Dimmer Switch or one of the Door Jamb Switches. UNDERHOOD LAMP WHT (156) wire at dome lamp.
Voltage is applied at all times to the Underhood Lamp Test lamp does not light GO to step 3.
The l/P Compartment Box and Vanity Lamps have from the Junction Block, through an in-line fuse. When
the switch is closed a ground path is provided. 3. Disconnect jamb switch Correct readings. GO to step 4.
their own switches that provide ground paths when their
connectors. Connect an
switches close.
ohmmeter from WHT (156) Incorrect readings. REPLACE jamb switch(es) that
terminal to BLK (150) terminal at have incorrect reading.
DIAGNOSIS - INTERIOR LAMPS jamb switch. Take a reading with
PRELIMINARY CHECKS: door open and a reading with
Checks condition of T/L CTSY fuse. If fuse is good, door closed. With door open
reading must be 0 ohms and door
refer to appropriate diagnostic procedure.
closed, infinite ohms.

c o u RTESY LA M P S D O N O T OPERA1rE 4. Disconnect light switch connector Correct readings. LOCATE and REPAIR open or
C202. Connect an ohmmeter from short in WHT (156) wire and BLK
TEST RESULT ACTION
WHT (156) terminal to BLK (150) (150) wire.
1. Connect test lamp from ORN (40) Test lamp lights. GO to step 2. terminal at light switch. Turn light
wire at courtesy lamp connector switch to ON and the OFF and Incorrect readings. REPLACE light switch.
Test lamp does not light. LOCATE and REPAIR open in take a reading in each position.
C218 to ground. Check at each
ORN (40) wire. When ON, reading must be 0
courtesy lamp.
ohms and when OFF, reading
2. Open right door. Connect test lamp Test lamp lights. REPLACE bulb. must be infinite ohms.
from ORN (40) wire to WHT (156)
Test lamp does not light. CHECK to make sure jamb switch
wire at courtesy lamp connector
is closing. If switch closes,
C218.
LOCATE and REPAIR open in l/P COMPARTMENT BOX LAMP DOES NOT WORK
WHT (156) wire and BLK (150)
wire. TEST RESULT ACTION
1. Open l/P compartment box door. Test lamp lights. GO to step 2.
CARGO LAMP DOES NOT WORK Connect test lamp from ORN (40)
Test lamp does not light. LOCATE and REPAIR open in
TEST RESULT ACTION wire l/P compartment box lamp
ORN (40) wire.
connector C230 to ground.
1. Turn cargo switch on. Connect a Test lamp lights. GO to step 2.
test lamp from ORN (140) wire at 2. Connect test lamp from ORN (40) Test lamp lights. REPLACE l/P compartment box
cargo lamp connector C436 to Test lamp does not light. GO to step 3. wire to BLK (150) wire at l/P lamp assembly.
ground. compartment box lamp connector
Test lamp does not light. LOCATE and REPAIR open in BLK
C230.
(150) wire from l/P compartment
2. Connect a test lamp from ORN Test lamp lights. REPLACE bulb. box lamp to ground terminal G202.
(140) wire to WHT (156) wire at
cargo lamp connector C436. Test lamp does not light. LOCATE and REPAIR open in
WHT (156) wire from cargo lamp to UNDERHOOD LAMP DOES NOT WORK
light switch.
TEST RESULT ACTION
3. Connect a test lamp from ORN Test lamp lights. GO to step 4.
1. Connect a test lamp from ORN Test lamp lights. REPLACE underhood lamp bulb.
(40) wire at cargo lamp switch
(40) wire to BLK (150) wire at
connector C431 to ground. Test lamp does not light. LOCATE and REPAIR open in ORN Test lamp does not light. GO to step 2.
(40) wire. underhood lamp connector C101 A.
2. Connect test lamp to RED (2) wire Test lamp lights. REPLACE in-line fuse.
4. Connect a test lamp from ORN Test lamp lights. LOCATE and REPAIR open in at in-line fuse connector C100A to
(140) wire at cargo lamp switch ORN/WHT (140) wire from cargo Test lamp does not light. LOCATE and REPAIR open in
ground.
connector C430 to ground. lamp switch to cargo lamp. RED (2) wire or fusible link.

Test lamp does not light. REPLACE cargo lamp switch.

A-118 DOME LAMPS, l/P COMPARTMENT LAMP, CARGO LAMP, UNDER­

HOOD LAMP AND LIGHTED VANITY MIRROR
 C219
12004886
RH DOOR
JAMB SWITCH
§ (CLOSED WITH
GT602
8911287
RH REAR
DOOR OPEN)
IREAR DOORJAMB jcuj8®
n w/-\!Vfw dqqp *N
OPE1™
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i n M A m [] i
^BATJ (SUBURBAN ONLY)
ig m E [w] g] [d]
WOO 156

i ] H] I i 1 1 c° i (i i [i (i i C438
ACC LPS
6288872
SHUNT SHUNT I . I h J h
153
HORN/DM
B d
1GN
INSTR LPS

K
AUX HTR A/C
| _ _ _ ^ s jp g p i p i l/P
COMPARTMENT
p H Ip w i IT fl-A p ' — BOX LAMP
lS j & G FRONT DOME LAMP REAR DOME LAMP
GAGE/IDLE HTR A/C AND SWITCH
(SUBURBAN/UTILITY) (SUBURBAN/UTILITY)
D d
30
A W E [fc-H W E t 0
TURNB/U PWRWDO

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CRANK__________
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FRONT
FUSE BLOCK
12103404
C218

I156-.8W HT I 156-.8 WHT

I40-.8 ORN ■ ■ ■ • S413

p 94 29 15 420 440 2
439 806 39 :
N 9 39 14
M 33 12 L 140 120
J
31 3
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35
436
2 S412
18 120 9

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93 97 422
91 92 6 156-.8 W H T I

GENERATOR REAR PANEL

AND BATTERY DOOR/END GATE
(SEE PAGE 10) HARNESS EXTENSION
44 (SUBURBAN ONLY)
(SEE PAGE)

40-.8 ORN

C323
12047682 12047683
i

150- ■ 159-.8 TAN I LIGHTED CARGO LAMPS

DOME (SUBURBAN ONLY)
2 -
VANITY (SEE PAGE 120)
GT502 MIRROR
12015958
CIRCUIT »PARK 156-.8 WHT
BREAKER C437
25 AMP KEY-IN 6288872
WARNING
LH DOOR BUZZER
HEAD
OFF JAMB SWITCH SHEET (SEEPAGE 113)

'PARK
(CLOSED WITH
C208
LEFT REAR (CLOSED WITH
DOOR OPEN) METAL DOORJAMB DOOROPEN>
12047682 12047683
t LIGHT SWITCH
GROUND / q )
SWITCH
G200 ^

DOME LAMPS, l/P COMPARTMENT LAMP, AND LIGHTED A-119

VANITY MIRROR
 RPO CODES

E63 - FLEETSIDE BODY

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HTR
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LAMP
M GNJ ACC LPS PWR

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FLEETSIDE
MODELS
C431
Dd K l
X H T R A /C STOP HA2
Ik s IpS p i nun (E63)
2962793

D d K l DRADIO
d I kS I kS [ k&h \ HORN/DM
T/L CTSY GAGE/IDLE HTR A/C
20 AMP
n — n I 30
D 3 L^U A
DWIPER
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ECM 1 DRL
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D3 □ D
CRANK
0 □ □ B^B I
FRONT

FUSE BLOCK CARGO

12103404 LAMP
FLEETSIDE
MODELS
(£63)

COURTESY LAMP
AND FRONT DOOR
JAMB SWITCHES
(SEE PAGE 119)

I 40-.8 ORN
C219
12004886

REAR GATE
C455 C433
12015987
C442 SWITCH
2977253 12015952

JI156-.8 WHT w ^ jh 5 6 ^ J
156*.8 WHT

40-.8 ORN I
C456

12004333
6288544 (UTILITY ONLY)
I
DOME
. LAMPS
(SEE PAGE 112)

A-120 CARGO LAMP

 BATTERY
JUNCTION BLOCK

C100A
12033769

S142

z
(L
o

UNDERHOOD
LAMP

SHEET METAL

S
■=■
GROUND
G118

UNDERHOOD LAMP A-121

CIRCUIT OPERATION CRUISE CONTROL DOES NOT OPERATE
TEST RESULT ACTION
The Cruise Control System operates a mechanical Cruise Switch and the Set Switch. A disconnect input to
linkage to the throttle by means of a Vacuum Motor. the module comes from a switch on the brake pedal and 1. Place ignition switch in RUN Test lamp lights. GO to step 2.
This is a diaphragm moved by a vacuum applied to one on vehicles equipped with a manual transmission, from and cruise control switch to
side. A solenoid operated valve connects the Vacuum the Clutch Switch. A separate vacuum shut-down of the ON. Connect a test lamp from Test lamp does not light. LOCATE and REPAIR open in
Motor to a Vacuum Tank. Another solenoid valve vents Cruise Control comes from the Brake/Clutch Cruise GRA (397) wire at cruise PNK/BLK (139) wire between
the vacuum to reduce the suction. The Cruise Control Release Valve on the brake pedal. control switch connector C252 cruise control switch and fuse
Module controls the vacuum motor and the throttle by to ground. block. If wire is in good
condition, REPLACE cruise
pulsing these solenoid valves on and off. The two outputs of the Cruise Control Module operate control switch.
the coils of the Vacuum Valve and the Vent Valve. Both
One input to the module is the vehicle speed. This valves are located in the Cruise Control Servo. These 2. Connect a test lamp from DK BLU Test lamp lights. REPLACE cruise control switch.
input comes from the DRAC. If the actual speed signal valves move the throttle by means of the Vacuum Motor. (84) wire at cruise control
is different from the speed that was sent into and The Servo Position Sensor coil senses the position and switch connector C252 to Test lamp does not light. GO to step 3.
remembered by the module, the module generates motion of the Vacuum Motor. It feeds this information ground.
pulses to change the vacuum and return the vehicle to back to the module to provide smooth acceleration while 3. Depress SET/COAST switch. Test lamp lights. GO to step 4.
the set speed. Other inputs to the module are from the the vehicle is in Cruise Control. Connect a test lamp from DK BLU
(84) wire at cruise control Test lamp does not light. LOCATE and REPAIR open in DK
DIAGNOSIS - CRUISE CONTROL module connector C252 to BLU (84) wire between cruise
CRUISE CONTROL DOES NOT DISENGAGE WHEN CLUTCH OR BRAKE PEDAL IS DEPRESSED ground. control switch and cruise
control module. If wire is in
TEST RESULT ACTION good condition, REPLACE cruise
control switch.
1. Place ignition switch in RUN Test lamp lights. GO to step 2, (man trans).
and cruise control switch to GO to step 5 (auto trans). 4. Depress and hold RESUME/ Test lamp lights. GO to step 5.
ON. Connect a test lamp from ACCELERATE switch. Connect a
GRA (397) wire at brake switch Test lamp does not light. LOCATE and REPAIR open in GRA test lamp from DK GRN (83) wire Test lamp does not light. LOCATE and REPAIR open in DK
connector C253 to ground. (397) wire between brake at cruise control module GRN (83) wire. If wire is in
switch and cruise control connector C252 to ground. good condition, REPLACE cruise
switch. control switch.

2. Connect a test lamp from BRN Test lamp lights. GO to step 3. 5. Connect a test lamp from GRA Test lamp lights. GO to step 6.
(86) wire at brake switch (397) wire at cruise control
connector C253 to ground. Do Test lamp does not light. CHECK adjustment of brake module connector C252 to Test lamp does not light. LOCATE and REPAIR open in GRA
not depress brake pedal. switch. If brake switch cannot ground. (397) wire between cruise
be adjusted, REPLACE brake control module and brake
switch. switch and/or brake switch and
cruise control switch.
3. Connect a test lamp from BRN Test lamp lights. GO to step 4.
(86) wire at clutch switch 6. Connect a test lamp from BLK Test lamp lights. GO to step 7.
connector C254 to ground. Test lamp does not light. LOCATE and REPAIR open in BRN (150) wire to GRA (397) wire at
(86) wire between brake switch cruise control module Test lamp does not light. LOCATE and REPAIR open in BLK
and clutch switch. connector C252. (150) wire between cruise
control module and bus bar
4. Connect a test lamp from Test lamp lights. REFER to "Cruise Control Does ground.
GRA/BLK (87) wire at clutch Not Operate" procedure.
switch connector C254 to 7. Place ignition switch to OFF. No continuity in any or all LOCATE and REPAIR open in
ground. Do not depress clutch Test lamp does not light. CHECK adjustment of clutch Disconnect cruise control wires. wire(s) that show no
pedal. switch. If adjustment cannot servo connector C184. Using continuity.
be corrected, REPLACE clutch four jumper leads, connect
switch. cavities A, B, D and E to Continuity. GO to step 8.
ground. Using a digital
5. Connect a test lamp from Test lamp lights. REFER to "Cruise Control Does ohmmeter, check for
GRA/BLK (87) wire at brake Not Operate" symptom. continuity in DK BLU/WHT
switch connector C253 to (403), TAN (398), LT BLU/BLK
ground. Do not depress brake Test lamp does not light. CHECK adjustment of brake (399) and LT GRN (402) wires at
pedal. switch. If adjustment cannot cruise control module
be made, REPLACE brake switch. connector C252 to ground.

A-122 CRUISE CONTROL

 CRUISE CONTROL DOES NOT OPERATE (CONTINUED)
TEST RESULT ACTION

8. Connect a digital ohmmeter at No continuity. LOCATE and REPAIR open in BLK

BLK (150) cavity in cruise (150) wire between cruise
control servo connector C184 control servo and bus bar
and check for continuity to ground.
ground.
Continuity. Problem is not related to the
cruise control system wiring
or switches, replace cruise
control module and test drive.
If still inoperative, replace
cruise control servo.

CRUISE CONTROL A-123

 RPO CODES

LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C

LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J

-1
i i— (LH6, LL4 ONLY)

j I

CRUISE
CONTROL
MODULE

C255
12034117

8911256

A-124 CRUISE CONTROL

CIRCUIT OPERATION FOUR-WHEEL DRIVE ENGAGES BUT 4WD INDICATOR LAMP DOES NOT LIGHT (V100, V200)
TEST RESULT ACTION
When the Ignition Switch is in RUN and the Four- Suburban models. On Fleetside, Wideside and
Wheel Drive Control (4WD) Lever is engaged, the Crew/Bonus Cab models, the closing of the switch 1. Place ignition switch in RUN. Test lamp lights. GO to step 2.
Transfer Case Switch closes and battery voltage is provides a ground for the indicator lamp. Battery voltage Remove transfer case connector
applied across the Front Axle Actuator. The Front Axle is also applied through the front axle switch contacts and C309. Connect a test lamp from Test lamp does not light. CHECK RADIO fuse. If fuse is
Actuator energizes and the four-wheel drive gears are the PPL (420) wires to the Electronic Rear Wheel Brake BRN (141) wire to ground. good, LOCATE and REPAIR open
meshed. This meshing action of the four-wheel drive Control Module in the Utility and Suburban models. This in BRN (141) wire between transfer
gears closes the Front Axle Switch, and battery voltage will keep the antilock braking system disabled in 4WD case switch connector C309 and
mode. The In-Line Resistor (automatic transmission only) fuse block connector C288.
is applied through the WHT (156) wire across the four-
wheel drive indicator lighting the bulb in Utility and prevents the TCC Solenoid from engaging when the 2. Connect transfer case connector Test lamp lights. GO to step 3.
Front Axle Switch is closed. C309. Connect a test lamp to the
WHT (156) wire at the back of the Test lamp does not light. REPLACE transfer case switch.
DIAGNOSIS - FOUR-WHEEL DRIVE INDICATOR LAMP transfer case connector C309 to
ground. Place the transfer case in
four-wheel drive.
PRELIMINARY CHECKS:
Make sure all mechanical components are operative While performing the following diagnostic procedures, 3. With ignition switch in RUN and Test lamp lights. GO to step 4.
before diagnosing the electrical portion of the four-wheel the Ignition Switch must be in RUN, and the 4WD Control transfer case in four-wheel drive,
drive system. Lever must be in the 4WD ENGAGED position. disconnect 4WD indictor lamp Test lamp does not light. LOCATE and REPAIR open in
connector C246. Connect a test WHT (156) wire between transfer
To determine whether the vehicle is in Two-Wheel lamp between WHT (156) wire and case switch connector C309. and
Drive or Four-Wheel Drive, it must be lifted up so the ground. four-wheel drive indicator lamp
wheels can spin freely. connector C246.
4. Connect a test lamp between Test lamp lights. REPLACE bulb.
WHT (156) wire and BLK (150)
wire at four-wheel drive indicator Test lamp does not light. LOCATE and REPAIR open in BLK
FOUR-W HEEL D R IV E IN D IC A T O R LAM P W IL L N O T TU R N O FF
lamp connector C246. (150) wire to ground.
TEST RESULT ACTION
Disconnect transfer case switch 4WD indicator lamp goes off. REPLACE transfer case switch.
connector C309. FO U R -W H E E L D R IV E EN G A G ES B U T 4W D IN D IC A TO R LA M P DO ES N O T L IG H T (V 300)
TEST RESULT ACTION
1. Disconnect 4WD indicator lamp Test lamp lights. GO to step 2.
connector C246. Connect test
lamp to BRN/WHT (141) wire to Test lamp does not light. CHECK RADIO fuse, if fuse is
ground. good, LOCATE and REPAIR open
in BRN/WHT (141) wire.
2. Connect test lamp to connector Test lamp lights. REPLACE 4WD indicator lamp.
C246 to BRN/WHT (141) to WHT
(156) wire. Engage four-wheel Test lamp does not light. GO to step 3.
drive.
3. Connect a self-powered test lamp Test lamp does not light. LOCATE and REPAIR open in
to WHT (156) wire at transfer case WHT (156) wire.
connector C309 to ground.
Test lamp lights. GO to step 4.
4. Connect a self-powered test lamp Test lamp lights. REPLACE transfer case switch.
between WHT (156) wire and BLK
(150) wire at transfer case switch Test lamp does not light. LOCATE and REPAIR open in BLK
connector C246. Make sure four- (150) wire to ground.
wheel drive is engaged.

FOUR-WHEEL DRIVE A-125

 C288
12004887
43*.8 YEL

0 0 0 0
L iG N ^f ACC LPS

SHUNT SHUNT El
INSTR LPS

K l KIGN l AUXKHTR lA/C k f i HMl to t

HORN/DM

3 3 IK K l
T/L CTSY GAGE/IDLE HTR A/C
kQ I kQ I k®
30
IK
ECM B
A
TURN B/U PWR WDO
I kB I kH
KECM 1l DDRLd B 'f l B^S o )

DC 0 □ □D ]
FRONT REAR

FUSE BLOCK
12103404

I 141-.8 BRN/WHT

ill
n BUS
FOUR-WHEEL
DRIVE E (ft) 13 BAR
GROUND
INDICATOR G200
LAMP
IF If ^T1

TRANSFER
CASE
SWITCH
(CLOSED
INFOUR- TRANSFER
WHEEL DRIVE)
CASE
SWITCH
(CLOSED
IN FOUR-
WHEEL DRIVE) FOUR-WHEEL DRIVE INDICATORS W/O RWAL
FOUR-WHEEL DRIVE
INDICATOR W/RWAL

A-126 FOUR-WHEEL DRIVE

CIRCUIT OPERATION DIAGNOSIS — POWER MIRRORS

POWER MIRRORS PRELIMINARY CHECKS:

Voltage is applied at all times to the Power Outside position, it completes the circuit to the Motors. Voltage 1. Check to see that the HORN/DM, PWR ACC and 2. Refer to Section 8 of the 1991 R/V,P Light Truck
Rearview Mirror Switch, through the HORN/DM Fuse and is applied to the GRA (295) wire and to the Door Lock in-line (C266) fuses are not blown. If blown, locate Service Manual for diagnosis and repair of all non-
an In-Line Auto Fuse. Motors, which are grounded by the TAN (294) wire from and repair source of the overload, then replace fuse. electrical system components.
the other terminal of the Motor through the other switch
The mirror assemblies contain two motors. One contact to ground. The Motor in each door runs to NEITHER MIRROR IS OPERATIONAL
motor positions the mirror up and down, the other motor operate the Door Locks. When the Door Lock Switch is
positions the mirror to the left or right. By reversing the released, the circuit is opened and the Motors turn off. TEST RESULT ACTION
polarity of the motors, the motors will move the mirrors 1. Connect test lamp from ORN (40) Test lajrnp does not light.
A similar action occurs with either of the Door Lock LOCATE and REPAIR open in ORN
either up/down or left/right. wire at mirror switch connector (40) wire between mirror switch
Switches closing to the UNLOCK position. Now the TAN C505 to ground. connector C505 and fuse block.
POWER DOOR LOCKS (294) wires to the Motors supply battery voltage and the
When a Door Lock Switch is operated, all of the doors GRA (295) wires are grounded. The polarity of the
will unlock or lock. Each lock can also be operated voltage to the Motors has reversed. The Motors run in
Test lamp lights. GO to step 2.
manually. The locks are operated by reversible motors the opposite direction to unlock the doors.
2. Connect test lamp from ORN (40) Test lamp does not light. LOCATE and REPAIR open in BLK
that receive voltage from the PWR/ACC Circuit Breaker. (150) wire between mirror switch
The Door Lock Switches are usually closed for just a wire to BLK (150) wire at mirror
The Door Lock Switches operate to turn the Motors on switch connector C505. connector C505 and bus bar ground.
by applying battery voltage to one of the terminals and moment. If the Door Lock Switches are held closed, a
ground to the other terminal. circuit breaker in each Motor will open to protect against Test lamplights. REPLACE mirror switch.
damage. The circuit breakers close automatically when
When either Door Lock Switch is moved to the LOCK they cool off. LH MIRROR WILL NOT ADJUST UP AND DOWN
TEST RESULT ACTION
Disconnect in-line fuse connector Continuity. REPLACE LH mirror motor.
C266 and connector C504 at LH
No continuity. LOCATE and REPAIR open in YEL
mirror motor. Place ohmmeter on
Rx1 scale and connect leads to (88) or LT BLU (82) wires between
YEL (88) and LT BLU (82) wires at mirror switch connector C505 and
LH mirror motor connector C504. LH mirror motor connector C504.
While holding mirror adjustment If none if found, REPLACE switch.
switch in the UP and DOWN
positions, measure for continuity.

LH MIRROR WILL NOT ADJUST LEFT AND RIGHT

TEST RESULT ACTION
Disconnect in-line fuse connector Continuity. REPLACE LH mirror motor.
C266 and connector C504 at LH
No continuity. LOCATE and REPAIR open in
mirror motor. Place ohmmeter on
Rx1 scale and connect leads to WHT (81) or LT BLU (82) wires
WHT (81) and LT BLU (82) wires at between mirror switch connector
LH mirror motor connector C504. C505 and LH mirror motor
While holding mirror adjustment connector C504. If none is found,
switch in the LEFT and RIGHT REPLACE switch.
positions, measure for continuity.

POWER MIRROR AND POWER DOOR LOCKS A-127

 RH MIRROR WILL NOT ADJUST UP AND DOWN ONE DOOR LOCK MOTOR DOES NOT LOCK OR UNLOCK FROM A PARTICULAR SWITCH
TEST RESULT ACTION TEST RESULT ACTION

Disconnect in-line fuse connector Continuity. REPLACE RH mirror motor. 1. Connect a test lamp from Test lamp does not light. LOCATE and REPAIR open in
C266 and connector C600 at RH ORN/BLK (60) wire at ORN/BLK (60) wire between switch
No continuity. LOCATE and REPAIR open in
mirror motor. Place ohmmeter on inoperative switch connector and splice S259.
YEL/BLK (888) and LT BLU (82) to ground.
Rx1 scale and connect leads to wires between mirror switch
YEL/BLK (888) and LT BLU/BLK Test lamp lights. If door lock will not lock, go to step
connector C505 and RH mirror
(82) wires at RH mirror motor 2. If door lock will not unlock, go
motor connector C600. If none is
connector C600. While holding to step 3.
found, REPLACE switch.
mirror adjustment switch in the UP
and DOWN positions, measure for 2. Connect a fused jumper from Door lock motor runs. REPLACE door lock switch.
ORN/BLK (60) wire to LT BLU
continuity.
(195) wire at inoperative switch Door lock motor does not run. LOCATE and REPAIR open in LT
RH MIRROR WILL NOT ADJUST LEFT AND RIGHT connector. BLU (195) wire between
inoperative switch connector and
TEST RESULT ACTION door lock relay connector C264.
Disconnect in-line fuse connector Continuity. REPLACE RH mirror motor. 3. Connect a fused jumper from Door lock motor runs. REPLACE door lock switch.
C266 and C600 at RH mirror ORN/BLK (60) wire to BLK/WHT
No continuity. LOCATE and REPAIR open in
motor. Place ohmmeter on Rx1 WHT/BLK (881) and LT BLU/BLK (194) wire at inoperative switch Door lock motor does not run. LOCATE and REPAIR open in
scale and connect leads to (82) wires between mirror switch connector. BLK/WHT (194) wire between
WHT/BLK (881) and LT BLU/BLK connector C505 and RH mirror inoperative switch connector and
(82) wires at RH mirror motor motor connector C600. If none is door lock relay connector C264.
connector C600. While holding found, REPLACE switch.
mirror adjustment switch in the ONE DOOR LOCK MOTOR DOES NOT OPERATE FROM ANY SWITCH
LEFT and RIGHT positions, TEST RESULT ACTION
measure for continuity.
1. Connect test lamp from TAN (294) Test lamp lights. REPLACE door lock motor.
DIAGNOSIS — POWER DOOR LOCKS wire to GRA (295) wire at
NONE OF THE DOOR LOCK MOTORS LOCK OR UNLOCK Test lamp does not light. GO to step 2.
inoperative motor and momentarily
place door lock switch in lock or
TEST RESULT ACTION
unlock position while observing
Connect test lamp from ORN/BLK Test lamp does not light. LOCATE and REPAIR open in ORN/ test lamp.
(60) wire at door lock relay BLK (60) wire between door lock
2. Connect test lamp from TAN (294) Test lamp lights. LOCATE and REPAIR open in
connector C264 to ground. relay connector C264 and fuse
wire at inoperative motor to ground GRA (295) wire between
block. Inspect splice S259 for
and momentarily place door lock inoperative motor connector and
open wire. If no open is found,
switch to unlock position while spliceS258.
REPLACE PWR ACC circuit breaker.
observing test lamp.
Test lamp does not light. LOCATE and REPAIR open in
Test lamp lights. INSPECT door lock relay for poor
TAN (294) wire between
ground condition or REPLACE
inoperative motor connector and
door lock relay.
splice S257.

A-128 POWER MIRRORS AND POWER DOOR LOCKS

 w v w w w w m
S HOT AT ALL TIM ES <

Z'VM/VWVWWN

I 640-1.0 ORN

HORN/DM
20 AMP

§ f 0 i i @
* BATj^
0 /[c] 0 ® E @
/ WDO

[cf |c ] [a ) [a ] m [D]
MGN^J ACC LPS

SHUNT SHUNT

D
H5RN3
/bl4l

GAGE/IDLE HTR A/C

\S ] \
TURN B/U PWR WDO
.

K
ECM 1
j K ] DRL

Kl 0□
FRONT

40-.5 ORN

150-.5 BLK

I 40-.5 ORN LEFT/RIGHT

s = i '
C266
12010105

IN-LINE
3 AMP
AUTO FUSE POWER WINDOWS
(SEE PAGE 139)

TT] BUS
BAR
__ GROUND
31

G201

POWER OUTSIDE REARVIEW MIRRORS A-129

 t ^ -----1l 2

I
? ' M 5

LH
DOOR LOCK
MOTOR

A-130 POWER DOOR LOCKS

2-DOOR (WITHOUT POWER OUTSIDE REARVIEW MIRRORS)
0 [c] 0 @ 1] @ i B ”fcAR
t-B A T -*
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T U R N B /U PW R W D O WIPER

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FRONT

D OOR
LOCK
RELAY

i
“ • -------------- l l 2

X
T ' -------------------m m 5

LH
DOOR LOCK
MOTOR

POWER DOOR LOCKS A-131

2-DOOR (WITH POWER OUTSIDE REARVIEW MIRRORS)
 RH FRONT DOOR
LOCK MOTOR

[c] (c) 0 0 0 0 l I
T batj

0 m 0 (W) 0 0
WDO
M il
0 0 0 0 0 0 MM
HGN^ ACC LPS

SHUNT SH UN T P iA ^ j
UE
INSTR LPS
Is T
HORN/DM
Kl Kl
IGN AUX HTR A/C
kfi BkA
K l Kl K
T/L CTSY GAGE/IDLE HTR A/C
VE I UE
30
kECM Bi B d A I VE
TURN B/U PWR WDO

K J KDHL]
ECM 1
B 'fl S'S
Kl □0
CRANK
0 D 0/fi
FRONT

60-2.0 GRN/BLK

ll 195-.8 LT
■ r jm v .m v ^ 194 -. a b lk / w h t ^ .^ b v j h t ^m a r

> 12020398

12015344
A B C LH DOOR
nn— nn LOCK SWITCH
12020397 UNLOCK
(O 0)
U1 0 <0
•Ik

TT LOCK’

GT500 GT501
8911670 12010247
194-.8 LT BLU H ■ i^ ^ ^ B H 1 9 4 - .8 L T B L U
60-2.0 ORN/BLK I W ^■■60-2.0 O R N /B LK iv K A JI
L = 195-.8 BLK/WHT ■ r ^ii95-.8 BL-K/WHT^*"^'
295-1.0 GRA
LH FRONT DOOR
295-1.0 GRA I LOCK MOTOR
294-1.0 TAN H H 1

294-1.0 TAN

A-132 POWER DOOR LOCKS

4-DOOR (WITH POWER OUTSIDE REARVIEW MIRRORS)
 GT800
12010366

..
RH REAR
i
I 295-1.0 GRA I 295-1.0 GRA i 295 DOOR LOCK
{
i 294
I 294-1.0 TAN 294-1.0 TAN MOTOR
C802
12004140

12015344
SIDE DOOR
CONTACT REAR
BUTTONS PANEL
C402 DOOR LOCK
MOTOR
I 295-1.0 GRA | 295-1.0 GRA
295-1.0 GRA

294-1.0 TAN 294-1.0 TAN

I 294-1.0 TAN I

I 294-1.0 TAN I C404

12047676 12020397
| 295-1.0 GRA

1295-1.0 GRA I

I 195-.8 LT BLU I CONTACTOR

1194-.8 BLK/WHT I
DOOR
LOCK
I 295-1.0 GRA I
RELAY
I 294-1.0 TAN I
I 294-1.0 TAN |
C264
2984378 I
I 294-1.0 TAN I

I 60-2.0 ORN/BLKI

1295-1.0 GRA I

I 195-.8 LT BLU I
I 194-.8 BLK/WHT I

I
12047675

C403
A B C

I 295-1.0 GRA H 295

LH REAR
r
L_ 294 DOOR LOCK
I 294-1.0 TAN r
MOTOR

GT700
12020366

POWER DOOR LOCKS A-133

4-DOOR (WITH POWER OUTSIDE REARVIEW MIRRORS)
 RH FRONT DOOR
LOCK MOTOR

LH FRONT DOOR
LOCK MOTOR

A-134 POWER DOOR LOCKS

4-DOOR (WITHOUT POWER OUTSIDE REARVIEW MIRRORS)
 GT800
12010366
I [*"'•—
. I CIRCUIT
RH
1 L
295-1.0 GRA 295 c
B R EA K E R
DOOR LOCK
294-1.0 TAN (-1 294
L MOTOR
fc = ■
C602
12004140

SIDE DOOR
CONTACT REAR
BUTTONS PANEL
DOOR LOCK
MOTOR

295-1.0 GRA

294-1.0 TAN

C404
AAA A A t f i

294-1.0 TAN 12047676 12020397

295-1.0 GRA

DOOR
194-.8 BLK/WHT
LOCK
RELAY
295-1.0 GRA

■ ■ ■ ■ 294-1.0 TAN

294-1.0 TAN Bl l — *
AA

294-1.0 TAN

m<
I I

194-.8 BLK/WHT

r nn— nn ’
12020397
KJ M l
□ „ n5
GT700 C702
12020366 12004140

Fn I"- LH REAR
295-1.0 GRA 295-1.0 GRA
r
294-1.0 TAN
?94 r DOOR LOCK
294-1.0 TAN
in u MOTOR

POWER DOOR LOCKS A-135

4-DOOR (WITHOUT POWER MIRRORS)
CIRCUIT OPERATION DIAGNOSIS - POWER WINDOWS
A permanent magnet (PM) motor operates each of circuit breaker and the ORN/BLK (60) wire. When the PRELIMINARY CHECKS:
the Power Windows. Each Motor raises or lowers the ignition switch is in RUN or ACC, battery voltage is Check condition of PWR WDO circuit breaker. If
window when voltage is supplied to it. The direction the applied to the PWR WOO circuit breaker and the PNK circuit breaker is in good condition, use the following
Motor turns depends on the polarity of the supply (76) wire to the front tailgate window switch. diagnostic procedures.
voltage. The Switches control the supply voltage
polarity.
POWER WINDOWS DO NOT OPERATE OR ONLY GO IN ONE DIRECTION
WINDOW SWITCH OPERATION
The Master Door Lock/Power Window Switch When the Ignition Switch is in RUN or ACC, battery TEST RESULT ACTION
Assembly controls all of the Window Motors. Each voltage is applied to the Window Switch through the Test lamp lights. GO to step 2.
1. Place ignition switch in RUN or
window also has its own control switch. PWR WOO Circuit Breaker and the PNK wires to terminal ACC position. Connect a test
76. When the UP Switch in the Window Switch is lamp from PNK (76) wire at Test lamp does not light. LOCATE and REPAIR open in PNK
Each Motor is protected by a built-in circuit breaker. operated, battery volt~ge is applied to the Window Motor affected window switch connector (76) wire from affected window
If a Window Switch is held too long with the window through the OK BLU/WHT (166) wire. The Motor is C500, C601, C700 or C800 to switch to fuse block.
obstructed or after the window is fully up or down, the grounded through the BRN (165) wire, the ON contact in ground.
circuit breaker opens the circuit. The circuit breaker the Window Switch, the TAN (167) wire and the ON
resets automatically. 2. Connect a test lamp from PNK Test lamp lights. GO to step 3.
contact in the Master Door Lock/Power Window Switch
(76) wire to BLK (150) wire at
Assembly. The Motor runs to drive the window up. Test lamp does not light. LOCATE and REPAIR open in BLK
affected window switch connector
When the Ignition Switch is in RUN or ACC, battery When the DN switch in the Window Switch is operated, C500, C601, C700 or C800. (150) wire from affected window
voltage is applied to the Master Door Lock/Power battery voltage is applied to the Window Motor in the switch to bus bar ground.
Window Switch Assembly, the PWR WDO Circuit Breaker, opposite direction through the BRN (165) wire. The
and the PNK (76) wires. Motor is grounded through the OK BLU (164) wire, the 3. Move and hold affected window Test lamp lights. GO to step 4.
UP contact in the Window Switch, the OK BLU/WHT (166) switch to UP position. Connect a
When any of the UP Switches are operated, battery wire and the UP contact in the Master Door Lock/Power test lamp from BRN (165,667, or Test lamp does not light. REPLACE affected window switch.
voltage is applied to the Window Motor through the DK Window Switch Assembly. The Motor runs to drive the 669) wire at affected window
BLU/WHT (166) wire. The Window Motor is grounded switch connector C500, C601,
window down.
C700 or C800 to ground.
through the DN contact. The Motor runs to drive the
window up. When any of the DN Switches are operated, The tailgate window motor receives voltage from 4. Connect a test lamp from BRN Test lamp lights. GO to step 5.
battery voltage is applied to the Window Motor in the either the front or key-operated tailgate switches through (165, 667, or 669) wire to OK BLU
opposite direction through the BRN (65) wire. The the LT BLU (183) wire for down or the TAN/WHT (184) for (164, 666, or 669) wire at affected Test lamp does not light. REPLACE affected window switch.
Window Motor is grounded through the UP contact. The up operation. The tailgate window motor is grounded at window switch connector C5 0 0,
Motor runs to drive the window down. the tailgate. C601, C700 or C800.
5. Connect a test lamp from BRN Test lamp lights. GO to step 6.
Battery voltage is supplied to the key-operated (165, 667, or 669) wire at affected
tailgate window switch at all times through the PWR ACC window motor connector C503, Test lamp does not light. LOCATE and REPAIR open in BRN
C604, C701 or C801 to ground. (165, 667 or 669) wire from
affected window motor to window
switch.
6. Connect a test lamp from BRN Test lamp lights. REPLACE affected window motor.
(165, 667, or 669) wire to OK BLU
(164, 666, or 668) wire at affected Test lamp does not light. LOCATE and REPAIR open in DK
window motor connector C503, BLU (164, 666 or 668) wire
C604, C701 or C801. between affected window motor
and window switch.

A-136 POWER WINDOWS

 POWER WINDOWS ONLY OPERATE FROM DRIVER’S SIDE WINDOW SWITCH 8. Connect test lamp from PNK (76) Test lamp lights at all wires. REPLACE affected window switch.
TEST RESULT ACTION wire to DK BLU/WHT (166), DK
Test lamp lights at only one wire or LOCATE and REPAIR open in
GRN (168) or LT GRN (170) wire
1. Place ignition switch in ACC GO to step 2. not at all. wires (166,168,170,167,169 or
Test lamp lights. and then to TAN (167), PPL (169)
position. Connect test lamp from 171) from affected window switch
Test lamp does not light. LOCATE and REPAIR open in or PPL/WHT (171) wire at affected
PNK (76) wire at affected window to left window switch.
PNK (76) wire from affected window switch connector C601,
switch connector C601, C700 or C700 or C800.
window switch to fuse block.
C800 to ground.
2. Move affected window switch to Test lamp lights. GO to step 3.
UP position. Connect test lamp
PRELIMINARY CHECKS:
Test lamp does not light. REPLACE affected window switch. 1. Tailgate should remain closed t hroughout the 2. CHECK condition of PWR WDO and PWR ACC
from BRN (667 or 669) wire at
affected window switch connector diagnosis of the POWER REAR WrINDOW circuit. circuit breakers. If circuit breakers are in good
C601, C700 or C800 to ground. condition, use the following diagnostic
procedures.
3. Move affected window switch to Test lamp does not light. REPLACE affected window switch.
DOWN position. Connect test lamp TAILGATE WINDOW DOES NOT OPERATE FROM FRONT TAILGATE WINDOW SWITCH
from DK BLU (666 or 668) wire at TEST RESULT ACTION
affected window switch connector
C601, C700 or C800 to ground. 1. Place ignition switch in RUN or Test lamp lights. GO to step 2.
ACC position. Connect a test
POWER WINDOWS DO NOT OPERATE FROM DRIVER’S SIDE WINDOW SWITCH lamp from PNK (76) wire at front Test lamp does not light. LOCATE and REPAIR open in PNK
tailgate window switch connector (76) wire from front tailgate window
TEST RESULT ACTION
C274 to ground. switch connector C274 to fuse
1. Place ignition switch in ACC Test lamp lights. GO to step 2. block.
position. Position and hold
Test lamp does not light. GO to step 3. 2. Position and hold tailgate window Test lamp lights. GO to step 3.
affected window switch to UP
position. Connect test lamp from switch in the UP position.
BRN (667 or 669) wire at affected Connect a test lamp from Test lamp does not light. REPLACE front tailgate window
window motor connector C604, TAN/WHT (184) wire at front switch.
tailgate window switch connector
C701 or C801 to ground.
C274 to ground.
2. Connect test lamp from BRN (667 Test lamp lights. REPLACE affected window motor.
or 669) wire to DK BLU (666 or 668) 3. Position and hold front tailgate Test lamp lights. GO to step 4.
Test lamp does not light. GO to step 3. window switch in the DOWN
wire at affected window motor
connector C604, C701 or C801. position. Connect a test lamp Test lamp does not light. REPLACE front tailgate window
from LT BLU (183) wire at front switch.
3. Connect a test lamp from PNK Test lamp lights. GO to step 4. tailgate window switch connector
(76) wire at affected window Test lamp does not light. LOCATE and REPAIR open in C274 to ground.
switch connector C506 to ground. PNK (76) wire from affected
window switch to fuse block. 4. Connect a fused jumper from PNK Test lamp lights. GO to step 5.
(76) wire at the front tailgate
4. Connect test lamp from PNK (76) Test lamp lights. GO to step 6. window switch connector C274 to Test lamp does not light. LOCATE and REPAIR open in
wire to DK BLU/WHT (166), DK Test lamp does not light. GO to step 5. TAN/WHT (184) wire. Then TAN/WHT (184) wire between
GRN (168) or LT GRN (170) wires connect a test lamp from tailgate window motor connector
at affected window switch TAN/WHT (184) wire at tailgate C905 and front tailgate window
connector C506. window motor connector C905 to switch.
Test lamp lights. REPLACE affected window switch. ground.
5. Connect test lamp from PNK (76)
wire to BLK (150) wire at affected Test lamp does not light. LOCATE and REPAIR open in BLK 5. Connect a fused jumper from PNK Test lamp lights at both wires. GO to step 6.
window switch connector C506. (150) wire from affected window (76) wire at the front tailgate
switch to bus bar ground. window switch connector C274 to Test lamp does not light at one or LOCATE and REPAIR open in LT
LT BLU (183) wire. Then connect both wires. BLU (183) wire from cutout switch
6. Connect test lamp from PNK (76) Test lamp lights. GO to step 8. a test lamp from one LT BLU (183) connector C904 to front tailgate
wire to TAN (167), PPL (169) or
Test lamp does not light. GO to step 7. wire at cutout switch connector window switch connector C274. If
PPL/WHT (171) wire at affected
C904 to ground. REPEAT for the wire is in good condition,
window switch connector C506. other LT BLU (183) wire. REPLACE cutout switch.
7. Connect test lamp from PNK (76) Test lamp lights. REPLACE affected window switch.
wire to BLK (150) wire at affected 6. Connect a test lamp from LT BLU Test lamp lights. REPLACE tailgate window motor.
Test lamp does not light. LOCATE and REPAIR open in BLK (183) wire at tailgate window
window switch connector C506.
(150) wire from affected window motor connector C905 to ground. Test lamp does not light. LOCATE and REPAIR open in LT
switch to bus bar ground. BLU (183) wire between tailgate
motor connector C905 and cutout
switch. If wire is in good condition,
REPLACE tailgate window motor.

POWER WINDOWS A-137

 ____________ RPO CODES____________________

D48 - ELECTRIC REMOTE CONTROL OUTSIDE MIRROR

76 -2.0 p n k

HTR
m
i l l « 6ca r

m
(g [c] 0 [wp’ ® 0 m /
WDO

@ @ 0 0 1 0 ®
L-IG
ig N
n^J ACC LPS PWR 1 167-2.0 TAN J
1 166-2.0 DK BLU/WHT
666-2.0 DK BLU

SHUNT SHUNT
El
INSTR LPS PWR ACC
176-2.0 PNK

w KIGN] AUXKHTR]A/C H 667-2.0 BRN

HORN/DM STOP HA RH WINDOW
GT601
Kl Kl Kl
T/L CTSY GAGE/IDLE HTR A/C
12010247
MOTOR

Kl Kl
ECM B
30
A
TURN B/U PWR WDO
CD^— t0 -
= = t
K Kl o \ / C £ } S'S S'S O ) A
rr 76
166
667
666
167

ECM 1

E 00
CRANK '
DRL

u)i q[ □ 0 S'S r 12015345_

m annni
n^^r,
in^irsn
«c -«o= r * ___ t

— —
RH WINDOW
FRONT
SWITCH
C262
FUSE BLOCK
150-2.0 blk

12004267

G200
POWER WINDOWS A-139
________________ 2-DOOR___________
 12004884
C259

DOWN

UP
RH REAR

MASTER
WINDOW SWITCH

n 64-2.0 DK BLU •

LH FRONT
WINDOW MOTOR
A-140 POWER WINDOWS
4-DOOR
 RPO CODES

D48 - ELECTRIC REMOTE CONTROL OUTSIDE MIRROR

□ 0 f—

r1 t—- 170-2.0 LT GRN ■ ■ ■

J-JnnLJ

C402
12047675 12015344

DOWN -------------------------------------------------- ,
-------------------- -- I- .
UP ^ • i 4
I 76 669 171 RH REAR
170 668 WINDOW SWITCH
k - o - - ..—-...• r
S261 (D48 ONLY)
POWER OUTSIDE
1150-3.0 BLKl 1150-.8 BLK I ^ REARVIEW MIRRORS
(SEE PAGE 127)

s
ffi

C403
12047675 12015344

FTVUFTl GT700
1 76-2.0 PNK ■ ■ ■ 76-2.0 PNK

1169-2.0 P P L M H 169-2.0 PPL

1 168-2.0 DK GRN I 168-2.0 DK GRN

DOWN
C D ^—tO—
76 669 169 LH REAR
up
170 668
i6 8 WINDOW SWITCH
T
BUS BAR
GROUND
C257 G201
12004267 POWER WINDOWS A-141
(4-DOOR)
 CUTOUT
SWITCH

183-3.0 LT BLU

183-3.0 LT BLU I 183

C904
12004480
(OPENS WHEN
WINDOW FULLY
UP OR DOWN)

(SUBURBAN ONLY)

TAIL GATE
WINDOW
183-3.0 LT BLU
MOTOR
184-3.0 TAN/WHT

183-3.0 LT BLU

184-3.0 TAN/WHT

(UTILITY ONLY)

TAIL GATE
WINDOW
SWITCH
(KEY OPERATED)

60-3.0 ORN/BLK

184-3.0 TAN/WHT

MOTOR
BRAKE
GROUND
G904

A-142 POWER REAR WINDOW

CIRCUIT OPERATION PANEL LAMP DOES NOT COME ON
TEST RESULT ACTION
The RADIO Fuse provides main power to the Radio. stations can be stored in the electronic memory. The
1. Disconnect radio connector C241. Battery voltage. REMOVE radio and send in for
With Ignition Switch in ACC or RUN, voltage is applied ETR model also provides a digital display of time or
Place light switch to PARK and service.
through the RADIO Fuse and the YEL wire to the On/Off station frequency. As in other models, the Panel Lamp panel dimmer switch to HIGH. No voltage.
Switch in the Radio. The On/Off Switch is located in the Switch controls panel lamp dimming. In the ETR model, Connect a voltmeter from GRA (8) CHECK condition of INST LPS
Radio. The circuit is grounded at Bus Bar Ground. With dimming is also controlled by the Radio itself by means wire at radio connector C241 to fuse. If fuse is good, LOCATE and
the On/Off Switch closed, voltage is applied to the Solid- of the DIM Display Input Signal. ground. REPAIR open in GRA (8) wire from
State Radio circuits to ground. Two wires connect each radio to fuse block.
speaker to the Radio. The ETR Radio has two inputs The ETR model’s Clock memory and Radio and
that other models do not have: Display Dim Signal and memory functions are supplied voltage at all times
Clock Power. through the HORN/DM Fuse. If voltage to the ETR DISPLAY DIMMING FUNCTION WILL NOT OPERATE
model is cut off - by disconnecting the Battery, for
The ETR model is an AM/FM Radio that changes example - the operator must reset the memory functions TEST RESULT ACTION
stations electronically. The frequency of preselected when voltage is restored. 1. Disconnect radio connector C204. Battery voltage. REMOVE radio and send in for
Place light switch to PARK. service.
Connect voltmeter from BRN (9)
wire at radio connector C204 to No voltage. LOCATE and REPAIR open in BRN
DIAGNOSIS -- RADIO ground. (9) wire from radio at light switch.
RADIO DOES NOT APPEAR TO WORK (NO DISPLAY LIGHTS, NO SOUND)
TEST RESULT ACTION
NO SOUND OR DISTORTED SOUND FROM A SPEAKER
1. Disconnect radio connector C241 Battery voltage. GO to step 2.
and place ignition switch to RUN TEST RESULT ACTION
or ACC. Connect a voltmeter No voltage. CHECK condition of RADIO fuse. 1. Disconnect suspected speaker Speaker pops. GO to step 2.
from YEL (43) wire at radio If fuse is good, LOCATE and
connector. Set analog ohmmeter
connector C241 to ground. REPAIR open in YEL (43) wire. on RX1 scale. Connect an No noise. REPLACE speaker.
2. Connect a voltmeter from YEL (43) Battery voltage. REMOVE radio and send in for ohmmeter across speaker
wire to BLK (150) wire at radio service. terminals.
connector C241. No voltage. Varying around 1 volt AC. REPLACE speaker.
2. Place ignition switch to RUN or
LOCATE and REPAIR open in BLK ACC and turn radio ON. Tune
(150) wire from radio to bus bar No voltage or greater than 1 volt LOCATE and REPAIR speaker
radio to a strong signal. Connect
ground. wires between radio and speaker.
a voltmeter across outputs for AC.
suspect speaker. If wires are good, REMOVE radio
and send in for repairs.
CLOCK DOES NOT OPERATE
TEST RESULT ACTION
1. Disconnect radio connector C204. Battery voltage. REMOVE radio and send in for
Connect a voltmeter form ORN service.
(40) wire at radio connector C204
to ground. No voltage. CHECK condition of HORN/DM
fuse. If fuse is good, LOCATE and
REPAIR open in ORN (40) wire.

RADIO A-143
 RADIO RECEIVER

BUS
BAR
GROUND
G200

A-144 AM RADIO
MONAURAL
 RPO COOES

HOT AT ALL TIMES ■ UM6 - RADIO, ETR AM/FM STEREO, CASSETTE

RH
REAR
SPEAKER

C440
12077787

C439
12077787

LH
LIGHT
SWITCH REAR
SPEAKER

RADIO A-145
AM/FM STEREO
CIRCUIT OPERATION DIAGNOSIS — REAR DEFOGGER
REAR WINDOW DEFOGGER DOES NOT WORK AND ON INDICATOR DOES NOT LIGHT
With the Ignition Switch in RUN, voltage is applied to The first time the Rear Defogger Switch is activated,
the Rear Defogger Switch. When the Rear Defogger the Timer-Relay will allow the Rear Defogger to operate TEST RESULT ACTION
Switch is moved to the ON position, voltage is then for 10 minutes. Each time after the Rear Defogger 1. Place ignition switch in RUN Test lamp lights. GO to step 2.
applied to the Rear Defogger Timer-Relay. The contact Switch is activated, the Timer-Relay will allow the Rear position. Connect a test lamp
closes, which provides voltage to the ON Indicator and Defogger to operate for a maximum of five minutes. The from ORN/BLK (60) at timer relay Test lamp does not light. CHECK condition of PWR ACC
the Rear Defogger. The rear window will become warm Timer-Relay will reset to 10 minutes when the Ignition connector C279 to ground. circuit breaker. If circuit breaker is
to remove fog from the surface of the window. Switch is turned OFF and then back to the RUN position. good, LOCATE and REPAIR open
in ORN/BLK (60) wire.
The contact in the Rear Defogger Control will stay The Timer also shuts off at any time the Rear
closed until the Rear Defogger Control Switch is turned 2. Connect a test lamp from Test lamp lights. GO to step 3.
Defogger Control On-Off Switch is depressed to OFF.
PNK/BLK (39) wire at rear window
off, or the timer cycle is complete.
defogger switch connector C278 Test lamp does not light. CHECK condition of IGN fuse. If
to ground. fuse is good, LOCATE and REPAIR
open in PNK/BLK (39) wire.
3. Connect a test lamp from Test lamp lights. GO to step 4.
PNK/BLK (39) and BLK (150) wires
at rear window defogger switch Test lamp does not light. LOCATE and REPAIR open in BLK
connector C278 to ground. (150) wire.

4. Place rear window defogger Test lamp lights. GO to step 5.

switch on and hold. Connect a
test lamp from LT BLU (292) wire Test lamp does not light. REPLACE rear window defogger
at rear window defogger switch switch.
connector C278 to ground.

5. Place rear window defogger Test lamp does not light. REPLACE timer relay.
switch ON and hold. Connect a
test lamp from PPL/WHT (293)
connector at timer relay to ground.

ON INDICATOR WORKS BUT REAR WINDOW DEFOGGER DOES NOT DEFROST

TEST RESULT ACTION

1. Place ignition switch in RUN and Test lamp lights. GO to step 2.

rear defogger switch ON.
Connect a test lamp from PPL Test lamp does not light. LOCATE and REPAIR open in PPL
(293) wire to ground (tailgate or PPL/WHT (293) wires.
models) or PPLVWHT (293) wire at
rear window defogger to ground
(panel door models).
2. Connect a test lamp from PPL Test lamp lights. REPAIR rear defogger as required.
(293) to ground wires at rear
window defogger (tailgate models) Test lamp does not light. LOCATE and REPAIR open in BLK
or PPL/WHT (293) (panel door (150) wire.
models) to BLK (150) wires at rear
window defogger, ground G411.

REAR DEFOGGER PANEL LAMP DOES NOT WORK

TEST RESULT ACTION
Turn headlamps ON and position Test lamp lights. REPLACE panel light bulb.
dimmer control to BRIGHT.
Test lamp does not light. LOCATE and REPAIR open in
Connect test lamp from GRA (8)
GRA (8) wire.
wire at rear window defogger
switch connector C278 to ground.

A-146 REAR DEFOGGER

 C212
12059884 12059885

r 293-3.0 PPL/WHT fc 9 3 j 293-3.0 PPL/WHT

293-3.0 PPL/WHT

293-.S PPL/WHT ________ \

RH DOOR
CONTACTOR

RH REAR
WINDOW
— A V A V v W /M W — L -A V A W A W A W A — HEATER

REARDEFOGGER A-147
PANEL DOORS
 293-3.0 PPL/WHT 293-.3 PPL I

C103A C449
2977976 6288585 6288585 2977976
8917583
GT108
8911213 C912

89177378
dm

I 0- 8 GRAl

FRONT

FUSE BLOCK
REAR
WINDOW
DEFOGGER
SWITCH
GROUND
JUMPER

293-3.0 PPL/WHT
C280
12004201

60-3.0 ORN/BLK

*
CD

BUS
BAR
GROUND
G201
TIMER
RELAY

1150-1.0 BLKI

P39-.8 PNK/BLK;

148 REAR DEFOGGER

TAILGATE
CIRCUIT OPERATION
BACKUP LAMPS PARK, TAIL, MARKER AND LICENSE LAMPS REAR TAIL, MA RKER AND LICENSE LAMPS DO NOT OPERATE
With the Ignition Switch in RUN, or START, voltage is Voltage is applied through the T/L CTSY Fuse to the TEST RESULT ACTION
applied through the TURN/BU Fuse to the Transmission Light Switch at all times. With the Light Switch in the
Position Switch or the Backup Lamp Switch. Whenever PARK or HEAD, voltage is applied to the Park, Tail, 1. Place light switch in HEAD or Test lamp does not light. LOCATE and REPAIR open in BRN
the gear selector lever is shifted to REVERSE the Marker, and License Lamps. PARK position. If only license (9) wire between light switch
Transmission Position Switch or the Backup Lamp Switch lamp does not operate, GO to connector C202 and connector
closes and voltage is applied to the Backup Lamps and TRAILER WIRING step 5. Connect a test lamp from C300.
the Lamps turn on. Trailer wiring is a modification of the existing rear BRN (9) wire at connector C300 to
ground. Test lamp lights. If only RH rear Tail/Marker lamps
body harness. The trailer lamps operate in the same
and license lamps do not operate,
manner as the vehicle lamps. The trailer lamps are
GO to step 2. If only LH rear
grounded to the vehicle lamps. Tail/Marker lamps do not operate,
GO to step 3.
DIAGNOSIS — REAR EXTERIOR LAMPS
2. Connect a test lamp from BRN (9) Test lamp does not light. LOCATE and REPAIR open in BRN
wire at RH tail or marker lamp (9) wire between connector C300
PRELIMINARY CHECKS: connector C411 or C414 to and RH tail or marker lamp
The rear lamp systems (taillamps, clearance lamps, ground terminals G402 and G403. If only one system is ground. connector C411 or C414.
end gate lamps, and license plate lamps) all receive not working, LOCATE and REPAIR an open in the wiring
Test lamp lights. GO to step 4.
voltage from same wire circuit BRN (9) and share same and/or bulbs that pertain to that system.
3. Connect a test lamp from BRN (9) Test lamp does not light. LOCATE and REPAIR open in BRN
BACKUP LAMPS DO NOT OPERATE wire at inoperative LH tail or (9) between LH tail or marker lamp
marker lamp connector C412 or connector C412 or C413 and
TEST RESULT ACTION C413 to ground. connector C300.
1. Place ignition switch to RUN and Test lamp lights. GO to step 2.
Test lamp lights. Go go step 5.
transmission in reverse. Connect
a test lamp from LT GRN (24) wire Test lamp does not light. GO to step 3. 4. Connect a test lamp from BRN (9) Test lamp does not light. LOCATE and REPAIR open in BLK
at backup lamp connector C428 wire and BLK (150) wire at (150) between tail or marker lamp
or C429 to ground. inoperative tail or marker lamp connector C411, C412, C413 or
connector C411, C412, C413 or C414 and G403.
2. Connect a test lamp from LT GRN Test lamp lights. REPLACE bulb.
C414.
(24) wire to BLK (150) wire at
Test lamp lights. If rear tail or marker lamp is
backup lamp connector C428 or Test lamp does not light. LOCATE and REPAIR open in BLK inoperative, REPLACE bulb. For
C429. (150) wire from backup lamp to inoperative license lamps, GO to
ground terminal G403. step 6.
3. Connect a test lamp from DK BLU Test lamp lights. GO to step 4.
(75) wire at backup lamp switch Test lamp does not light. LOCATE and REPAIR open BRN
5. Connect a test lamp from BRN (9)
connector C286 or C118 to Test lamp does not light. CHECK condition of TURN/BU wire at license lamp connector (9) wire between license lamp
ground. fuse. If fuse is good LOCATE and C419, C420 or C421 to ground. connector and S300 and S404.
REPAIR open in DK BLU (75) wire
from backup lamp switch Test lamp lights. Inspect ground connection at
connector C286 or C118 to license lamp socket. If satisfactory
backup lamps. REPLACE bulb.

4. Connect a test lamp from LT GRN Test lamp lights. LOCATE and REPAIR open in LT
(24) wire at backup lamp switch GRN (24) wire from backup lamp
connector C286 or C118 to switch connector C286 or C118 to
ground. fuse block.

Test lamp does not light. Adjust backup lamp switch. If

backup lamp switch will not adjust
properly, REPLACE backup lamp
switch.

REAR LAMPS A-149

 RADIO/CLOCK
I 4 0 .8 ORN (SEE PAGES 144, 145)

LIGHT
SWITCH
RH SIDE
MARKER LAMP
(SEE PAGE 156)

T/L CTSY
20 AMP
ywwwwww 156
S HOT A T A L L T M E S ?
mwwwwvs C411
8911035

RH TAIL,
STOP AND
C ji TURN LAMP

9-.8BRN

9-.8BRN

p 420 440 2
29 15
439 806 39
N 9 39 14
M I 12 J
L 140 120
31 3
L 3 11
(m 50 436
5300
35 2 9-.8BRN
r
93 97 422
91 92 6

12015024

LH TAIL
■ I9 -.8 BRN I
STOP AND
TURN LAMP
LH SIDE (Q )
MARKER LAMP ____
(SEE PAGE 156) •“

I9 -.8 BRN I SHEET SHEET |

(SUBURBAN) C412
METAL
GROUND
METAL
GROUND I
m m
8811035

b lk ■ ■ m m
G402 G403
A-150 TAILLAMPS
SUBURBAN/UTILITY
 RPO COOES
RADIO/CLOCK
(SEE PAGES 144, 145) R05 - DUAL REAR WHEELS

T/L CTSY
20 AMP

RH SIDE
MARKER LAMP
(SEE PAGE 156)

156

RH TAIL,
STOP AND
TURN LAMP

LIGHT
SWITCH
I I 150-.8BLK

11 150-.8 BLK
RH CLEARANCE
LAMPS (R05)
1 1 9-.S BRN ■
(SEE PAGE 156)

Ll 9-.8 BRN ■

9- 8 BRN

C300

■M 9-.8B R N M I

19-.8 BRN I LH CLEARANCE

■■ 9-.8 BRN ■ I
LAMPS (R05)
(SEE PAGE 156) ■ I 150-.8 BLK I

■ I 150-.8 BLK

C101
12020099 SHEET SHEET
LH SIDE METAL METAL
MARKER LAMP
(SEE PAGE 156) GROUND GROUND
G403 G404
TAILLAMPS A-151
FLEETSIDE AND WIDESIDE
 w w w vw w w *
S204 44
S HOT A T ALL TIMES < RADIO/CLOCK
40-.8 ORN | 0 M B M 40-, 8 ORN
W W W W W 'T (SEE PAGES 144, 145)

l/P CTSY LPS

T/L CTSY | 40-.8 ORN
(SEE PAGE 118)
20 AMP
Z
tr
o

150- ■1
DOME
2-
RH TAIL,
CIRCUIT
BREAKER* STOP AND
25 AM P
l«l-HEAD TURN LAMP
-1
OFF
' PARK

HEAD

LIGHT
SWITCH

C412
6288424

LH TAIL
STOP AND
TURN LAMP

LH TAIL, STOP, FRAME RH TAIL, STOP,

AND TURN GROUND AND TURN
LAMP GROUND G405 LAMP GROUND
G406 G407

A-152 TAILLAMPS
STEPSIDE
 75-.8 DK BLU I

WW WAM C286
wmm M 24-.8 LT GRN ■
< HOT IN RUN < 2973407
> w w vw *

TURN/BU e. 175-.S DK BLU

15 AMP BACKUP
LAMP SWITCH
(AUTO TRANS ONLY)
CLOSED WHEN TRANS
IN REVERSE

o 24
B
*
REV

LL © S402
i

~> EA l © RH TAIL, STOP,

I

Ui TURN AND SIDE

z 75 MARKER LAMPS
(SEE PAGE 150)

BACKUP
LAMP SWITCH
(MAN TRANS ONLY) CJD
CLOSED WHEN TRANS
IN REVERSE

RH BACKUP
24- 0 LT GRN LAMP

GT401 8911027 (UTILITY)

(SUBURBAN ONLY) 8911028 (SUBURBAN)

I 150-.8BLK

P 94 29 15 I 420 440 2
439 806 39 :
LH BACKUP

r
N 9 39 14
L 140 120 I 24-.8LTGRN
M 33 12 J
31 3
LAMP
L 93 11
35
r
50
35
436
2
C428

z 8911027 (UnLTTY)
93 97 422 : cc 8811028 (SUBURBAN)
(S
91 92 6

I 150-.8 BLK LH TAIL, STOP,

TURN AND SIDE
MARKER LAMPS
I 150-.8 BLK
C100 24-,8 LT GRN (SEE PAGE 150)
1202184

l/P
GT400
(SUBURBAN ONLY)

9 120 18
12015798
c 19 30 I 24-.0 LT GRN I
SHEET SHEET
METAL METAL
GROUND GROUND
G402 G403
BACKUP LAMPS A-153
SUBURBAN/UTILITY
 RPO CODES

LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE VIN J

kAAWWWW
\ HOT IN START ?

>w w w w v^

TURN/BU
15 AMP I 175-.S DK BLU I BACKUP
LAMP SWITCH
(AUTO TRANS ONLY)
CLOSED WHEN TRANS
BACKUP IN REVERSE
C200
LAMP SWITCH
(MAN TRANS ONLY)
CLOSED WHEN TRANS
IN REVERSE
H D
O 24 B
U-
i

(o ) I 24- 8 LT GRN RH TAIL, STOP,

R EV

TURN AND SIDE

i

K
3U E @ I75 -.8 DK BLU MARKER LAMPS
I

L A 150-.8 BLK
Z 75 J A (SEE PAGE 151)
12064769

GT101 I
12064740 I
L
75-. 8 DK BLU

— I24-.8 LT GRN I
-r±K (LL4 ONLY)

24-.S LT GRN
RH BACKUP
LAMP

l/P

150-.8 BLK

p 94 29 15 I 420 440 2

N 9 39 14
439 806 39 LH BACKUP
24-.8 LT GRN
M 33 12 L 140 120
LAMP
J 31 3
L 93 11
C428
y 50 75 I
35 2
18 120 9 r
93 97 24
91 92 1

150-.8 BLK LH TAIL, STOP,

TURN AND SIDE
MARKER LAMPS
(SEE PAGE 151)

I 24-.6 LT GRN I
SHEET
METAL
GROUND
G403
A-154 BACKUP LAMPS
FLEETSIDE AND WIDESIDE
 75-. 8 DK BLU I

yw w w w C266
I 24- 8 LT GRN M ■ ^ y g g l
V HOT IN RUN C 2973407

w vvw *

TURN/BU BACKUP
15 AMP LAMP SWITCH
(AUTO TRANS ONLY)
CLOSED WHEN TRANS
IN REVERSE

o 24 B PART OF
>
LL

E
> LAMP ASSEMBLY 24-.8 LT GRN
_ Ul
\- CC
ID
UJ A
z 75

C118
BACKUP 12015792

LAMP SWITCH RH BACKUP

(MAN TRANS ONLY)
LAMP
CLOSED WHEN TRANS
IN REVERSE

CO
4;
§
o
o
24-.S LT GRN I
I S410

2
CC
o

I 420 440 2
P 94 29 15
439 806 39
N 9 39 14
L 140 120
M 33 12 J 12015798
31 3
L 93 11
(J 50 436

18 120 9 r 35
97
2
422 :
93
91 92 6

\
2 4 -.8 L T G R N
PART OF
LAMP ASSEMBLY

l/P 150-.8 BLK 150-.8 BLK ■ M H |

r Y I
LH BACKUP
LAMP

I 24-.S LT GRN I

LH TAIL, STOP, FRAME RH TAIL, STOP,

AND TURN GROUND AND TURN
LAMP GROUND G405 LAMP GROUND
G406 G407
BACKUP LAMPS A-155
STEPSIDE
 RADIO/CLOCK
(SEE PAGES 144, 145)

RH SIDE
LIGHT
MARKER LAMP
SWITCH

0
C414
6294015

BACKUP LAMP
(SEE PAGE 153)

RH TAIL, STOP
ANDTURN LAMP
(SEE PAGE 150)

9- .8 BRN 9-.8BRN

GT 401
(SUBURBAN ONLY)

12015024 12015798
UCENSE LAMP
I 9-.S BRN I
(SEE PAGE 158)

I 420 440 2
29 15
439 806 39 :
9 39 14
J 12 J L 140 120
5
31 3 CD
3 11 co
(D ] 50 436
g
r 35 2 S300 9*.8 BRN 9-.8 BRN
93 97 422
91 92 6

V GT 400
(SUBURBAN ONLY)
*
| S405
150-.8 BLK | BACKUP LAMP
(SEE PAGE 153)

9-.8 BRN I LH TAIL STOP

AND TURN LAMP
S403 • 150-.8 BLK ■ ■ ■

I
(SEE PAGE 150)
i V
I 150-.8 BLK H i

C413
6294015

I9 -.8 BRN I SHEET SHEET

METAL METAL
C101 LH SIDE
12020099 GROUND GROUND
MARKER LAMP
G402 G403
A-156 REAR PARK AND MARKER LAMPS
SUBURABN/UTILITY
 RRO CODES
S204
RADIO/CLOCK
40-.8 ORN 0 M r 40-.8 ORN WIDESIDE PICK-UP R05 - DUAL REAR WHEELS
(R05 ONLY)

T/L CTSY
20 AMP RH FRONT RH REAR
RH SIDE
CLEARANCE CLEARANCE
MARKER LAMP
LAMP LAMP
C414
6264015

BACKUP LAMP
(SEE PAGE 154)

RH TAIL STOP
AND TURN LAMP
(SEE PAGE 151)

LICENSE LAMP
(SEE PAGE 158)

94 29 15
I420 440 2 ■9-.BBRN
439 806 39
9 39 14
33 12 J L 140 120
31 3 END GATE
93 11 f
D j SO 436 IDENTIFICATION
LAMPS
r 9735 2 (SEE PAGE 151)
18 120 9 93 422 i
24 30 19 j
91 92 6

LH TAIL, STOP
AND TURN LAMP
(SEE PAGE 151)

BACKUP LAMP
t/P
(SEEPAGE 154)

19-. 8 BRNI LH FRONT LH REAR LH SIDE

CLEARANCE CLEARANCE MARKER LAMP
LAMP LAMP SHEET
METAL
GROUND
■WIDESIDE PICK-UP ■ G403
(R05 ONLY)

REAR PARK AND MARKER LAMPS A-157

FLEETSIDE AND WIDESIDE
 RADIO/CLOCK
40-.8 ORN (SEE PAGES 144, 145)

l/P CTSY LPS

(SEE PAGE 118)

LIGHT
SWITCH

RH SIDE
MARKER LAMP
| (SEE PAGE 156) |
T/L CTSY
20 AMP
1150-.8 B L K M
yvwvwwwv/ D C202
150- - 156
S H O TATALLTN ES < DOME 1 9-.8 BRN H
12004628 2-
Ta w w w v w v n I OFF
(SUBURBAN)

C1RCUIT RH TAIL, STOP

' PARK
BREAKER AND TURN
2$ A M P LAMP
I * HEAD -10 (SEE PAGE 156)

OFF
'P A R K
40-

HEAD

RADIO/CLOCK
9-.8 BRN I 9-.8 BRN I
(SEE PAGES 144, 145)

§
o LICENSE
o
LAMP
VP

9-.8BRN

cc
.cl I 420 440 2
439 806 39 :
L 140 120
31 3
D ] 50 436

r
93
35
97
2
422
9- 8 BRN ■

30
91 92 6

33

12020184
C100 LH TAIL, STOP
AND TURN
LAMP
(SEE PAGE 156)

19 -8 BRN I
150-.8 BLK m
(SUBURBAN)
I9-.8 BRN I

[I 9 120 18 LH SIDE
L 19 30 24 MARKER LAMP
(SEE PAGE 156) SHEET SHEET
I9 -.8 BRN I METAL METAL
C101 GROUND GROUND
12020099
G402 G403
A-158 LICENSE LAMP
SUBURBAN/UTILITY
 LICENSE LAMP A-159
FLEETSIDE AND WIDESIDE __________
 RPO CODES

TP2 - AUXILIARY BATTERY

BATTERY
JUNCTION
BLOCK
(W/OTP2)
Z
cc
0
*o
r
z
X
o
TAIL, STOP
■ TURN SIG, MARKER
AND BACKUP LAMPS
BATTERY
JUNCTION
BLOCK
(W/O TP2)
TAIL, STOP
— TURN SIG, MARKER
oj cn AND BACKUP LAMPS

|J jtO ) ( 0 7 I C300

IN-LINE IN-LINE
FUSE Q D 'S'C D FUSE
30 AMP (30 AMP)

O
O
47-3.0 DK BLU- AUX

2-5.0 RED- POWER FEED 2-5.0 RED- POWER FEED

24-.8 LT GRN- BACKUP LAMP

24-.A LT GRN- BACKUP LAMP 9-.8 BRN- TAIL AND UCENSE LAMP

S-.8 BRN- TAIL AND LICENSE LAMP 18-.8 YEL- LH STOP AND TURN SIG LAMP
TRAILER
18-.8 YEL- LH STOP AND TURN S/G LAMP 19-.8 DK GRN- RH STOP AND TURN SIG LAMP

t0-.8 DK GRN- RH STOP ANO TURN S/G LAMP 22-5.0 WHT- GROUND
IN-LINE IN-LINE
FUSE FUSE
30 AMP (30 AMP)

19-.8 DK GRN REAR 19-.8 DK GRN

REAR LAMP
LAMP 24-.S LT GRN 24-.S LT GRN
CONNECTOR
BATTERY CONNECTOR 9-.8 BRN ■ ■ BATTERY C101
B-.8 BRN
C101
JUNCTION 12020099 18-.8 YEL ■ ■ JUNCTION 12020099 18-.8 YEL
FRAME BLOCK
BLOCK
(W/TP2) GROUND CAMPER EQUIPMENT (W/TP2) FRAME HEAVY DUTY TRAILER
G403 GROUND G403

A-160 CAMPER AND TRAILER WIRING

DIAGNOSIS
Conditions most likely to cause vacuum system vacuum gage of the pump provides a means of checking IMPROPER AIR DISTRIBUTION FROM OUTLETS
problems include hoses that leak or become for a vacuum leak as well. Once vacuum is applied to
disconnected. With the engine running, either condition operate the component, the gage should hold steady TEST RESULT ACTION
is easily detected from the hiss of air at the opening. until the vacuum is purposely released. Vacuum at or near engine vacuum
1. Disconnect the vacuum hose at REPAIR binding condition in air
Other common vacuum problems are kinked or On vacuum system that are controlled by electrical or the actuator for the inoperative at idle. valve or linkage. (If no binding is
obstructed hoses, hoses connected incorrectly or electronic switches, check for a blown fuse, wiring that is air valve (“door”). With the found, REPLACE actuator.)
binding components. cracked, frayed or burned, and high resistance in engine idling and the mode Little or no vacuum. GO to step 2.
A vacuum pump can be used as a vacuum source to connectors of the control circuits) before checking for a lever set in a position that will
operate components and test the system. The built-in suspected vacuum system problem. apply vacuum to the actuator,
check for vacuum at the
disconnected hose.
DIAGNOSIS - AUXILIARY HEATER VACUUM CONTROL 2. Disconnect the vacuum hose Vacuum at or near engine vacuum REPAIR obstruction or vacuum
harness at the rotary selector at idle. leak in hose to the affected
PRELIMINARY CHECKS: valve on the A/C control actuator.
With the engine warmed up and running, verify that heater or A/C heating system is functioning correctly but assembly. With the same test Little or no vacuum. GO to step 3.
the front heater can deliver a strong flow of heated air the auxiliary heater does not, the problem is in the conditions as in step 1, check
from the floor outlets with the blower switch on “HI," the auxiliary heater system. The following procedure will for vacuum at the rotary selector
mode selector set for heater operation and the isolate the cause. valve port that feeds the
temperature lever in the full "HOT" position. If the front suspected vacuum hose.
LITTLE OR NO HEAT FROM AUXILIARY HEATER 3. With the vacuum supply hose Vacuum at or near engine vacuum. REPLACE rotary selector valve.
TEST RESULT ACTION disconnected from the rotary
selector valve and with the Little or no vacuum. REPAIR obstruction or vacuum
1. With the engine running and the No airflow (or improper airflow). REFER to Auxiliary Heater
same test conditions as in step leak in vacuum supply hose.
auxiliary heater “OFF,’’move the Diagnosis in this manaul. 2, check for vacuum at the open
auxiliary heater control rocker Proper airflow in both control end of the tan vacuum supply
switch to “ LO” and then to switch positions. GO to step 2. hose.
“ HI,” pausing to listen for a
change in the force of the
airflow from the heater outlet
with the change. DIAGNOSIS - CRUISE CONTROL VACUUM HARNESS
2. With the engine running and the No vacuum. GO to step 3.
auxiliary heater switch in “ LO,”
CRUISE CONTROL DOES NOT OPERATE
Vacuum. GO to step 4.
disconnect the vacuum hose at
TEST RESULT ACTION
the hot water valve and feel for
vacuum at the hose end. 1. Disconnect vacuum hose Vacuum is less than normal engine REPAIR vacuum pump (diesel
(smaller hose) at vacuum valve vacuum at idle. engine) or air leak in hose or
3. Disconnect the hot water valve No vacuum. REPAIR vacuum source line or connections between cruise
inlet of servo unit. Connect a
vacuum hose at the auxiliary REPLACE auxiliary heater control
vacuum gage to the control servo and vacuum source
heater control switch and feel switch, as necessary.
disconnected hose. Start engine (inlet manifold vacuum fitting or
for vacuum at the open port of Vacuum. REPAIR or REPLACE faulty hot vacuum pump).
and allow it to idle. Measure
the switch. water valve vacuum hose. vacuum at vacuum hose. Vacuum is same as normal GO to step 2 (gas engine).
4. Connect all vacuum hoses. With Little or no heat. REPAIR or REPLACE the hot engine vacuum at idle. Verify complaint (diesel engine).
the engine warmed up and water valve, heater core or heater
2. Momentarily accelerate engine Vacuum reduces noticeably as REPLACE check valve in line from
running, place the auxiliary hoses and pipes as necessary.
sharply while watching vacuum engine accelerates. vacuum source.
heater control switch in “ HI.” Adequate heat. VERIFY complaint. Vacuum gage. Vacuum does not change. GO to step 3.
After at least a minute of system is OK.
operation in this mode, carefully 3. Stop engine. Disconnect Vacuum drops. REPAIR air leak in hose or
feel the temperature of the vacuum gage and connect connections, or ADJUST or
heater inlet pipe downstream vacuum hose to servo unit. REPLACE vacuum release valve
from the hot water valve. Disconnect vent hose (larger on brake pedal bracket.
hose) from servo unit and Vacuum does not change. REFER to Cruise Control
DIAGNOSIS - FRONT MANUAL AIR CONDITIONING VACUUM CONTROL connect a vacuum pump with Diagnosis in this manaul.
PRELIMINARY CHECKS: built-in vacuum gage to the
Use the charts in this section to verify that air is either disconnected hose. Operate
for the hiss of a vacuum leak, checking for proper
begin delivered from an outlet when it should not be, or vacuum pump to obtain the
vacuum hose connections and kinked, pinched or
same vacuum as observed in
that air is not being delivered when it should be, during misrouted hoses), be sure the complaint is not caused step 1. Stop pumping and
operation in one or more modes. by a mechanical problem before making additional observe the vacuum reading.
After making checks of the vacuum system (listening vacuum system checks.

VACUUM SYSTEM A-161

CIRCUIT OPERATION AIR DISTRIBUTION
MODE UPPER (l/P) LOWER (FLOOR) DEFROSTER REMARKS
VACUUM SYSTEMS SELECTION A/C OUTLETS HEATER OUTLETS OUTLETS
A vacuum-operated component uses the force of The servo unit of the cruise control is a special type OFF NONE NONE NONE
normal air pressure working against the lower air of vacuum actuator with an internal control valve that can MAX A/C HIGH NONE NONE a, b
pressure of a partial vacuum to provide voltage that apply varying amounts of vacuum to the diaphragm. The NORM A/C HIGH NONE NONE a
operates the component. With a gasoline engine, the varying vacuum provides a calibrated range of throttle BI-LEVEL MEDIUM MEDIUM NONE a
vacuum created in the inlet manifold when the engine is positions that can accurately control vehicle speed. The V EN T HIGH NONE NONE c
HEAT NONE HIGH LOW c
running is stored in a ball-shaped vacuum tank function of the servo is explained more fully under
DEF NONE LOW HIGH a
suspended from the center of the hood inner panel. A -CRUISE CONTROL VACUUM CONTROL" in this section.
check valve in the line feeding vacuum to the tank keeps REMARKS:
the stored vacuum from weakening when inlet manifold AUXILIARY HEATER VACUUM SYSTEM a — Refrigeration system operates. b — Inside air recirculated. c — Refrigeration system off; no air cooling available.
vacuum drops during high speed or high voltage The auxiliary heater control switch in the instrument
operation. panel routes battery voltage to the auxiliary heater blower
motor when the auxiliary heater control switch is "ON" ROTARY SELECTOR VALVE OPERATING CHART
An engine-driven mechanical vacuum pump serves as
and the ignition switch is in RUN. CONNECTIONS MODE SELECTION
the source of vacuum with a diesel engine. A vacuum HOSE
tank is not required with a vacuum pump. VALVE COLOR MAX NORM BI­
TERMINAL OFF VENT HEAT DEF
In addition, the switch routes vacuum from the PORT NO. A/C A/C LEVEL
Vacuum is routed through hoses to a mechanical or vacuum tank to the vacuum actuator that opens the 1 SOURCE GRA VAC VAC VAC VAC VAC VAC VAC
electric valve that provides a means of controlling the auxiliary heater hot water valve. When open, the hot 2 A/C MODE TAN V EN T VAC VAC VENT VAC VENT VEN T
vacuum-operated component. When the valve is open, water valve admits heated coolant to the auxiliary heater 3 HEAT MODE BLUE VAC VENT VENT VENT VEN T VAC VAC
it allows vacuum to go to an actuator that actually inlet pipe and auxiliary heater core. 4 RECIRC & PLENUM ORN VEN T VAC VENT VENT VEN T VENT VEN T
operates the component. When the component is to be 5 DEFROST MODE BLK V EN T VENT VENT VEN T VEN T VENT VAC
returned to its original position, the valve cuts off the When the auxiliary heater control switch is turned
vacuum to the actuator hose and vents the hose to “OFF," electric voltage to the blower motor is cut off and
normal air pressure. the hot water valve vacuum actuator is vented to
CRUISE CONTROL VACUUM SYSTEM When the system is engaged and operating, the
The cruise control system uses vacuum to operate a servo operates the throttle as follows:
A typical actuator is a metal shell with a movable atmospheric air to close the valve. This stops the flow of
coolant to prevent unwanted heat. servo unit that adjusts throttle position to maintain a Steady Cruise: Both the vacuum valve and the vent
shaft that retracts and extends to mechanically operate
desired vehicle speed. The electronic control module of valve are closed, trapping vacuum in the diaphragm
the component. A flexible diaphragm separates the
the cruise control system operates a vacuum valve and
interior of the shell into two chambers - a sealed FRONT MANUAL chamber to hold a steady throttle setting.
a vent valve in the servo to trap enough vacuum in the
chamber to which vacuum can be admitted, and an AIR CONDITIONING Vehicle Losing Speed: The cruise control module opens
servo to hold the required throttle setting. A vacuum
open chamber exposed to normal air pressure. The the vacuum valve to increase the strength of the vacuum
movable shaft is attached to the center of the diaphragm
VACUUM SYSTEM release valve on the brake pedal bracket vents the
The front manual air conditioning system uses trapped vacuum to atmosphere when the brake pedal is in the diaphgram chamber. The vent valve remains
and extends from the open chamber.
vacuum to operate the air valves (“doors") that control depressed, allowing the servo to quickly return the closed.
When vacuum is directed to the sealed chamber, airflow through the air conditioning module. throttle to idle.
Vehicle Gaining Speed: The cruise control module
normal air pressure presses on the other side of the
opens the vent valve to the atmosphere to reduce the
diaphragm and causes it to retract the shaft. When the Vacuum is supplied from the vacuum tank on the Control Module Functions vacuum in the diaphragm chamber so the throttle return
vacuum is cut off, the sealed chamber is vented to cowl panel in the left corner of the engine compartment. The cruise control module continually interprets the spring can take over and reduce the throttle opening.
outside air to balance the air pressure on both sides of The vacuum supply line brings vacuum to the rotary setting of the mode control switches, the position of the The vacuum valve remains closed.
the diaphragm and eliminate the force that retracted the selectors valve that is operated by the mode lever of the servo linkage to the throttle and the output of the vehicle
shaft. A coiled spring within the sealed chamber air conditioning control assembly in the instrument panel. speed sensor. In response to these inputs, the cruise The cruise control module pulses the opening of the
expands to push the diaphragm back to its original A vacuum hose harness brings vacuum from the ports in control module electrically signals the momentary vacuum valve or the vent valve for minor speed
position. This extends the shaft. the rotary selector valve to the vacuum actuators for the opening or closing of the vacuum and vent solenoid corrections until the vehicle reaches the set speed.
In addition to the two-position actuator described air valves of the air conditioning system. All actuators valves in the servo unit. Under normal road load conditions, the vacuum valve will
above, a three-position actuator may be used for certain except the heater and air conditioning actuator are two- remain completely open, instead of pulsing, when vehicle
applications. The three-position actuator has a vacuum position actuators controlled by one vacuum hose. The Servo Unit Functions speed drops 5 mph below the set speed. When the
hose at each end of the shell. When vacuum is applied heater and air conditioning actuator is a three-position vehicle speed exceeds 3 mph over the set speed, the
The cruise control servo consists of a vacuum-
to either end of the actuator and the opposite end is actuator with two vacuum hoses. Application of vacuum operated diaphragm, a normally closed solenoid valve to vent valve will remain completely open, instead of
vented, the shaft will move in the direction of the end or vented air to each actuator is determined by the pulsing.
admit vacuum to the servo diaphragm chamber, a
having the vacuum. When both ends of the actuator are operating mode selected by setting the mode lever in the normally open solenoid valve to vent the diaphragm The servo will go into a completely open vent valve
vented to normal air pressure, internal springs center the control assembly. The following charts indicate the air chamber to atmosphere, and a variable inductance position, returning the throttle to idle, when the brake or
shaft. This provides a center position as well as both outlets that operate in each mode selection and the position sensor that signals the position of the servo clutch pedal is depressed, when electrical voltage to the
extremes for an actuator application that requires three response of the rotary selector valve to each mode lever linkage - and accordingly, the throttle setting - to the system is lost (such as when the cruise control switch or
operating positions. The heater and air conditioning position. cruise control module. the ignition switch is turned off) or when there is an open
actuator of the R/V truck front manual air conditioning in the variable inductance position sensor coil in the
system is a three-position actuator. servo.

A-162 VACUUM SYSTEM

CIRCUIT OPERATION
POWER BRAKE BOOSTER VACUUM The EGR system used with gasoline engines remains When the ECM recognizes the operating range in EGR VALVE
closed during periods of engine idle and deceleration to which no exhaust gas recirculation is needed, the EGR
SYSTEM VACUUM SYSTEM
The power brake booster is a tandem diaphragm prevent rough idle from excessive dilution of the air/fuel vent solenoid opens to vent the vacuum at the EGR
A leak in the EGR (exhaust gas recirculation) vacuum
vacuum-suspended unit. When the engine is running, mixture. It also remains closed at wide-open throttle to valve.
system can upset the ECM’s programmed control of
inlet manifold vacuum is transmitted to the booster unit prevent power loss. At other times, it rapidly cycles open
exhaust gas recirculation and adversely affect engine
through a vacuum hose. A check valve at the power and closed to modulate the flow of exhaust gas as At idle, the ECM energizes the EPR valve solenoid to
operation. Too much exhaust gas recirculation at idle or
brake booster end of the hose keeps air from flowing required. Under certain circumstances, it may remain send vacuum to close the EPR valve. This increases
cruise with a gasoline engine can result in the engine
from the hose into the booster unit and weakening the fully open to provide the maximum EGR. exhaust back pressure to force more exhaust gas
stalling after closed throttle deceleration, surging during
power brake operating force when inlet manifold vacuum through the EGR system and lower combustion
steady throttle cruising, or a rough idle. Too little
is low. In gasoline engines, the manifold absolute pressure temperatures to reduce oxides of nitrogen emissions.
exhaust gas flow allows combustion temperatures to
(MAP) sensor measures the strength of inlet manifold
become too high and bring about detonation ("spark
With the service brakes released, vacuum is supplied vacuum in the EGR vacuum circuit and sends a signal
knock") or an overheated engine. In addition, nitrous
equally to both sides of the two diaphragms in the back to the electronic control module (ECM). The ECM
oxide emissions may be high enough to cause the
booster unit. JJecause pressure on both sides of the uses the signal from the MAP sensor to control fuel PRELIMINARY CHECKS: vehicle to fail an emissions test.
diaphragms are balanced, no boost is provided to the delivery and ignition timing. In addition, the ECM will
braking system and the brakes are not applied. adjust the on-off intervals of the EGR valve to correct the POWER BRAKE BOOSTER VACUUM Because the source of an EGR system symptom
flow of exhaust gas into the cylinders if actual vacuum
SYSTEM might be traced to a mechanical or electrical condition
When the driver presses down on the brake pedal, differs from the preferred vacuum as calculated by the
Little or no power assist upon brake application can as well as a faulty vacuum system, an effective
the pedal pushrod depresses a spring-loaded air valve ECM. This provides the required control of oxides of
be caused by a faulty power brake booster vacuum systematic diagnosis procedure should examine all three
within the power brake booster. The air valve opens to nitrogen emissions while retaining engine performance
system. A simple two-step procedure can be used to categories of components - not just the vacuum system
admit air at atmospheric pressure to the back side of under all operating conditions.
check out the vacuum system if a visual inspection fails alone. Therefore, no exclusive vacuum system diagnosis
both diaphragms. This forces the diaphragms forward to uncover the cause. procedures are provided here. For more information on
and causes a piston rod in the booster unit to push the Vacuum for the EGR system of gasoline engines is
the EGR system, refer to the "Fuel and Emissions Service
brake master cylinder pistons and apply the service taken from the throttle body and routed through a hose
• With the engine off, apply and release the brake a Manual."
brakes. to the electronic vacuum regulator valve (EVRV). This
number of times to exhaust all vacuum from the
valve is controlled by the 435 circuit from the ECM.
power brake booster. As many as 8 to 10 strokes
The amount of atmospheric air admitted to the back When the EVRV solenoid is energized, the valve routes
may be required. Then hold your foot on the brake
side of both diaphragms depends upon the force the vacuum to the EGR actuator. The actuator opens the
pedal with a firm pressure (comparable to the
driver applies to the brake pedal. The greater the pedal EGR pintle valve to allow exhaust gas to flow into the
pressure required to bring the vehicle to a normal
pressure, the more the valve opens. This provides a inlet manifold. When the EVRV solenoid is released, the
gradual stop). While maintaining a steady pressure,
power boost that multiplies the force applied to the valve vents the EGR actuator to outside air to close the
start the engine. If the vacuum system is working
master cylinder pistons in proportion to the pressure on EGR pintle valve.
properly, you should feel the brake pedal "fall away"
the brake pedal. slightly under your foot as the engine starts. If there
In the LH6 diesel engine, the operation of the EGR
is no power assist, refer to the R/V, G and P Truck
When the brake pedal is released, the flow of valve is assisted by the exhaust pressure regulator (EPR)
Service Manual, Section 5A-1.
atmospheric air is cut off and inlet manifold vacuum valve. At idle, the EPR valve increases exhaust back
draws off the air behind the diaphgrams. As a result, air pressure to force more exhaust through the EGR valve
• With no pressure applied to the brake pedal, shut off
pressures within the diaphgram chambers are once and reduce combustion temperatures. The vacuum
the engine and allow the vehicle to stand undisturbed
again balanced so no power boost is developed. which operates the EGR valve and the EPR valve is
for 3-5 minutes. Then depress and release the brake
supplied by an engine-driven vacuum pump.
pedal a number of times until firm resistance is met
with very little brake pedal travel. A vacuum leak or
EGR VALVE VACUUM SYSTEM The electronic control module (ECM) controls the
a faulty check valve at the booster unit end of the
The exhaust gas recirculation (EGR) system allows a EGR valve solenoid to regulate the vacuum to the EGR
vacuum hose is indicated if firm resistance is
small amount of exhaust gas to flow from the exhaust valve in the same way as with a gasoline engine. The
encountered with very little brake pedal travel on the
manifold into the inlet manifold when the throttle is ECM calculates the amount of exhaust gas recirculation
first few strokes.
opened beyond idle and inlet manifold vacuum is normal. based on inputs from the engine speed sensor and the
This reduces combustion temperatures in the engine to throttle position sensor, and pulses the EGR valve
control oxides of nitrogen emissions. solenoid to control EGR. The manifold absolute pressure
(MAP) sensor monitors the control of exhaust gas
The EGR valve is operated by an integral vacuum recirculation as indicated by the air pressure in the EPR
actuator that controls a pintle within the valve. The pintle vacuum line. If actual vacuum differs from the preferred
remains closed to prevent exhaust gas recirculation until vacuum as calculated by the ECM, the ECM will adjust
vacuum is applied to the actuator. The vacuum causes the on-off intervals of the EGR valve to correct the flow
the pintle to open, allowing the measured flow of exhaust of exhaust gas into the cylinders.
gas to enter the inlet manifold.

VACUUM SYSTEM A-163

A-164 VACUUM HOSE ROUTING
 CRUISE CONTROL
AIR CONDITIONING
AUXILIARY HEATER
(SEE PAGES 94, 99, 124)

VACUUM
PUMP

ECM
I538-.8 DK GRN I
(SEE PAGE 65)

EPR
VALVE
SOLENOID = 3 VENT

EGR
VALVE
BRAKE SOLENOID
PEDAL

DIAGNOSTIC
CONNECTOR
(SEE PAGE 65)

EGR VENT
VALVE
SOLENOID

EPR
MAP
VALVE
ENGINE SENSOR
ACTUATOR
GROUND
G115

POWER BRAKE BOOSTER VACUUM SYSTEM EGR VALVE VACUUM SYSTEM (GASOLINE ENGINE) EGR/EPR VACUUM SYSTEM (DIESEL ENGINE)

VACUUM HOSE ROUTING A-165

 C187

FRONT
OF VEHICLE

GT105

S112

12C10

Figure 1 - Daytime Running Lamps Relay

1. Battery Junction Block

G105
C100 FRONT ^ 2. Windshield Washer Motor and Reservoir
OF V E H IC L E ^ LH High-Low Headlamp
4. LH High Beam Headlamp
5. LH Park and Turn Lamp
6. LH Front Side Marker Lamp
S111 7. RH High Beam Headlamp
8. RH High-low Headlamp
GT105 9. RH Front Side Marker Lamp
10. RH Park and Turn Lamp

C140 \ \ ^ FRONT
OF VEHICLE
C137 C139 12H2

VIEW G105 C149 G106 FRONT

FRONT ^ OF VEHICLE
S112 OF VEHICLE C154
C155

C150
S111 S113'
1. Battery Junction Block
2. LH High-Low Headlamp
3. LH Park and Turn Lamp C145
4. LH Front Side Marker Lamp
5. RH High-Low Headlamp C146 C157
C153-
6. RH Front Side Marker Lamp FRONT C151 r i _9 G107
7. RH Park and Turn Lamp OF VEHICLE V )E W VIEW A I C152
12H1 B

Figure 2 - Front Headlamps-Base Figure 3 - Front Headlamps-Dual Headlamps-Quad Halogen

A-166 COMPONENT LOCATOR VIEWS

 S212
S209

1. Clutch Switch
2. Dimmer Switch
3. Backup Lamp Switch
4. Ignition Switch
5. Steering Column
6. Turn Signal Switch

C286
S210

S207
C100
FRONT
OF VEHICLE
FRONT
OF VEHICLE

1. I/P Cluster
2. Headlamp Switch
GT105 3. Parking Brake Switch 12H37.2
4. Turn Signal Flasher
5. Fuse Block

12H37.1

V FRONT
OF VEHICLE

C206

VIEW A VIEW B
Figure 4 - Headlamp Switch and Fuse Block Figure 6 - l/P Ground

COMPONENT LOCATOR VIEWS A-167

 1. LH Rear Marker Lamp
2. RH Rear Backup Lamp
C424 3. RH Rear Taillamp
(INSIDE 4. LH Rear Taillamp
HARNESS 5. LH Rear Marker Lamp
WRAP) 6. LH Rear Backup Lamp

FRONT
OF VEHICLE

G403 (LH SIDE)

FRONT
C413 G402 (RH SIDE) OF VEHICLE

C300

S410
>C423 (INSIDE
HARNESS WRAP)
12H73.73.1

Figure 7 - Rear Lamps Wiring Extension Harness Figure 9 - Rear Lamps-Fleetside

1. LH Front Clearance Lamp

C417 (LH SIDE) 2. LH Rear Clearance Lamp
C428 C415 (RH SIDE) (LH shown, RH same)

1. RH Rear Taillamp
2. RH Rear Backup Lamp
3. License Lamp
4. LH Rear Backup Lamp
5. LH Rear Marker Lamp
6. LH Rear Taillamp
7. RH Rear Marker Lamp FRONT
C413 OF VEHICLE

'GT400 (LH)
12H101 12H100

Figure 8 - Rear Lamps-Suburban and Utility Figure 10 - Side Clearance Lamps-Dual Rear Wheels

A-168 COMPONENT LOCATOR VIEWS

 VIEW

* FRONT
1. Stoplamp Switch with Cruise Control OF VEHICLE
2, Stoplamp Switch
VIEW B
Figure 11 - Rear Lamps - Stepside FigureJ 3 - Stop Lamp Switch

Figure 12 - Endgate Identification Lamps Figure 14 - Convenience Center

COMPONENT LOCATOR VIEWS A-169

 "C239

FRONT
OF
VEHICLE
VIEW |~A~|

^ FRONT
^ C OF VEHICLE

1. Right Roof Marker Lamp

2. Front Roof Identification Lamps
VEHICLE
3. Left Roof Marker Lamp
4. Headlamp Switch
VIEW B 12H106

Figure 15 - Roof Marker Lamps

1. LH Battery
2. RH Battery

Figure 16 - Rear Lamps Extension Harness Figure 18 - Batteries - 6.2L V8 and 6.2L V8 HD Engines

A-170 COMPONENT LOCATOR VIEWS

C200

C106

FRONT
OF VEHICLE

1. Generator
2. Starter Motor
3. Starter Motor Solenoid

12H12

Figure 19 - Generator and Starter Motor ■ 5.7L and 7.4L Engines Figure 21 - Battery - 5.7L and 7.4L Engines

COMPONENT LOCATOR VIEWS A-171

 C196 3
C171 FRONT 1 9 ill
1 * HI
^ OF
VEHICLE

C135
VIEW
C167

C106

FRONT ^
OF
VEHICLE

FRONT
OF V E H IC L E ^ ^
C198
C134

S107

12H19
VIEW B

G110

1. Water in Fuel Sensor

2. Cold Advance Control Solenoid
3. Fast Idle Solenoid
4. Fuel Shut Off Solenoid
5. Coolant Temperature Switch
6. Throttle Position Sensor
7. Starter Motor
8. Cold Advance/Fast Idle Temperature Switch
9. Fuel Heater
10. Starter Motor Solenoid S103
11. Manifold Absolute Pressure Sensor
12. Generator
VIEW C VIEW D

Figure 22 - Engine Wiring, Right Side - 6.2L and 6.2L HD V8 Engines

A-172 COMPONENT LOCATOR VIEWS

C200

GT102

FRONT
OF VEHICLE

FRONT
10 OF V E H I C L E ^ G110
11 ^ FRONT
^ O F VEHICLE

VIEW |~A]

1. Electronic Control Module 1. Engine Temperature Sender

2. Idle Air Control Actuator 2. Fuel Pump Oil Pressure Switch
3. Fuel Injector 2 3. Generator
4. Fuel Injector 1
5. Throttle Position Sensor
6. Coolant Temperature Sensor G115
7. Generator
8. EVRV Solenoid
9. Idle Air Control Actuator
10. Knock Sensor
11. Auxiliary Cooling Fan Temperature Switch
12. Starter Motor Solenoid
FRONT
12H16.4 OF VEHICLE VIEW B 12H15

Figure 23 - Engine Wiring, Right Side - 7.4L Engine Figure 24 - Engine Wiring, Left Side - 7.4L Engine (Fleetside)

COMPONENT LOCATOR VIEWS A-173

 C106
C134
C217

GT102

C200 S101 G115

C216 C124

C148

FRONT S117
OF VEHICLE
C170 C115
C136

1. Electronic Control Module

2. Idle Air Control Actuator FRONT 1. Generator
3. Fuel Injector 2 OF VEHICLE
C159 2. Coil
4. Fuel Injector 1 3. Distributor
5. Throttle Position Sensor
4. Electronic Spark Timing Module
6. Knock Sensor 5. Fuel Pump Oil Pressure Switch
7. EGR Solenoid 6. Oxygen Sensor
8. Auxiliary Cooling Fan Temperature Switch
9. Fuel Pump Relay
12H14.2 12H14

Figure 25 - Engine Wiring, Right Side - 5.7L Engine Figure 26 - Engine Wiring, Rear Left Side - 5.7L Engine (Suburban Utility)

A-174 COMPONENT LOCATOR VIEWS

 C200

GT101

C216

FRONT
OF V E H IC L E ^ ^

1. Electronic Control Module

12H21

Figure 29 - Electronic Control Module - LH6

C168-
1. EPR Valve 5197
2. EGR Valve 5198
3. EGR Dump Valve C104A
5199
4. Water Temperature Sender
5. Glow Plug Controller
6. Oil Pressure Sensor
7. Cold Advance Glow Plug Inhibit Relay
C136

C107A
FRONT
J r OF VEHICLE

^ FRONT
1. Transmission
OF VEHICLE
2. Transfer Case
3. VSS
4. Output Speed Sensor
5. Oxygen Sensor
6. Input Speed Sensor
12H8.2

Figure 28 - Diesel Engine Harness - LH Side Figure 30 - MT1 Electronically Controlled Transmission

COMPONENT LOCATOR VIEWS A-175

 FRONT ^
OF VEHICLE

C106A
1. Auxiliary Fuel Tank
Selector Switch
2. Fuse Block
FRONT 3. Bus Bar Ground
OF VEHICLE 4. Grommet 105

Figure 33 - Auxiliary Fuel Tank Selector Switch

C170
1. Auxiliary Fan Temperature Switch C409 G409
Figure 31 - Auxiliary Cooling Fan Wiring Harness
FRONT ^
OF VEHICLE
C100

12H34

FRONT
FRONT
OF VEHICLE 1. LH Fuel Tank (Production)
OF VEHICLE
1. Battery Junction Block 2. LH Fuel Sender Assembly
2. Auxiliary Cooling Fan Relay C191 3. RH Fuel Sender Assembly
3. Auxiliary Cooling Fan 4. RH Fuel Tank (Auxiliary)
5. Fuel Tank Selector Valve and Motor Switch VIEW A
Figure 32 - Auxiliary Cooling Fan Figure 34 - Auxiliary Fuel Tanks - Diesel

A-176 COMPONENT LOCATOR VIEWS

 G409

G410

C305
A + fFRONT
ro n t
« O F VEHICLE VIEW

1. LH Fuel Sender and

Pump Assembly
2. LH Fuel Tank (Production)
3. RH Fuel Sender and
Pump Assembly
4. RH Fuel Tank (Auxiliary)
5. Fuel Tank Selector Valve FRONT
and Motor Switch OF VEHICLE \

Figure 35 - Auxiliary Fuel Tanks - Gasoline

C200 C130
FRONT
OF V E H IC L E ^ ^

C216

1. Electronic
Control Module
2. MAP Sensor
3. Idle Air Control Actuator
4. Fuel Injectors
5. Throttle Position Sensor
6. Coolant Temperature Sensor
7. ESC Knock Sensor
8. ESC Hybrid Function 8 S119
9. EVRV Solenoid 9 7 1. Transmission Converter Clutch Solenoid
10. Fuel Pump Relay C159 2. Vehicle Speed Sensor

Figure 36 - Electronic Engine Controls, RH Side - 5.7L Engine Figure 38 - Automatic 4-Speed Transmission Wiring

COMPONENT LOCATOR VIEWS A-177

 C129 C131

C189

C107
C100

12H15
C115

> FRONT C103

OF VEHICLE

1. Electronic Control Module

2. Fuel Pump Relay
3. Manifold Absolute Pressure Sensor 1. EVRV Solenoid
4. Idle Air Control Actuator 2. Windshield Wiper Motor
5. Fuel Injectors 3. Fuel Pump Oil Pressure Switch
6. Throttle Position Sensor 4. Coolant Temperature Sensor
S145
7. ESC Knock Sensor 5. Rear Wheel Antilock Controller Module
8. ESC Hybrid Function 6. Brake Pressure Warning Switch
12H14.2 VIEW A
Figure 39 - Electronic Engine Controls, RH Side - 7.4L Engine Figure 40 - Electronic Engine Controls, LH Side - 7.4L

A-178 COMPONENT LOCATOR VIEWS

 C218

C289

1. Heater A/C Control Assembly Lamp

2. Digital Ratio Adapter Controller Module
3. Courtesy Lamp
4. Cigarette Lighter
12H37

Figure 41 - Digital Ratio Adapter Controller Module

COMPONENT LOCATOR VIEWS A179

 1. Fuse Block
2. Selector Control
3. Blower Switch - Front
VIEW [ a ]
Figure 44 - A/C and Heater Control Wiring ■ Front

3. Fuse Block
12H61.1

Figure 45 - A/C Control Wiring - Rear Figure 47 - Rear Heater Switch Wiring

A-180 COMPONENT LOCATOR VIEWS

 FRONT ^
OF
VEHICLE
C426

C312

GT402
1. Rear Blower Motor C425
2. Rear Resistors

12H61.3
VIEW [ a ]

Figure 48 - Rear Heater Blower Wiring

C223 C222

1. Glow Plugs Wait Lamp

2. Water in Fuel Indicator
3. Check Engine Lamp Driver Module FRONT
4. Low Coolant Warning Module * OF
5. Instrument Center VEHICLE
FRONT
* OF
VEHICLE

VIEW A FRONT w
OF
VEHICLE

VIEW [ a ]
C225

FRONT
OF
VEHICLE

1. Safety Belt Retractor Switch

C306

Figure 49 - l/P Wiring - 6.2L V8 and 6.2L V8 HD Engine Figure 50 - Safety Belt Retractor Switch Wiring

COMPONENT LOCATOR VIEWS A-181

 r n C246 1
1. Four-Wheel Drive Indicator Lamp C166
2. Transfer Case Switch
3. Four-Wheel Drive Shift Lever Lamp
4. Diode Assembly
5. Fuse Block

2. Transfer Case Switch

OF V E H IC L E ^ 12H121.1

Figure 52 - Transfer Case Wiring - V300

12H122

C224

FRONT
OF VEHICLE
v ie w Pb ]

Figure 51 - Transfer Case Wiring - V100, V200 Figure 53 - Transfer Case - Power and Ground Connections

A-182 COMPONENT LOCATOR VIEWS

 C251

FRONT
OF VEHICLE
FRONT
OF VEHICLE

GT106
1. Bus Bar Ground
2. Clutch Switch 1. Bus Bar Ground
3. Fuse Block 2. Fuse Block
4. Cruise Control Module 3. Cruise Control Module
5. Brake Switch 4. Brake Switch
6. DRAC Module G200 5. DRAC Module
12H72 12H72.1

» FRONT C250
OF VEHICLE

C252 FRONT
OF V E H IC L E ^ ^
^ FRONT
FRONT OF VEHICLE
OF VEHICLE
VIEW [ a ] VIEW VIEW [A~| VIEW B

C256

C244 C253 C289

FRONT FRONT
OF VEHICLE OF VEHICLE
C244
VIEW C VIEW C
Figure 54 ■ Cruise Control Wiring - Manual Transmission Figure 55 - Cruise Control Wiring - Automatic Transmission

COMPONENT LOCATOR VIEWS A-183

 Figure 56 - Cruise Control Servo - 6.2L and 6.2L V8 HD Engines Figure 57 - Cruise Control Servo - 5.7L and 7.4L Engines Figure 58 - Cruise Control Actuator

A-184 COMPONENT LOCATOR VIEWS

 GT602

C435

1. Glove Box Lamp Switch

2. Fuse Panel OF VEHICLE

12H 1 2 7 12H 123

C438 (RH SIDE)

C437 (LH SIDE)

2 (FRONT)
3 (REAR)

VIEW A VIEW B

Figure 59 - Dome Lamp Wiring Figure 60 - Front Door Jamb Switch Wiring

COMPONENT LOCATOR VIEWS A-185

 12H7.1

Figure 61 - Vanity Mirror Switch Wiring

Figure 64 - Rear Gate Switch Wiring

A-186 COMPONENT LOCATOR VIEWS

 FRONT
OF VEHICLE

1 2H 50

GT601

GT500

FRONT
OF VEHICLE
1. Power Door Lock Relay
2. Bus Bar Ground
3. In-Line Auto Fuse
1. Tailgate Window Switch 4. Fuse Block VIEW A

Figure 66 - Tailgate Window Front Wiring Figure 67 - Power Window, Locks, and Mirror Wiring

COMPONENT LOCATOR VIEWS A-187

 FRONT ^
C501 (LH) OF V E H IC L E ^

FRONT
C502 (LH)
OF V E H IC L E -^
C603 (RH)

VIEW A

C501 (LH)
C602 (RH)

FRONT
OF VEHICLE

FRONT
^ OF VEHICLE FRONT
OF V E H IC L E ^

1. Rear Panel Door Lock Actuator 1. Power Door Lock Actuator VIEW
2. Contact Assembly VIEW [ a ] VIEW B 12H52.2 2. Power Door Lock Switch 12H54 TYPICAL
Figure 68 - Rear Panel Door Lock Wiring Figure 70 - Power Door Lock Wiring

C500 (LH-2 DOOR) C700 (LH)

C506 (LH-4 DOOR) C800 (RH)
C508 (LH)
0603 (RH) :C600 (RH)

%
^ -C 5 0 9

FRONT

C501 (LH)
C602 (RH)

0503 (LH)
0604 (RH)

1. Power Mirror Switch

2. Power Window Motor
3. Power Door Lock Actuator VIEW [ a ]
4. Power Window Switch
TYPICAL 12H56

Figure 69 - Front Door Wiring with Power Door Locks, Windows and Mirrors Figure 71 - Rear Door Power Windows and Locks

A-188 COMPONENT LOCATOR VIEWS

 C904 C904

S908

— , FRONT
^ OF
VEHICLE

FRONT S908
OF VEHICLE

12H121

C904

C447

FRONT
OF VEHICLE
1. Tailgate Window Motor 1. Rear Tailgate Window Motor
2. Cut-Out Switch 2. Tailgate Window Switch, Key Operated
3. Tailgate Window Switch, Key Operated 3. Cut-Out Switch
VIEW [A]

FRONT
* OF C448
VEHICLE

C905 G904
G401

C405 FRONT C905

FRONT ^ J T q F VEHICLE
FRONT ^
OF #▼ C406 OF VEHICLE
VEHICLE
VIEW [ a ] VIEW B VIEW B VIEW C
Figure 72 - Tailgate Rear Window Wiring - Utility Figure 73 - Tailgate Rear Window Wiring - Suburban

COMPONENT LOCATOR VIEWS A-189

 FRONT
OF VEHICLE

C214

1. Pulse Wiper Module Wiring

Figure - 78 Pulse Wiper Module Wiring

C118
1. Backup Lamp Switch
2. Vehicle Speed Sensor

FRONT
OF VEHICLE

C141

Figure 79 - Backup Lamp Switch - Manual Transmission

1. RH License Lamp
2. LH License Lamp

12H104

Figure 80 - License Lamps Wiring - Fleetside

COMPONENT LOCATOR VIEWS A-191

 FRONT
C300B OF VEHICLE
FRONT
OF VEHICLE

VIEW |~A~l
S118
FRONT
OF VEHICLE G109
GT 105

1. Auxiliary Battery Junction Block

2. Auxiliary Battery Relay
FRONT ^
3. Auxiliary Battery
OF VEHICLE
12H116
VIEW

Figure 83 - Camper and Trailer Wiring - Utility Figure 85 - Auxiliary Battery

C300B

12H117.1

Figure 84 - Camper and Trailer Wiring - Fleetside Figure 86 - Radio Wiring, Front Harness

A-192 COMPONENT LOCATOR VIEWS

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page -- Figure
A/C Compressor ................................... Front of engine.................................................... .............. 179 42 Convenience C enter................... LH side of l / P ...................................................................... 169 11
A/C Diode ............................................... At A/C compressor............................................. .............. 179 42 Coolant Temperature Sender
Automatic Transmission (7.4L G aso lin e)........................ Lower LH side of engine................................................... 173 24
Backup Lamp Switch ........................ Bottom of steering column ............................... .............. 167 5 177 37
Auxiliary B attery...................................... LH side of vehicle behind headlam p.............. .............. 192 85 178 40
Auxiliary Battery Relay, LH side ......... On inner fender w e ll.......................................... .............. 192 85 Coolant Temperature Sensor
Auxiliary Cooling Fan (5.7L and 7.4L Gasoline) . Top center of engine ........................................................ 173 23
Temperature Switch .......................... Lower RH side of e n g in e ............................... .............. 173 23 177 36
174 25 178 40
176 31 Coolant Temperature Switch (Diesel) . Front of engine.................................................................... 172 22
Auxiliary Cooling F a n ............................ Below radiator s u p p o rt...................................... .............. 176 32 173 23
Auxiliary Cooling Fan Relay ................. LH inner fender w e ll............................ .............. .............. 176 32 Courtesy Lamp ...................................... Below l/P ............................................................................. 179 41
Auxiliary Fuel Tank Selector Cruise Control A c tu a to r........................ Part of multi function switch ............................................ 184 58
Switch .................................................. RH side of d a s h .................................................. .............. 176 33 Cruise Control M o d u le .......................... Behind l/P, on LH side of steering column ................... 183 54
Auxiliary Junction Block, LH side On inner fender w e ll........................................... .............. 191 81 183 55
192 85 Cruise Control Servo
Backup Lamp S w itc h ............................ At top of transmission........................................ .............. 191 79 (5.7L and 7.4L G asoline)................... Rear of e n g in e .................................................................... 184 57
Backup Lamp, LH ................................. LH rear of vehicle............................................... .............. 168 8 Cruise Control Servo (6.2L Diesel) . . . Front of en gine.................................................................... 184 56
168 9 Cut-Out Sw itch........................................ Upper RH side of tailgate (Utility) ................................... 189 72
Backup Lamp, RH ................................. RH rear of vehicle............................................... .............. 168 8 Cut-Out Sw itch........................................ Upper LH side of tailgate (Suburban) ............................ 189 73
168 9 DRAC Module ........................................ l/P near steering column................................................... 179 41
Battery Junction B lo c k .......................... Engine compartment, LH C o w l........................ .............. 166 2 183 54
166 3 183 55
176 32 DRL R e la y ............ LH front inner fender ........................................................166 1
179 42 Distributor ............ Top rear of e n g in e ............................................................. 174 26
186 62 Dome Lamp, Front Above passenger seats on roof ...................................... 185 59
186 63 Dome Lamp, Rear Above rear cargo area on roof ........................................ 185 59
Blower M o to r.......................................... RH side of cowl .................................................. .............. 179 43 ECM ..................... Under LH side of l / P .......................................................... 173 23
Brake Pressure Warning S w itc h ......... Below master cylinder........................................ .............. 178 40 174 25
Brake Switch .......................................... On top of brake pedal assem bly..................... .............. 183 54 175 29
183 55 177 36
Bus Bar G round...................................... LH side of l / P ...................................................... .............. 167 6 178 39
176 33 EGR Dump V a lv e ................................... Top LH side of engine ...................................................... 175 28
180 47 EGR Solenoid ........................................ Top RH side of e n g in e ...................................................... 174 25
182 53 EGR V a lv e ............................................... Top LH side of engine ...................................................... 175 28
183 54 EPR V a lv e ............................................... Top LH side of engine ...................................................... 175 28
183 55 ESC Hybrid Function (5.7L Gasoline) . Top RH side of e n g in e ...................................................... 177 36
187 67 ESC Hybrid Function (7.4L Gasoline) . On RH side of cowl p an el................................................. 178 39
190 74 EVRV Solenoid........................................ Top front of engine............................................................. 173 23
191 81 177 36
Cargo Lamp Switch Upper ................ LH B-Pillar ........................................................................... 187 65 178 40
Check Engine Lamp Driver Module . . . Under l / P ............................................................. ................ 181 49 Electronic Spark Timing M o d u le ......... Top rear of e n g in e ............................................................ 174 26
Cigarette Lighter ................................... . In ash receptacle ............................................... ................ 179 41 Engine Speed Sensor .......................... Top RH side of e n g in e ...................................................... 172 22
Clutch Start Switch................................. LH side of steering colum n............................................... 167 5 Evaporator Pressure Control Switch . . RH side of cowl ................................................................. 179 43
Clutch Sw itch.......................................... , On top of clutch pedal assembly ................... ................ 183 54 Fast Idle Solenoid ................................. On top of engine ............................................................... 172 22
Coil ............................................................ Top rear of e n g in e ............................................................. 174 26 Four-Wheel Drive Indicator Lamp In l/P cluster........................................................................ 182 51
Cold Advance Control Solenoid ......... , Front LH side of engine ................................... ................ 172 22 Four-Wheel Drive Shift Level Lamp . . . At transfer case shift lever ............................................... 182 51
Cold Advance Glow Plug Inhibit Front Blower S w itch ............................... Center of l / P ........................................................................ 180 44
Relay ...................................................., Engine compartment, LH rear side ................ ................ 175 28 Front Resistor B lock............................... RH side of cowl panel........................................................ 179 43
Cold Advance/Fast Idle Temp Switch . Lower RH rear of engine................................... ................ 172 22 Fuel Heater ............................................. Engine compartment, on cowl behind e n g in e .............. 172 22
Combination Lamp, LH Rear .............. . LH rear of vehicle............................................... ................ 169 11
Combination Lamp, RH Rear .............. . RH rear of vehicle............................................... ................ 169 11

A-194 COMPONENT LOCATER INDEX

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page -- Figure
Fuel Injector . . ..................................... . Top center of engine ............................................... ___ 173 23 Idle Air Control A ctuator..................... . Top RH side of e n g in e .......................................... ............173 23
173 24 174 25
174 25 176 31
177 36 Ignition S w itc h ...................................... . RH side of steering column................................... ........... 167 5
178 39 In-Line Diode (4 W D )............................ . In 4WD harness at RH side of fuse block ......... ........... 182 51
Fuel Pump Oil Pressure Switch In-Line Fuse (Camper/Trailer Wiring) . . Center of cowl panel in dash conduct................ ........... 191 81
(5.7L G asolin e)................................ . Top rear of e n g in e .................................................... . . . . 174 26 In-Line Fuse (Underhood lamp)
Fuel Pump Oil Pressure Switch (Diesel)............................................... . LH inner fender w e ll............................................... ........... 186 62
(7.4L G aso lin e)................................. . Lower LH side of engine........................................... . . . . 173 24 In-Line Fuse (Underhood lamp)
178 40 (Gasoline).......................................... ............186 63
Fuel Pump R e la y ................................ . Engine compartment on cowl behind engine . . . ___ 173 23 In-line Fuse (TP2 O n ly )........................ . LH side on inner fender w e ll................................. ............191 81
174 25 Input Speed S e n s o r............................ . LH side of transmission ........................................ ............175 30
177 36 Instrument cluster ............................... . LH side of l / P .......................................................................181 49
178 39 Knock Sensor ...................................... . Lower RH side of engine ................................................. 173 23
Fuel Pump and Sender Assembly . . . . In fuel ta n k .................................................................. ___ 175 27 174 25
176 33 178 39
177 35 184 56
Fuel Shut Off S olenoid....................... . Front LH side of engine .......................................... ___ 172 22 LH B a tte ry ............................................. . Engine Compartment, front LH side ...............................170 18
Fuel Tank Selector Valve and Motor LH H o rn ................................................. . LH front of vehicle ................................................. ............170 17
Switch ............................................... . RH frame rail near auxiliary fuel ta n k ..................... . . . . 176 34 LH License L a m p ................................. . Rear center of vehicle............................................ ............191 80
177 35 LH Rear Door Jamb Switch .............. ........... 185 59
Fuse Block............................................ . LH side of l / P ............................................................. . . . . 167 4 LH Rear Side Marker Lamp .............. ........... 168 8
176 33 168 9
180 44 License Lamp ...................................... . Rear center of vehicle........................................................ 168 8
180 45 Light S w itch.......................................... . LH side of l / P ........................................................... ......... 167 4
180 47 170 15
182 51 Low Coolant Warning M odule............ . Behind LH side of l/P ............................................ ............181 49
182 53 MAP S ensor.......................................... . Top RH rear of engine .......................................... ............172 22
183 54 177 36
183 55 178 39
185 60 Multi Function S w itc h .......................... . On steering column ............................................... ........... 184 58
187 67 Oil Pressure Sensor (Diesel).............. ........... 175 28
186 64 Output Speed Sensor ....................... . LH side of transmission ........................................ ......... 175 30
Generator ............................................ . Front of engine........................................................... ___ 171 19 Oxygen Sensor ................................... . LH exhaust manifold............................................... ......... 174 26
172 22 175 30
173 23 Powertrain Control Module (PCM) . . . . Under LH side of l / P .......................................................... 173 23
173 24 Panel Door C ontractor....................... ........... 188 68
174 26 Park Brake Warning Switch .............. . Under LH side of l / P .......................................................... 167 4
Glove Box Lamp S w itc h ..................... . In glove box on RH side of l/P ............................... ___ 185 60 Park and Turn Lamp, LH (Base) . . . . . LH front of vehicle ................................................. ........... 166 2
Glow Plug Controller ......................... . Top rear of e n g in e .................................................... . . . . 175 28 Park and Turn Lamp, LH (Quad) . . . . LH front of vehicle ................................................. ........... 166 3
Glow Plugs Wait L a m p ....................... . In instrument cluster................................................. ___ 181 49 Park and Turn Lamp, RH (Base) . . . . . RH front of vehicle ................................................. ......... 166 2
Hazard Flasher ................................... . LH side of l/P on convenience c e n te r ................... . . . . 169 14 Park and Turn Lamp, RH (Quad) . . . . RH front of vehicle ................................................. ......... 166 3
Headlamp Dimmer Switch ................ . LH side of steering colum n...................................... ___ 167 5 Power Door Lock A c tu a to r................ ........... 188 69
Headlamp, LH High Beam (Quad) . . . LH front of vehicle .................................................... . . . . 166 3 Power Door Lock A c tu a to r................ . RH front d o o r .......................................................... ........... 188 70
Headlamp, LH Low Beam (Quad) . .. . LH Front of v eh ic le .................................................... . . . . 166 3 Power Door Lock A c tu a to r................ . Rear side d o o r s ................................................................. 188 71
Headlamp, Low Beam (Quad) ......... . RH front of vehicle .................................................... ___ 166 3 Power Door Lock Relay ..................... . At RH side of steering column s u p p o rt.............. ........... 187 67
Headlamp, RH High Beam (Quad) . . . RH Front of vehicle.................................................... . . . . 166 3 Power Door Lock Switch ................... . Upper RH front d o o r.......................................................... 188 70
Headlamp, RH High-Low (Base) . RH front of vehicle .................................................... ___ 166 2 Power Mirror S w itch ............................ . Upper LH front d o o r .......................................................... 188 69
Heater A/C Control Assembly Lamp . . Front center of l/P .................................................... . . . . 179 41 Power Window M o to r.......................... . Lower LH front d o o r ............................................... ......... 188 69
High Blower R e la y .............................. . Engine compartment near blower m o to r.............. ___ 179 43 Power Window M o to r.......................... . Rear side d o o r s ...................................................... ......... 188 71
I/P C lu s te r............................................ . LH side of l / P ............................................................. ___ 167 4 Power Window Switch ........................ . At LH front d o o r ...................................................... ......... 188 69
Power Window M o to r.......................... . Lower LH front d o o r .......................................................... 188 69

COMPONENT LOCATER INDEX A-195

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page -- Figure
Pulse Wiper M o d u le ............................ . Under LH side of l / P ............................... ....................191 78 Taillamp, L H ........................................ . . Rear LH side of vehicle................................................. . . 168 8
RH Battery............................................. . Engine compartment, front LH s id e .............. ....................1 7 0 18 168 9
171 21 Taillamp, RH ...................................... . . Rear RH side of vehicle .............................................. . . 168 8
RH Fuel Sender A ssem bly................ . RH Fuel T a n k .................................................... ....................1 7 6 34 168 9
17 7 35 Throttle Position Sensor (Diesel) . . . . . Front RH side of e n g in e .............................................. . . 171 22
RH Horn ............................................... . RH front of vehicle .......................................... ....................1 7 0 17 Timer R e la y ........................................ . . Below fuse block .......................................................... . . 190 74
RH License Lam p................................. . Rear center of vehicle............................ .. ....................191 80 Transfer Case S w itch ........................ . . Top of transfer c a s e ..................................................... . . 182 51
RH Rear Door Jamb Switch .............. . On RH B-pillar ................................................. ....................185 59 Transmission Converter Clutch
RH Rear Side Marker Lamp .............. . RH rear of vehicle............................................. ....................168 8 Solenoid.......................................... . . LH rear of transmission................................................. . . 177 38
168 9 Turn Signal Flasher .......................... . . LH side of l/P, on fuse block........................................ . . 167 4
Radio Receiver...................................... . Center of l / P ...................................................... ....................192 86 Turn Signal S w itch ............................ . . LH side of steering colum n.......................................... . . 167 5
193 87 Underhood Lamp (Gasoline) ......... . . RH side of cowl ............................................................ . . 186 63
Rear A/C Blower M otor....................... . Top rear of v e h ic le .......................................... ....................1 8 0 46 Underhood Lamp (Diesel) .............. . . LH inner fender w e l l ..................................................... . . 186 62
Rear A/C Blower S w itc h ..................... . Center of l / P ...................................................... ....................180 47 Vehicle Speed S e n s o r ..................... . . Rear of transfer case (4WD) ........................................ . . 175 30
Rear A/C and Heater Controls ......... . Center of l / P .......................................... .. ....................1 8 0 45 Vehicle Speed Sensor ..................... . . Rear of transmission (2WD) ........................................ . . 177 38
Rear Gate S w itch ................................. . RH rear of vehicle............................................. ....................186 64 191 79
Rear Heater Blower Motor ................ . Rear LH side of vehicle................................... ....................181 48 Washer Motor ................................... . . Engine compartment, LH fe n d e r................................. . . 166 3
Rear Heater Blower Resistors............ . At rear heater blower motor ........................ ................181 48 Water Temperature Sender ............ . . Front LH side of engine .............................................. . . 175 28
Rear Panel Door Lock Actuator . At rear d o o r ................................................... ....................1 8 8 68 Water in Fuel Indicator..................... . . In instrument cluster..................................................... . . 181 49
Rear Resistor Block ........................... . RH side of engine com partm ent .................. ....................1 8 0 45 Water in Fuel S e n s o r........................ . . Engine compartment on cowl behind engine ......... . . 172 22
Rear Wheel Antilock ........................... . LH side of master cylinder ............................ ....................1 7 8 40 Windshield Wiper M o to r................... . . Top LH side of c o w l..................................................... . . 178 40
Controller Module Connectors:
Rear Window Defogger S w itch ......... . Center of l / P ...................................................... ....................190 74 C100 ............................................... . . Engine compartment, LH cowl ................................... . . 162 2
Roof Identification L am p s................... . Front top of ro o f............................................... ....................170 15 166 3
Roof Marker Lamp, L H ....................... . Front top LH side of roof ............................... ....................1 70 15 186 63
Roof Marker Lamp, R H ....................... . Front top RH side of roof ............................... ....................1 70 15 167 4
Safety Belt Retractor S w itc h .............. . At safety belt assembly................................... ....................181 50 168 7
Selector Control ................................. . Center of l / P ................................................... ....................180 44 175 28
Side Marker Lamp, LH Front 176 31
(Base)................................................. . Front LH side of vehicle ................................. ....................166 2 C100A ............................................. . . In engine compartment at LH inner fender well . . . . . . 186 62
Side Marker Lamp, LH Front 186 63
(Base)................................................. . Front RH side of v e h ic le ................................. ....................166 2 C101A ............................................. . . At underhood lam p....................................................... . . 186 62
Side Marker Lamp, LH Front C103 ............................................... . . At rear wheel anti-lock controller module................... . . 178 40
(Quad) ............................................... . Front LH side of vehicle ................................. ....................166 3 C103A ............................................. . . In lower LH side of engine compartment near cowl . . . 190 74
Side Marker Lamp, RH Front C104 ............................................... . . At brake pressure warning switch.............................. . . 178 40
(Quad) ............................................... . Front RH side of v e h ic le ................................. ....................166 3 C104A ............................................. . . At top center of transmission ..................................... . . 175 30
Speaker, F ro n t...................................... . Top center of l/P .......................................... ................193 87 C105 ............................................... . . At output speed sensor .............................................. . . 175 30
Speaker, Left Front.............................. . LH side of l / P .................................................... ....................1 93 87 C106 ............................................... . . Front of engine at generator....................................... . . 171 19
Speaker, Left R e a r ............................... . LH rear side of vehicle ................................... ................... 193 87 172 22
Speaker, Right Front .......................... . RH side of l / P .................................................... ................... 193 87 174 26
Speaker, Right R e a r............................ . RH side of vehicle .......................................... ....................193 87 C106A ............................................. . . At cowl, above steering column ................................. . . 176 33
Starter Motor U n d e r............................ . RH side of engine............................................. ................... 171 19 C107 ............................................... . . At coolant temperature sensor ................................... . . 172 22
Starter Motor L o w e r .......................... . RH side of engine .......................................... ................... 172 22 173 23
Starter Motor S olenoid....................... . Under RH side of engine ............................... ................... 171 19 177 36
Starter Motor S olenoid....................... . Lower RH side of engine .............................. ................... 1 7 3 23 177 37
Stop Lamp Switch .............................. . Above brake pedal ...................................... ............... 1 6 9 13 178 40
Tailgate Window Motor (Utility) ......... . RH center of tailgate ...................................... ................... 189 72 C107 ............................................... . . At coolant temperature switch..................................... . . 172 22
Tailgate Window Motor (Suburban) . LH center of ta ilg ate ...................................... ................... 1 8 9 73 C108 ............................................... . . At cold advance glow plug inhibit re la y ..................... . . 175 28
Tailgate Window Switch C109 ................................................ . . At coil ............................................................................. . . 174 26
(Key O p erated)................................. . Center of tailgate ............................................. ................1 89 72 C110 ............................................... . . 172 22
189 73 cm .............................. . , . At glow plug # 4 ............................................................ . . 172 22
C112 ............................................... . . 172 22

A-196 COMPONENT LOCATER INDEX

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page -- Figure
C113 ........................................ At glow plug # 8 .................................................................. 172 22 C147 ............................................... . . Front RH turn la m p ........................................................ . . 166 2
C114 ........................................ Top of engine near c o il...................................................... 174 26 C148 ............................................... . . At fuel pump relay ........................................................ . . 173 23
C115 ........................................ At fuel pump oil pressure sw itch...................................... 173 24 174 25
174 26 177 36
175 28 178 39
178 40 C149 (Q u a d )................................... . . Front LH low beam headlam p...................................... . . 166 3
C118 At backup lamp s w itch ...................................................... 191 79 C150 (Q u a d )................................... . . Front LH high beam h ead lam p ................................... . . 166 3
C120 At glow plug #1 .................................................................. 175 28 C151 (Q u a d )................................... . . Front LH turn la m p ........................................................ . . 166 3
C121 At glow plug # 3 .................................................................. 175 28 C152 (Q u a d )................................... . . Front LH park lamp ...................................................... . . 166 3
C122 At glow plug # 5 .................................................................. 175 28 C153 (Q u ad )................................... . . Front LH side marker la m p .......................................... . . 166 3
C123 At glow plug # 7 .................................................................. 175 28 relay.................................................................................. . . 167 4
C124 At electronic spark timing m odule.................................... 174 26 C154 (Q u a d )................................... . . Front RH low beam headlamp ................................... . . 166 3
C125 Engine compartment, near LH front of cowl .................166 2 C155 (Q u a d )................................... . . Front RH high beam headlam p................................... . . 166 3
166 3 C156 (Q u a d )................................... . . Front RH turn la m p ........................................................ . . 166 3
167 4 C157 (Q u a d )................................... . . Front RH park lamp ...................................................... . . 166 3
C126 . LH inner fender, at daytime running lamp re la y ............166 1 C159 ............................................... . . At knock s en s o r............................................................. . . 173 23
C127 . In engine compartment at LH side of cowl ................... 187 66 174 25
C128 . In engine compartment at LH side of cowl ................... 187 66 177 36
C129 . At fuel injector 1 .................................................................. 173 23 178 39
174 25 C161 ............................................... . . At idle air control actuator............................................. . . 173 23
177 36 174 25
178 39 177 36
C130 At fuel injector 2 .................................................................. 173 23 178 39
174 25 C162 ............................................... . . Engine compartment, near battery junction block . , . . 179 42
177 36 C163 ............................................... . . At engine temperature sender ................................... . . 173 24
178 39 175 28
C131 At EVRV solenoid................................................................169 13 C165 ............................................... . . At A/C compressor........................................................ . . 179 42
177 36 C166 ............................................... . . At clutch switch ............................................................. . . 183 54
178 40 C166 ............................................... . . Near steering colum n.................................................... . . 183 55
C132 At ESC hybrid function...................................................... 177 36 C167 ............................................... . . At cold advance control solenoid .............................. . . . 172 22
178 39 C168 ............................................... . . At glow plug controller................................................. . . . 175 28
C133 At LH side of cowl p a n e l.................................................... 177 37 C169 ............................................... . . At transmission converter clutch solen oid................ . . 177 38
C134 At TP sensor ....................................................................... 172 22 C170 ............................................... . . At auxiliary cooling fan temperature s w itc h .............. . . 173 23
C134 At throttle position sensor.................................................. 173 23 174 25
174 25 176 31
177 36 C171 ............................................... . . At fast idle solenoid ...................................................... . . 172 22
178 39 C172 ............................................... . . At rear LH side of transmission................................... . . 175 30
C135 At map s e n s o r.................................................................... 172 22 C173 ............................................... . . At input speed sensor ................................................. . . . 175 30
177 36 C174 ............................................... . . At EGR valve .................................................................. . . 175 28
178 39 C175 ............................................... . . At engine speed s e n s o r............................................... . . 172 22
C136 At top center of transmission ........................................... 174 26 C177 ............................................... . . At high blower r e la y ...................................................... . . . 179 43
175 30 C178 ............................................... . . At evaporator pressure control sw itch ....................... . . 179 43
C137 Front LH side marker la m p ............................................... 166 2 C179 ............................................... . . At front resistor b lo c k ...................................................., . . 179 43
C138 Front LH high-low headlam p.............................................166 2 C180 ............................................... . . At front blower motor ...................................................., . . 179 43
C139 Front LH park lamp ...........................................................166 2 C181 ............................................... . . At rear resistor block ..................................................... . . 180 45
C140 Front LH turn la m p ............................................................. 166 2 C184 ............................................... . . At cruise control servo ................................................. . . . 184 56
C141 At vehicle speed s e n s o r....................................................191 79 184 57
C142 At LH h o r n ........................................................................... 170 17 C185 ............................................... . . In cruise harness near servo........................................, . . 184 56
C143 At RH h o rn ........................................................................... 170 17 184 57
C144 Front RH high-low headlamp .......................................... 166 2 C187 ............................................... . . At windshield washer bottle ......................................... . . 184 3
C145 Front RH side marker la m p ............................................... 166 2 C188 ............................................... . . At windshield wiper m otor............................................ , . . 178 40
C146 Front park la m p .................................................................. 166 2 C189 ............................................... . . At windshield wiper m otor............................................ . . . 178 40

COMPONENT LOCATER INDEX A-197

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page - Figure
C190 ........................................ At auxiliary cooling fan re la y ................................... . . . . 176 32 C231 ............................................... . . 176 33
C191 ........................................ At auxiliary cooling f a n ............................................. ___ 176 32 C232 ............................................... . . At auxiliary fuel tank selector switch .......................... . . 176 33
C192 ........................................ Engine compartment, LH side near c o w l.............. ___ 176 32 C233 ............................................... . . At selector control .................. ..................................... . . 180 44
C193 ........................................ At EGR dump valve . ............................................. ___ 175 28 C234 ............................................... . . At front blower switch................................................... . . 180 44
C194 ........................................ At EPR valve ............................................................. ___ 175 28 C235 ............................................... . . l/P harness, near front blower switch ........................ . . 180 44
C195 ........................................ At EGR solenoid......................................................... ___ 174 25 C238 ............................................... . . LH side of l/P, near light switch................................... . . 170 15
C196 ........................................ At fuel h e a te r............................................................. ___ 172 22 C239 ............................................... . . At light switch................................................................. . . 170 15
C197 ........................................ At water in fuel sensor ............................................. ___ 172 22 192 86
C198 ........................................ At cold advance/fast idle temperature switch ___ 172 22 C240 ............................................... . . At radio .......................................................................... . . 193 87
C199 ........................................ At fuel shut off solenoid ........................................... ___ 172 22 C241 ............................................... . . At radio .......................................................................... . . 192 86
C200 ........................................ Under l/P near ECM /PCM /TCM ............................... ___ 171 19 C242 ............................................... . . At LH front speaker ..................................................... . . 193 87
173 23 C243 ............................................... . . At front mono-speaker ................................................. . . 193 87
174 25 C244 ............................................... . . 183 55
175 29 C246 ............................................... .. At 4WD shift lever c a m ................................................. . . 182 51
177 36 C247 ............................................... .. At LH front speaker ..................................................... . . 193 87
178 39 C248 ............................................... .. At RH front speaker ..................................................... . . 193 87
C202 At light switch............................................................. ___ 167 4 C250 ............................................... .. At DRAC module .......................................................... . . 183 55
170 15 C251 ............................................... .. At brake switch............................................................... . . 183 55
192 86 C252 ............................................... .. At cruise control module............................................... . . 183 55
C203 LH side of l / P ............................................................. . . . . 167 4 C253 ............................................... .. At brake switch............................................................... . . 183 55
C204 At radio ....................................................................... ___ 192 86 C254 ............................................... . . 183 55
C207 At pulse wiper module ............................................. ___ 191 78 C256 ............................................... . . At DRAC module .......................................................... . . 183 55
C208 Near fuse block ......................................................... ___ 185 60 C258 ............................................... . . At fuse block ................................................................. . . 187 67
C212 Under LH side of l/P near fuse block..................... ___ 190 74 C259 ............................................... . . At fuse block ................................................................. . . 187 67
C214 At pulse wiper module ............................................. ___ 191 78 C260 ............................................... . . At fuse block ................................................................. . . 187 67
C215 Under l/P at ECM /PCM /TCM ................................... ___ 171 19 C261 ............................................... . . In engine compartment near LH side of cowl ......... . . 187 67
173 23 C262 ............................................... . . l/P harness, under RH side of l/P .............................. . . 187 67
174 25 C263 ............................................... . . In engine compartment near LH side of cowl ......... . . 187 67
175 29 C264 ............................................... . . At power door lock relay............................................... . . 187 67
177 36 C265 ............................................... . . At power door lock relay.............................................. . . 187 67
178 39 C266 ............................................... . . Near fuse panel ............................................................ . . 187 67
C216 Under l/P at ECM /PCM /TCM ................................... . . . . 171 19 C268 ............................................... . . l/P harness, under RH side of l/P .............................. . . 187 67
173 23 C271 ............................................... . . In engine compartment near LH side of cowl ......... . . 187 67
174 25 C274 ............................................... . . At tailgate window s w itch ............................................ . . 187 66
175 29 C275 ............................................... . . Under LH side of l/P near fuse block.......................... . . 190 74
177 36 C276 ............................................... . . Under LH side of l/P near fuse block.......................... . . 190 74
178 39 C277 ............................................... . . Under LH side of l/P near fuse block.......................... . . 190 74
C217 Under l/P near ECM /PCM /TCM ............................... . . . . 174 25 C278 ............................................... . . At rear window defogger switch ................................. . . 190 74
C218 At courtesy lamp ...................................................... ___ 179 41 C279 ............................................... . . In lower LH side of engine compartment near cowl . . . 190 74
185 60 C280 ............................................... . . Under LH side of l/P near fuse block.......................... . . 190 74
C219 At fuse block ............................................................. ___ 185 60 C281 ............................................... . . At A/C heater controls ................................................. . . 180 45
C220 At l/P courtesy la m p .................................................. ___ 185 60 180 47
C221 At heater A/C control assembly lamp ................... ___ 179 41 C282 ............................................... . . RH side of l/P near A-pillar.......................................... . . 180 45
C222 At glow plugs wait la m p .......................................... ___ 181 49 C283 ............................................... . . . At fuse block ................................................................. . . 180 45
C223 At water in fuel indicator........................................... . . . . 181 49 C285 ............................................... . . . At fuse block ................................................................. . . 180 47
C224 At fuse block ............................................................. ___ 182 53 C288 ............................................... . . . At 4WD indicator la m p ................................................. . . 182 51
C225 At low coolant warning m odule............................... ___ 181 49 C289 ............................................... , . . At DRAC module .......................................................... . . 179 41
C226 At transfer case s w itch ............................................. ___ 182 52 183 55
C227 At LH front door jamb switch ................................. . . . . 185 60 C291 ............................................... , . . l/P Harness, LH side, at diode assembly................... . . 167 4
C228 At Lh front door jamb sw itch................................... . . . . 185 60 C299 ............................................... , . . At cigarette lighter ........................................................ . . 179 41
C229 At RH front door jamb switch ................................. ___ 185 60 C300 ............................................... . . . LH side rail at rear crossmember (Utility)................... . . 192 83
C230 At glove box lamp switch ........................................ . . . . 185 60 C300 ............................................... . . . LH side rail at rear crossmember (Fleetside)............ . . 192 84

A-198 COMPONENT LOCATER INDEX

JOMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page - Figur
C300 ............................................... . . Above rear crossmember, towards RH side C421 ............................................... . . At LH license la m p ........................................................ . .
191 80
of veh icle........................................................................... . 168 8 C423 ............................................... . . Rear lamp harness, LH side inside harness wrap . . . .
168 9
168 9 C424 ............................................... . . Rear lamp harness, RH side inside harness wrap . . . .
168 9
C300 . . < ........................................ . . LH side rail at rear crossmember (Suburban) ............ . 191 82 C425 ............................................... . . At rear heater blower motor ........................................ . .
181 48
C300A ............................................ . . LH side rail at rear crossmember (Utility)..................... . 192 83 C426 ............................................... . . At rear heater blower motor ........................................ . .
181 48
C300A ............................................ . . LH side rail at rear crossmember (Fleetside).............. . 192 84 C427 ............................................... . . At rear crossmember, towards LH side of vehicle . . . .
169 12
C300A ............................................ . . LH side rail at rear crossmember (Suburban) ............ . 191 82 C428 ............................................... . . At RH backup lamp ...................................................... . .
168 8
C300B ............................................. . . LH side rail at rear crossmember (Utility)..................... . 192 83 168 9
C300B ............................................ . . LH side rail at rear crossmember (Fleetside).............. . 192 84 169 11
C300B ............................................ . . LH side rail at rear crossmember (Suburban) ............ . 191 82 C429 ............................................... . . At LH backup lam p ........................................................ . . 168 8
C301 ............................................... . . Above rear crossmember, towards LH side of vehicle . . 8 8 168 9
C303 ............................................... . . At LH frame rail near fuel tank ...................................... . 175 27 169 11
C305 ............................................... . . At fuel tank selector valve and motor switch .............. . 176 34 C430 ............................................... . . At LH B-pillar .................................................................. . . 187 65
177 35 C431 ............................................... . . At LH B-pillar .................................................................. . . 187 65
C306 ............................................... . . At LH safety b e lt................................................................ . 181 50 C432 ............................................... . . At LH B-pillar .................................................................. . . 187 65
C309 ............................................... . . At shift le v e r....................................................................... . 182 52 C433 ............................................... . . At LH B-pillar .................................................................. . . 187 65
C310 ............................................... . . At fuse block .................................................................... . 183 54 C434 ............................................... . . In LH B-pillar .................................................................. . . 185 59
183 55 185 60
C311 .............................................. . . . In LH kick p a n e l................................................................ 181. 48 C435 ............................................... . . In LH B-pillar .................................................................. . . 185 59
C312 .............................................. . . . In LH kick p a n e l................................................................ . 181 48 185 60
C313 .............................................. . . . RH side of fuse b lo c k ...................................................... . 182 51 C436 ............................................... , . . At cargo lamp ............................................................... . . 187 65
C323 .............................................. . . . At RH side of l/P ............................................................... . 186 61 C437 ............................................... , . . At LH rear door jamb sw itch ........................................ . . 185 60
C324 .............................................. . . . At RH vanity m irror........................................................... . 186 61 C438 ............................................... , . . At RH rear door jamb switch........................................ . . 185 60
C400 .............................................. . . . At door panel contactor ................................................. . 188 68 C439 ............................................... . . At LH rear s p ea k er........................................................ . . 193 88
C401 .............................................. . , . At door panel contactor .................................................. . 188 68 C440 ..............................................., . . At RH rear speaker........................................................ . . 193 88
C402 ............................................ . . . At LH B-pillar .................................................................... . 188 71 C442 ............................................... . . At RH rear gate s w itc h ................................................. . . 186 64
C403 ............................................ . . . At RH B -pillar.................................................................... . 188 71 C447 ................................................ . . Under LH side of rear bumper (suburban) .............. . . 189 73
C404 ............................................ . . . At RH B -pillar.................................................................... . 188 68 C448 ..............................................., . . Under LH side of rear bumper (suburban) .............. . . 189 73
C405 ............................................ . . . LH side rear crossmember (Utility) ............................... . 189 72 C449 ..............................................., . . Below bumper on LH side .......................................... . . 190 75
C406 ............................................ . . . LH side rear crossmember (Utility) ............................... . 189 72 C450 ................................................ . . At LH panel door lock actu ato r................................... . . 190 77
C409 ............................................ . . . At fuel pump and sender ............................................... . 175 27 C451 ................................................ . . At LH panel door lock actuator................................... . . 190 77
176 34 C452 ................................................ . . At RH panel door lock actuator................................... . . 190 76
177 35 C453 ................................................ . . At RH panel door lock actuator................................... . . 190 76
C410 ............................................ . . . At RH auxiliary fuel t a n k ................................................. . 176 34 C454 ................................................ . . In LH B-pillar .................................................................. . . 187 65
177 35 C455 ................................................ . . In LH B-pillar .................................................................. . . 187 65
180 46 C456 ..............................................., . . Rear of vehicle in roof p a n e l........................................ . . 186 64
C411 ............................................ . . . At RH tail, stop and turn lam p ........................................ . 168 8 C500 ................................................ . . At LH power window switch (2-door).......................... . . 188 69
168 9 C501 ................................................ . . At LH power door lock sw itch...................................... . . 188 69
169 11 188 70
C412 ............................................ . . . At LH tail, stop and turn la m p ........................................ . 168 8 C502 ................................................ . . At LH front power door lock actuator ........................ . . 188 70
168 9 C503 ................................................ . . At LH power window m otor.......................................... . . 188 69
169 11 C506 ................................................ . . At LH power window switch (4-door).......................... . . 188 69
C413 ............................................ . . . At LH rear side marker la m p .......................................... . 168 8 C508 ................................................ . . At LH power m irror........................................................ . . 188 69
168 9 C509 ................................................ . . At upper LH front d o o r ................................................. . . 188 69
C414 ............................................ . . . At RH rear side marker lam p.......................................... . 168 8 C600 ................................................ . . At RH power mirror........................................................ . . 188 69
168 9 C602 ................................................ . . At RH power door lock switch..................................... . . 188 69
C415 ............................................ . . . At RH side front clearance la m p ................................... . 168 10 188 70
C416 ............................................ . . . At RH side rear clearance lamp ................................... . 168 10 C603 ................................................ . . At RH front power door lo c k ........................................ . . 188 70
C417 ............................................ . . . At LH side front clearance lamp ................................... . 168 10 C604 ................................................ . . At RH power window motor ........................................ . . 188 69
C418 ............................................ . . . At LH side rear clearance la m p ...................................... . 168 10 C700 ................................................ . . At LH rear window s w itch ............................................. . . 188 71
C419 ............................................ . . . Rear lamp harness, towards LH side of veh ic le......... . 168 9 C701 ................................................ . . At LH rear power window m o to r ................................. . . 188 71
C420 ............................................ . . . At RH license la m p ........................................................... . 191 80 C702 ............................................. . . . At LH rear power door lock actuator.......................... . . 188 71

COMPONENT LOCATER INDEX A-199

COMPONENT LOCATION Page - Figure COMPONENT LOCATION Page -- Figure
C800 ............................................... .. At RH rear window sw itch........................................ ___ 188 71 Grounds:
C801 ............................................... .. At RH rear power window m o to r............................ ___ 188 71 G105 ............................................... . . LH front of vehicle, above LH headlamps ................. . . 166 2
C802 ............................................... .. At RH rear power door lock actuator..................... ___ 188 71 166 3
C900 ............................................... .. At rear panel door lock actu ato r............................ ___ 188 68 G106 ............................................... . . RH front of vehicle, above RH headlamps................. . . 166 2
C901 ............................................... .. At rear panel door contactor, door s id e ................ ___ 188 68 166 3
C902 ............................................... .. At rear panel door contactor, door s id e ................. ___ 188 68 G107 ............................................... . . RH front of vehicle on frame below RH headlamps . . . 166 2
C904 ............................................... .. At cut-out switch......................................................... ___ 189 72 166 3
189 73 G108 ............................................... . . In engine, compartment above auxiliary battery
C905 ............................................... . . At tailgate window motor ........................................ ___ 189 72 junction block................................................................. . . 192 85
189 73 G109 ............................................... . . LH side of vehicle on radiator support........................ . . 192 85
C906 ............................................... . . At tailgate window switch (key operated) ............ ___ 189 72 G110 ............................................... . . Top RH rear of engine ................................................. . . 172 22
189 73 179 42
C907 ............................................... .. In top LH panel door ............................................... ___ 190 77 G110 ............................................... . . Top RH front of engine................................................. . . 173 24
C908 ............................................... .. In top RH panel d o o r ............................................... ___ 190 76 G111 ............................................... . . RH front of vehicle above RH battery ........................ . . 170 18
C909 ............................................... .. At LH panel door lock actuator............................... . . . . 190 77 172 22
C910 ............................................... .. At LH panel door lock actuator............................... ___ 190 77 G112 ............................................... . . Front of RH cylinder h e ad ............................................ . . 171 21
C911 ............................................... .. At RH panel door lock actuator............................... ___ 190 76 G113 ............................................... . . Front of LH cylinder h e a d ............................................ . . 170 18
C912 ............................................... .. At top LH side of tailgate ........................................ . . . . 190 75 G114 ............................................... . . At alternator bracket..................................................... . . 170 18
C913 ............................................... .. At center LH side of ta ilg a te ................................... ___ 190 75 G115 ............................................... . . Rear of RH cylinder h e a d ............................................ . . 173 24
Grommets: 174 26
GT100 ............................................. . . Engine compartment, RH C o w l............................... ___ 179 43 G117 ............................................... . . Above blower motor in engine compartment............ . . 179 43
GT101 ............................................. . . Engine compartment, RH C o w l............................... ___ 171 19 G118 ............................................... . . In engine compartment at top of c o w l........................ . . 186 63
173 23 G200 ............................................... . . LH side of l / P ................................................................. . . 167 6
174 25 180 47
177 36 182 53
178 39 183 54
GT102 ............................................. . . Engine compartment, near LH cylinder head ___ 173 23 187 67
174 25 G201 ............................................... . . Under l/P near fuse panel............................................ . . 176 33
175 29 183 54
177 36 183 55
178 39 190 74
GT103 ............................................. . . Cowl panel, above transmission tu n n e l................ ___ 180 47 G401 ............................................... . . At LH rear crossmember (Suburban) ........................ . . 189 73
180 45 G402 ............................................... . . RH rear side of vehicle................................................. . . 168 8
GT105 ............................................. . . Engine compartment, LH C o w l............................... ___ 166 2 168 9
166 3 G403 ............................................... . . LH rear side of v e h ic le ................................................. . . 168 8
167 4 168 9
GT106 ............................................. . . Engine compartment, top LH side of c o w l............ ___ 182 51 G403 ............................................... . . LH side rail at rear crossmember .............................. . . 191 82
183 55 192 84
GT107 ............................................. . . Cowl panel, above transmission tu n n e l................ ___ 176 33 G404 ............................................... . . Under tailgate near LH side of vehicle....................... . . 169 12
187 66 G406 ............................................... . . LH rear side of v e h ic le ................................................. . . 169 11
GT400 ............................................. . . LH rear lamp harness, below RH rear lamps ___ 168 8 G407 ............................................... . . RH rear side of vehicle................................................. . . 169 11
GT401 ............................................ . . LH rear lamp harness, below LH rear lamps ___ 168 8 G409 ............................................... . . LH frame rail above fuel tank ..................................... . . 175 27
GT500 ............................................ . . LH side at kick panel ............................................... ___ 187 67 176 33
188 69 177 35
GT501 ............................................ . . Between front LH door jamb and door ................. ___ 188 69 G410 ............................................... . . RH rail above fuel ta n k ................................................. . . 176 34
GT502 ............................................ . . At LH A-pillar ............................................................. ___ 185 60 177 35
GT600 ............................................ . . RH side at kick p a n e l............................................... ___ 187 67 G411 ............................................... . . Above rear blower motor ............................................ . . 180 46
GT601 ............................................ , . . Between front RH door jamb and d o o r ................ ___ 187 67 190 77
GT602 ............................................ , . . At RH A -p illar............................................................. ___ 185 60 G904 ............................................... . . At rear tailgate window motor (Suburban)................ . . 189 73
GT700 ............................................ , . . Between B-pillar and LH rear door ........................ ___ 188 71
GT800 ............................................ . . . Between B-pillar and RH rear d o o r ........................ ___ 188 71

A-200 COMPONENT LOCATER INDEX

COMPONENT LOCATION Page -- Figure COMPONENT LOCATION Page -- Figure
Splices: 520 1 l/P harness, LH s id e ........................................................... 167 4
S 1 0 0 ................................................. . . Engine harness, near junction b lo c k .......................... . . 173 24 193 87
175 28 5202 l/P harness, LH s id e ........................................................... 167 4
S 1 0 1 ................................................. . . Engine harness, front of LH valve cover ................... . . 174 26 5203 l/P harness, LH s id e ........................................................... 167 4
S 1 0 3 ................................................. . . Engine harness, near starter m o to r............................ . . 172 22 179 41
174 25 5205 l/P harness, behind steering column support .............. 183 54
S 1 0 4 ................................................. . . At LH inner fender w e ll................................................. . . 192 85 183 55
S 1 0 5 ................................................. . . At LH inner fender well near auxiliary 5206 l/P harness, LH side of steering column ........................167 5
battery re la y .................................................................... . . 192 85 5207 l/P harness, bottom of steering colum n..........................167 5
S 1 0 6 ................................................. . . Engine harness, near junction b lo c k .......................... . . 174 26 5209 l/P Harness, LH side under l/P ........................................ 167 4
S 1 0 7 ................................................. . . Engine harness, near g en erato r................................. . . 172 22 193 87
S 1 0 8 ................................................. . . Engine harness, near starter m otor............................ . . 172 22 521 0 l/P harness, LH s id e ........................................................... 167 4
S109 . . ............................................. . . Engine harness, near center of e n g in e ..................... . . 175 28 521 1 l/P harness, behind steering column support .............. 183 54
S 1 0 9 ................................................. . . Engine harness, top rear ............................................. . . 172 22 183 55
S 1 1 0 ................................................. . . Forward lamps harness, LH s id e ................................. . . 166 2 521 2 l/P harness, LH side under l/P ........................................ 167 4
S 1 1 1 ................................................. . . Forward lamps harness, in front of 521 3 l/P harness, above ra d io .................................................... 179 41
RH headlam ps............................................................... . . 166 2 S 2 1 5 .......................................... l/P harness, LH s id e ........................................................... 167 4
166 3 521 7 l/P harness, above fuse b lo c k .......................................... 185 60
S 1 1 2 ................................................. . . Forward lamps harness, in front of LH 521 8 l/P harness, above glove b o x ........................................... 185 60
headlamps...................................................................... . . 166 2 5257 l/P harness, beneath l / P .................................................... 187 67
166 3 5258 l/P harness, beneath l / P .................................................... 187 67
S 1 1 3 ................................................., . . Forward lamps harness, LH side behind 5259 l/P harness, beneath l / P .................................................... 187 67
headlamps...................................................................... . . 166 3 5260 l/P harness, behind l/P cluster ........................................ 187 67
S 1 1 4 .................................................. . . Forward lamps harness, LH side in front of 188 69
washer b o ttle .................................................................. . . 166 3 526 1 l/P harness, behind l/P cluster ........................................ 187 67
S 1 1 7 .................................................. . . Engine harness, rear top of e n g in e............................ . . 173 23 188 69
174 26 5300 Rear lamps extension harness, at rear crossmember . 170 16
530 1 Rear lamps extension harness, at rear crossmember . 170 16
S 1 1 8 .................................................. . . At LH inner fender well near auxiliary battery relay . . . 192 85 5302 Rear lamps extension harness, at rear crossmember . 1 6 8 8
S 1 1 9 .................................................. . . Engine harness, center of RH valve c o v e r................ . . 172 25 170 16
177 36 S304 ........................................ LH side rail at rear crossmember (Suburban) .............. 191 82
S121 (6.2L Diesel)......................... . . . Engine harness, rear top of e n g in e............................ . . 130 28 192 83
S130 (6.2L HD D iesel).................. . . . Engine harness, rear top of e n g in e............................ . . 130 28 5304 LH side rail at rear crossmember (Fleetside)................ 192 84
S 1 3 6 .................................................. . . Engine harness, RH side of e n g in e ............................ . . 172 22 5305 LH side rail at rear crossmember (Suburban) .............. 191 82
173 24 192 83
174 25 5305 LH side rail at rear crossmember (Fleetside)................ 192 84
S 1 3 7 .................................................. . . Engine harness, RH side of e n g in e ............................ . . 172 22 5306 LH side rail at rear crossmember (Suburban) .............. 191 82
173 23 192 83
174 25 5306 LH side rail at rear crossmember (Fleetside)................ 192 84
S 1 3 8 ............................................... . . . Under l/P near E C M ...................................................... . . 175 29 5307 LH side rail at rear crossmember ................................... 191 82
S 1 3 9 ............................................... . . . Engine harness, rear top of e n g in e ............................ . . 173 23 192 83
174 26 5307 LH side rail at rear crossmember (Fleetside)................ 192 84
5308 Rear lamps extension harness, at rear crossmember . 168 8
S 1 4 0 ............................................... . . . Engine harness, rear top of e n g in e ............................ . . 173 23 S 3 1 0 ........................................ l/P harness behind LH kick panel ................................... 188 69
174 26 531 2 l/P harness behind LH kick p a n e l................................... 188 69
531 3 l/P harness behind LH kick p a n e l................................... 188 69
S 1 4 5 .............................................. . . . LH side of cowl panel near antilock control module . . . 178 40 5326 Auxiliary fuel tank harness, at crossm em ber................ 176 34
S 1 6 9 .............................................. . . . Engine harness, RH rear of e n g in e ............................ . . 172 22 5327 Auxiliary fuel tank harness, at crossmember ................. 176 34
S 1 7 1 .............................................. . . . Engine harness, center of LH valve c o v e r................. . . 175 28 5328 Auxiliary fuel tank harness, at crossm em ber................. 177 35
S 1 9 7 ............................................... . . . Engine harness, rear center of engine ..................... . . 175 28 5329 Auxiliary fuel tank harness, at crossm em ber................. 177 35
S 1 9 8 ............................................... . . . Engine harness, rear center of engine ..................... . . 175 28 5400 Rear of vehicle at top LH s id e .......................................... 190 77
S 1 9 9 .............................................. . . . Engine harness, rear center of engine ..................... . . 175 28 540 1 Rear of vehicle at top LH s id e .......................................... 190 77

COMPONENT LOCATER INDEX A-201

COMPONENT LOCATION Page - Figure
S 4 0 2 .................................................. . . LH rear lamp harness, above rear crossmember . . . . . 168 8
168 9
S 4 0 3 .................................................. . . RH rear lamp harness, below RH rear lam ps......... . . . 168 8
168 9
S404 ................................................. . . Rear lamp harness, near center of vehicle ............ . . . 168 9
S405 ................................................. . . RH rear lamp harness, below RH rear lam ps......... . . . 168 8
S406 .................................................. . . LH rear lamp harness, above rear crossmember . . . . . 168 8
S 4 1 0 ................................................. . . Rear lamp harness, toward LH side of vehicle . . . . . . . 168 9
S 4 1 1 ................................................. . . Rear center of vehicle behind bumper ................... . . . 191 80
S 4 1 2 .................................................. . . Rear dome lamp harness, behind LH B-pillar,
above LH rear door .................................................... . . . 185 59
S 4 1 3 ................................................. . . Rear dome lamp harness, above LH rear door . . . . . . 182 51
S908 ................................................. . . RH side of tailgate (Utility) ........................................ . . . 189 72
S908 ................................................. . . LH side of tailgate (Suburban) ................................. . . . 189 73
S909 ................................................. . . LH center of tailgate (Suburban)............................... . . . 189 73
S909 ................................................. . . Center of tailgate (Utility) .......................................... . . . 189 72

A-202 COMPONENT LOCATER INDEX

 SECTION B
P MODEL
(COMMERCIAL)

SECTION B - P-MODEL B-1

 STEERING
COLUMN
BULKHEAD SWITCHES
CONNECTOR (SEE PAGES, 32, 34)
(SEE PAGES 4, 5) FUEL TANK
SENDER
BATTERY JUNCTION (SEE PAGE 54)
BLOCK DRL
(SEE PAGES 4,5) RELAY
(SEE PAGE 28)

BATTERY
(SEE PAGES 4,5)

REAR
LAMPS
HARNESS
(SEE PAGE 76)

FUEL PUMP
RELAY
(SEE PAGE 48)

ESC
REAR MODULE
BODY (SEE PAGE 42)
CONNECTOR
(SEE PAGE 54)

8-2 PHANTOM VIEW

 SYMPTOMS INDEX
SYMPTOM PAGE

BRAKE WARNING SYSTEM REAR EXTERIOR LAMPS

Brake indicator remains on with ignition switch in RUN and park brake o f f ............................................. B-73 None of the rear lamps operate .................................................................................................................. b -75
Alarm will not s o u n d ........................................................................................................................................... B-73 Backup lamps do not operate...................................................................................................................... b -75
Alarm will not shut o f f ................................................................................................................. ....................... B-73
START AND CHARGE
DIESEL ENGINE FUEL CONTROLS Starter solenoid clicks, engine does not crank or cranks slowly.............................................................. b -39
Fuel heater does not o p e ra te ........................................................................................................................... B-62 Engine does not crank and starter solenoid does not click .................................................................... b -39
Water in fuel indicator lights with no water in fuel ........................................................................................B-62 Battery is undercharged or overcharged.................................................................................................... b -39
Water in fuel indicator does not light briefly with ignition switch turned to RUN ....................................B-62
TURN LAMPS
GAGES AND INDICATORS Turn signals do not o p e ra te ........................................................................................................................ b -33
Fuel gage indicates full or beyond at all tim e s ...............................................................................................B-66 Turn signals do not operate on one side.................................................................................................... b -33
Fuel gage indicates empty when there is fuel in the ta n k ............................................................................ B-66 Turn signal lamps flash rapidly.................................................................................................................... b -33
Fuel gage is inaccurate ...................................................................... ......................................................... B-66
Temperature indicator stays on at all times with ignition switch in RUN .................................................. B-66 WIPER/WASHER
Temperature gage indicates cold all the time ...............................................................................................B-67 Wipers do not operate in any mode ........................................................................................................... b -37
Temperature gage is in a cc u ra te ...................................................................................................................... B-67 Wipers do not operate in HI ........................................................................................................................ b -37
Temperature gage indicates hot with engine coolant below operating temperature and ignition Wipers do not operate in L O ........................................................................................................................ b -37
switch in R U N ..................................................................................................................................................B-67 Washer motor does not operate................................................................................................................. b -37
Oil pressure gage is not a ccu ra te .................................................................................................................... B-67 Washer motor does not shut o f f ................................................................................................................. b -37
Oil pressure gage indicates high pressure at all tim e s .................................................................................B-67
Oil pressure gage indicates low pressure when oil pressure is g o o d .......................................................B-67
Low coolant indicator does not light with coolant level low (diesel o n ly ) ..................................................B-67
Low coolant indicator is lit when coolant level is g o o d .................................................................................B-68

GLOW PLUGS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is
below operating tem perature........................................................................................................................ B-59

HEADLAMPS
Headlamps do not illuminate high or low beams - both sides .................................................................. B-22
Low beam lamp(s) do not operate ..................................................................................................................B-22
High beam lamp(s) do not o p e ra te ..................................................................................................................B-22

HEADLAMPS (WITH DRL)

Headlamps do not illuminate high or low beams - both sides .................................................................. B-25
Low beam lamp(s) do not operate ..................................................................................................................B-25
High beam lamp(s) do not o p e ra te ..................................................................................................................B-26
Canadian daytime running lamps do not operate ....................................................................................... B-26

HORNS
Hom(s) will not operate ....................................................................................................................................B-35
Horn sounds continuously without depressing horn switch ....................................................................... B-35

PARK, MARKER AND HAZARD LAMPS

Park lamps do not o p e ra te ............................................................................................................................... B-30
Hazard warning lamps do not operate .......................................................................................................... B-30
Side marker lamp(s) do not o p e ra te ............................................................................................................... B-30
Rear marker lamp(s) do not o p e ra te ............................................................................................................... B-30

SYMPTOM INDEX B-3

 RPOCODES

g
B3D - SCHOOL BUS EQUIPMENT
. ._ _ _ _ _ _ 2-32.0 BLK _ _ _ _ _ _ _- .
. .- - - - - 6-3,0 PPL _ _ _ _II CLUTCH
,11______ 1-19.0 BLK _ _ _ _• . ._ _ 5-3,OYEL _ _ _. _ START

'r.-~:
3
SWITCH
2_
%
r
2
IGNITION
_ _ _ _ 2-5,0 RED _ _ _ _- .

-
SWITCH 0
START
RUN
+ 2-13.0 RED
(B3D)
0 0 0 OFF
LOCK
BATTERY 8917053
~ ACC
'z
·0 1000001
i BODY BUILDER
100 AMP JUNCTION
~ ~ BLOCK (B3D ONLy)
C298
o 0 C299
51
ai ~

-----.
1201966 6294641
S207 II: 44
o

I ~
. .- _ _ _ _ 4-5,0 BRN _

300-5,00RN
I • • _1 ____________
HEADLAMP
J
SWITCH
K PANEL DIMMER 150-+--_
DOME
---r-'e--- 158
SWITCH 2

\o:...J 0
ira: w
II: if CIRCUIT
STARTER 00 0 III BREAKER
MOTOR ~;g ~
o 25AMP

C209
~
-'o:H;::"EA"Orl--t-- 10
S198. 12020030 12020029

•
-.S205 _ _ __
_ '9-1,OBRN OFF
\
@ 'PARK
II: 300-5,0 ORN _ _ _, 4O-t--- --~"'r-I
_ _ _ _ _ 2-1,ORST _ _ _ _S199
• _ __ - - - - - <Xl - - - - - - " " ' "
.;; Cl00 _ 2-5,0 RED _ _ _ _ _ __ HEAO
'" 12020184
(FUSIBLE LINK)

.
. .- - - - - 1 _ 2 - 5 , O R E D _ _ _ _ _ _ II LIGHT

-- --
_ 6-3,0 PPL _ _ _ I HTR SWITCH INSTR-LPS
S208 . . . . " . . . . " ...." 25 AMP 5AMP
(SEE PAGE 70)
_3-5,OPNK_

:5III
0
oj
...J
£l..
£l..
0
:5III
0
N ENGINE
_2-5,ORED_
---
-.
~ ~
= ~8A~ [g~ m [BJ
L 3
@
L
0
if
m:l m:l @ ill~ m [BJ 0 Z
II:
III
0 51
II:

S197 I/PCLUSTER m:l@@omoo

o o
"1
(SEE PAGE 70) ACC IGN HTR PWR ECM-BAT

~DD~qwp
10 AMP
Sl11 --~I_:r
~
(SEE PAGE 46)

~M QRA~ ~
TAIL LPS

GENERATOR Cl0B @~ a IQQS

-;rir-..!~~~h::~~
20 AMP

,
~
~~OO~
12045896 10AMP
ACC-RADIO
=
~ TAIL LPS INJ HTR ACC-RADIO STOP-HAl
Cl00
ns:l~DD~
15AMP
12020183
S~ ECM-CRNK AUX WIPER

o ~~
-- ALT

TQ5J
CRNK

Qsp~
INJ

SHEET IGNITION COIL

FRONT 10AMP
ENGINE METAL (SEE PAGE 42) FUSE BLOCK
GROUND GROUND 12089776 CRNK

G111 G110 10 AMP

15AMP
B-4 POWER DISTRIBUTION
GASOLINE ENGINES WIMAN TRANS
 RPOCODES

B3D - SCHOOL BUS EQUIPMENT

_ _ _ _. . . 2-32.0 BLK _ _ _ _ _ _ _ _•
.~

IGNITION SWITCH
"'lIlIIII____ 1-19.0 BLK _ _ _ _•

-r- 'f1!
3 33

111
2

-
0
START
2-13.0 RED

+ (B3D)
0 0 0
RUN
OFF
LOCK
BATTERY
10 0 0 0 0 1 - __ I

0 0 0
ACC

BODY BUILDER
100 AMP JUNCTION
BLOCK (B3D ONLy) C298 C299
1201966 6294641 44
"_.~ _ _ _ _ _ _ 6-3.0PPL _ _ _ _ _ _•

3-S.0 PNK ..._ _ _ _ _ 4-S.0 BRN_

300-S.0 ORN

HEADLAMP

~~
12"
z
::J
fil5
a:z
0 0
J
K
__ . -:1-----------1 PANEL DIMMER
1
SWITCH 150-~-_

2
DOME
156

qffi MO SWITCH
"'::>
NI:!:- ;;;~ L

• D
w 0w
CIRCUIT
'-,PARK

I
M a: a: BREAKER
STARTER • Sl92 N
q a 25AMP I ,
d! ~
MOTOR 10

l~~
1tIl: ._S2.1~.~.~ .7_~
P C209 HEAD
12020029
OFF
S198. _ .9-1.0BRN \
'PARK
~~:i
",0
40-+-......- . 9
qUiD _ _ _• 300-S.0 ORN _ _ _•
Il?;::)M
N ~,Q1
co Cl00 _2-S.0 RED _ _ _ _ _ __

.
S199 ~
2-1.0 RST
• '"
~
12020184

-~7i1
(FUSIBLE LINK) _2-S.0RED GAUGES

----
HTR
2SAMP 20 AMP
• _ AI 39-.8 PNKlBLK • S206 _ 3-S.0 PNK _ _ _ __
S208 _
_ 2-S.0 RED - - - - .
(SEE PAGE 70) , .---------
:s
'"a
..J
Q.
Q.
a
~
c;j
a
• •
oj N ENGINE HORN/DM

~
~ ~ lSAMP
3 = ~8A~ ~ m~ OJ
L lID 0

-b
I/PCLUSTER
z
a:
L
(SEE PAGE 70) Z 0
lID lID ~ ill ~ OJ [ffi 0 a:
o '"
S197 IID!ID~OOJOO ECM-BAT
ACC IGN HTR PWR
10 AMP
Slll ._ ... _
~OOOODD
(SEEP~~ GAUGES PWR TAIL LPS

C106 D;;:
OOOODOc=J
HORN/OM INSTR-LPS TRANS ECM-BAT
20 AMP

, OO~OOOO
GENERATOR 12045896 ~ if
a co TAIL LPS INJ HTR ACC-RADIO 15AMP
~ ~
nstl~ODOO
Cl00

,
~ 12020183
if S~ ECM-CRNK AUX WIPER

_ ~,a
a
M
o 00 00
ALT CRNK

-- -- ~ Qspg
SHEET IGNITION COIL FRONT
(SEE PAGE 42)
ENGINE METAL 12089776
CRNK
GROUND GROUND 10AMP
G111 G110
POWER DISTRIBUTION B-5
GASOLINE ENGINE W/AUTO TRANS
 RPOCODES

CLUTCH B3D - SCHOOL BUS EQUIPMENT

• _ _ _ _ _ _ 6-3.0 P P l - - - - - - - - - - e ,A
___
5-3.0 YEl _ _ _ _ _ _ _ _ _ _._ S6 B l START
• SWITCH IGNITION SWITCH

C219
4

~':
8911921

f.~t
2-13.0 RED o

+ RH
+ LH 8917053
(B3DONly)
START
RUN
o BATTERY BATTERY
w 0 0 0 OFF
a:
o
ai
N
10 0 0 0 01 B LOCK

c _L J
BODY BUilDER
0 0 0
100 AMP JUNCTION
. ._ _ 1-50.0 BlK _ _ _ _ __
BLOCK (B3D ONLy) C298 C299
1-32.0 BlK (B3D ONLy) 1201986 6294641 44
~t!~~------6-3.0 PPl _ _ _ _ _ _. . .

3-5.0 PNK
-
• _ _ _ _ _ 4-5.0 BRN _

BATTERY STARTER
JUNCTION MOTOR
300-5.00RN
BLOCK
-1-----1

~~ 7'
II~-" 'iC5~ -- .. PANEL DIMMER
SWITCH
150-.----

2
156

--
_ v ~ 2-1.0RST_
(B3D)

~
~ • ~........:;:-;:;, (FUSIBLE LINK) S192
CIRCUIT
"_~ t0~2-1.0RST_ BREAKER

~~ (FUSIBLE LINK)
25 A ....
q I
~
(f) ~
I--

I
•
N~
M
Z
:J

Q;!
\!:-

S195
II
'

(~
~2-1.0RS~._2-3.0RED'
(FUSIBLE LINK)

GLOW PLUG
S197
2-13.0 RED_._ _

-
•

---- -------
3
~ 0 c::::::;, 0
~--------""
~
:
6

Cl00
5
• -.S205
12020030

- 300-5.0 ORN _ _ __
4O-1---~
HEAD

,
OfF

_--"'!oiH-,
'PARK

HEAD
10

~ '" 12020184 LIGHT

CONTROLLER 5 ~ - 2-5.0 RED _ _ _ _ _ _ __

I
,~" 7-1
SWITCH

1
C191

@@"'
~ a: & CD CD
a
ffi ffi I HI
M , . , eN",,", - - '"
(SEE PAGE 70)
cw'""
(SEE PAGE 70)
M q a q q a 01 a .--------.;.

::"".·_~ _~2 :2 ~t. ~ .,~-it!~m~t3jfilT-;~'=:'-,

c
£ATir £AI L
U!J ~ III ~ ITl lHl 0
L ~
Z o
12015982 lID lID !Al III ~ ill [ill 0 a:
co
o
ENGINE
DmDD
-- -
GROUND IIDIID@ ECM-BAT
ACC IGN HTR PWR HORN/DM
10AMP
LH
~
15AMP

CYLINDER DO 00 0 0
HEAD ~ 00 O~ [jUG
ACC-RADIO
G113 HORN/OM
~ INSTR-LPS L.r-.J
t;-;;-fl TRANS ECM-BAT
10AMP
~~~~
GENERATOR
00
o 0 . o
M
t?
'
~
STOP-HAZ ECM-CRNK

o
~

~~
OHTRO

AUX
A~O
~
WIPER

l 11~
ALT CRNK

ENGIN-l-= -,- T~ QS/P~ ECM-CRNK

fRONT 10AMP
GROUND
RH SHEET H"" •____ •
FUEL SHUT
OFF VALVE
METAL CRNK 20 AMP
CYLINDER GROUND
(SEE PAGE 63) FUSE BLOCK 10AMP
TURN-B/U
12089776 15AMP
HEAD G113 G110
B-6 POWER DISTRIBUTION
DIESEL ENGINE WIMAN TRANS
 RPO CODES

B3D - SCHOOL BUS EQUIPMENT

IGNITION SWITCH

2-13.0RED~
3

- 2
;Jj'~.
!I~:
• 0

+ RH
+ LH 89170S3
(B3D')
o
START
RUN
ow
cr:
o
ai
N
BATIERY BATIERY
1000 0 01 B
1 OFF
LOCK
ACC
BODY BUILDER
100 AMP JUNCTION o
. ._ _ 1-S0.0 BLK _ _ _ _ __
BLOCK (B3D ONLy) C298 C299
1-32.0 BLK (B3D) 1201966 6294641
fj~~~ _____ 6-3.0 PPL _ _ _ _ _ _. . . 44

3-S.0 PNK ..._ _ _ _ _ 4-5.0 BRN _

BATTERY STARTER
JUNCTION MOTOR
300-S.0 ORN
BLOCK HEADLAMP
-- --11·-----------1
-- ..
SWITCH 150-~-_ .......-+--il-- 156
K PANEL DIMMER o E F DOME
2
SWITCH
S192 o L
z
1....,~_It:I=tttL ".-YI-+---i ~
M a: CIRCUIT
S196 tD BREAKER
- - • C N o o 25 AMP
.,; I
B "? ... I

s~~~~~~30
6 C209
A
12020029
~1 N -.
_ .9-1.0BRN
"J '-0'-o:=="..-'~ __

-,
S299
~

4
0
-
~
--~t--I-,

----- ~ ------"'"
tJ
300-S.0 ORN _ • _ _ __

co C100
~ 12020184
~o LIGHT

I
-'
"- • -2-S.0RED-------7i- -------
"- HTR SWITCH INSTR-LPS

l .. ~
--- i - .............
q

-------J
SAMP

..
2SAMP
39-.8 PNK/BLK I/P CLUSTER S206 _ 3-S.0 PNK _ •
S208 (SEE PAGE 70) I~ ________
~ ~ ~~ ~
----.
_ 2-S.0 RED _ _
@cr: 0: @ (SEE PAGE 70) --.~
o 0 "-0 0 q a ~ ~ 44-1.0DKGRN _ _ _
M
.
_,'
-~
u;>"
..~~ C\I
~ ~
d ..
~ ~

E
3-3.0PNK. ;;; -

C128
1201S982
'" _I_.!-_.
[
-- . £AT@ ~ [g~CD
L

lID lID ~ m~ CD [BJ 0

[BJ 0
Z
~
z
a:
0
0

ENGINE
[IDlID~D[i]DD
o
GROUND
.--11- - -
-....
ACC IGN HTR PWR HORN/OM
LH
~DDOODD
lSAMP

CYLINDER
HEAD
G113
~ ~ 00 O
HORN/OM INSTR-LPS
[jUG
TRANS
c=J
ECM-BAT
TAIL LPS
20 AMP

GENERATOR
Cl07
12045896 = sa
00D800~
~---------------------'
TAIL LPS INJ HTR ACC-RADIO lSAMP
o
~~DDOO
M "-
o
N oj
STOP-HAZ ECM-CRNK AUX WIPER
c?
• I o 00 [}?f]
-1 O_ -:::=-
O

l
ALT CRNK

~~g~%~
Sl13

T~ Qs/pQ
FRONT
SHJET FUEL SHUT
RH METAL 3-3.0PNK _ _ _ _. . .~ OFF VALVE
(SEE PAGE 63) FUSE BLOCK GAUGES TURN-B/U
CYLINDER GROUND 12089776 20 AMP 15 AMP
HEAD G113 G110
POWER DISTRIBUTION B-7
DIESEL ENGINE W/AUTO TRANS
 RPOCOoES

MTI - AUTO TRANS, Ho, 4-SPO., WITH OVERDRIVE

MT8 - MAN TRAN8, 5-SPO., WITH OVERDRIVE
BODY BUILDER
100 AMP
JUNCTION
2-13.0REo~ BLOCK
(B30)
I
GT104 100 0001
+ RH
+ LH
_ _ _ _ _ _ _ _ _ _ _ 6-3.0PPl _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
8917053

ow . ._ _ _ _ _ 3-3.0 PNK _ _ _ _ _. .
II:
o
BATTERY BATTERY
...J
~
~
N

o
Cl00
lIP 12020164

. .- - - - - - 1-50.0 BlK
1-32.0 BlK (B30)
-------BGl
BATTERY
B
JUNCTION
BLOCK STARTER c
B I ......L-+-..-+-T..LI
MOTOR C
It--~I-{r

/ \
---- ---.
---. S192
o I ~=--+-i'-;
E

G
n 15
r
If 14
I 11
12

29
v
9
l
M
N
p

r~
/ \

~
\
~2-1.0RST-.-2-3.0RED~
-'
a..
a..

~
. ._ _ _ 3-3.0 PNK _ _ __
--.1.._..........
8205
I
I- ~ (FUSIBLE LINK) S 197
11
r-
(J) -'
II: W
~ ~ isE~l~:~~~O)

--
q ffi S208 . . - . - 39-.8 PNK/BLK . . . . . . ,
CO? (jj (SEE PAGE 70)

i~ GLOW PLUG ._1 _____

l
, - - - - 2-3.0 RED - - - - - - - - - - - - - - - - - -
CONTROLLER t S208
• 8195
=
I
0

---
IGN
~
20~AMP i
~-~I
oW 0
II: W

• ~ __ J
[]'[) I
L
o II:
<Xi 0

~
I'" I c
--
, -
S113 ~

... - -
z
-1l-fi:==*~i!!:!!="11 a..
~
... -
- -
- -. - 3-3.0 PNK

A Cl00
FUSE
HOLDER
12010105
.,
0
C'l

12020183
~
~ a ~
Ii3 = 'a..z"' 'za.."'
'"'
-'
CD
-'
CD
CD '"
o!!!.
CD 0 0
GENERATOR Cl07
12045696 Z
~
~ CD~
0
~ . ._ _ _ _ 3-3.0 PNK _ _ _ _ _ FUEL SHUT ..,<',i ~
n. ~ .~

eD OFF VALVE

/~~ ~,
a; (SEE PAGE 63)
'""'II
FUSE BLOCK

-.J FRONT 12052472

ENGINE ENGINE SHEET

GROUND GROUND METAL
LH CYLINDER RH GROUND
-- INJECTION ECM
(MT1)
HEAD CYLINDER G110 7.5 AMP 10 AMP 20 AMP

G113 HEAD
G112
B-8 POWER DISTRIBUTION
DIESEL ENGINE (DRIVEAWAY)
 RPO CODES

BSD - SCHOOL BUS EQUIPMENT

TEMPORARY RUN
IGNITION SWITCH

FRONT
FUSE BLOCK
SHEET 12052472
ENGINE METAL
GROUND GROUND
G111 G110
POWER DISTRIBUTION B-9
GASOLINE ENGINE (DRIVEAWAY)
 8-1.0 GRA-

240-1.0 ORN - HORN RLY - DOME LAMP

SHUNT 12041235
8-.8 GRA - INSTRUMENT LAMPS
8-1.0 GRA---------------------------------------------

44-1.0 DK GRN - LT SW RHEOSTAT

40-1.0 ORN - TAIL LAMPS
481-1.0 RED - INJECTORS

140-1.0 ORN - STOP LAMP SW - HAZ FLSHR

439-1.0 PNK/BLK - ECM (FUSED)

16-.8 PPL - TURN SIGNAL SW

3-5.0 PNK • IGN SW - ENG IGN
75-.8 DK BLU - BACK-UP LAMP SW
39-.8 PNK/BLK - INSTRUMENT CLUSTER
39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

6-5.0 PPL - CLUTCH START SWITCH

6-5.0 PPL - STARTER SOLENOID FEED

908-.8 PPL - CRANK DISCONNECT (FUSED)

38-.8 DK BLU - TURN SIGNAL -

COLOR MALE CONN FUSE FUSE COLOR HOT DESCRIPTION FUSE FUSE COLOR HOT
LOCATION PART NO. AND CONDITION LOCATION PART NO. AND CONDITION DESCRIPTION
A BRN 12004887 AMPERE AMPERE
B BLK 12004886 ACC-RADIO 12004007 RED HOT IN ACC RADIO ACCESSORIES HTR 12004010 WHITE HOT IN HEATER
10 AMP OR RUN 25 AMP RUN
H GRN 12004885
ALT 12004009 YELLOW HOT IN RUN ALTERNATOR INJ 12004006 BRN HOT IN RUN INJECTORS
1 NAT 12004888 20 AMP OR START 7.5 AMP OR START
L BLU 12004884 CRNK 12004007 RED HOT IN ELECTRONIC CONTROL MODULE INSTR-LPS 12004005 TAN HOT W/ HEADLAMP IN INSTRUMENT PANEL LAMPS
10 AMP START CRANK CIRCUIT 5 AMP PARK OR HEAD
ECM-BAT 12004007 RED HOT AT ELECTRONIC CONTROL MODULE STOP-HAZ 12004008 LT BLUE HOT AT STOP LAMPS
10 AMP ALL TIMES 15 AMP ALL TIMES HAZARD FLASHER
ECM-CRNK 12004007 RED HOT IN RUN ELECTRONIC CONTROL TAIL LPS 12004009 YELLOW HOT AT TAIL LAMPS
10 AMP OR START MODULE IGNITION 1 20 AMP ALL TIMES
GAUGES 12004009 YELLOW HOT IN PROVISIONS FOR GAGES TURN-B/U 12004008 LT BLUE HOT IN RUN TURN SIGNALS
20 AMP RUN 15 AMP OR START BACK-UP LAMPS
HORN-DM 12004008 LT BLUE HOT AT PROVISIONS FOR WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS
15 AMP ALL TIMES HORN AND DOME LAMPS 25 AMP ACC OR RUN

B-10 FUSE BLOCK

GASOLINE ENGINE W/MAN TRANS
 8-1.0 G R A -
m 1

xc>
BAT
L

□
B] \B 0 mi> s
m 0 □

090
L

□
(U S I 0 0S (El □

350-.8 PNK/WHT - FUEL CYC MDL

[3 ® 0 □ m □ □ 240-1.0 ORN - HORN RLY - DOME LAMP
ACC IGN HTR PWR 250-1.0 BRN - TRANSMISSION SHUNT 12041235
440-1.0 ORN - ECM 8-.8 GRA - INSTRUMENT LAMPS
gcg □ □ [M] □ 0 GAUGES PWR 2-5.0 RED - BATTERY 8-1.0 GRA ---------------------------------------------
50-3.0 BRN
_15A^_
[X ] K ] D
HORN/DM INSTR-LPS
_3_ TRANS ECM-BAT
300-5.0 ORN - IGNITION
44-1.0 DK GRN - LT SW RHEOSTAT

K l
TAIL LPS
K l [Jt] D3
INJ HTR ACC-RADIO
-141-1.0 BRN/WHT
4-5.0 BRN - IGN SW
40-1.0 ORN • TAIL LAMPS
481-1.0 RED - INJECTORS

K Dd □ D D§]
STOP-HA : ECM-CRNK AUX WIPER
93-3.0 WHT - WINDSHIELD WIPER 140-1.0 ORN - STOP LAMP SW - HAZ FLSHR
439-1.0 PNK/BLK - ECM (FUSED)

EG 0 D
ALT CRNK
16-.8 PPL - TURN SIGNAL SW
75-.8 DK BLU - BACK-UP LAMP SW
3-5.0 PNK - IGN SW - ENG IGN
39-.8 PNK/BLK - INSTRUMENT CLUSTER
3-5.0 PNK - IGNITION
IM1P o
t Or n -b Tu fus / p lr 39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

FRONT
12034359 - BLOCK MOLD
12089776 - PRINTED BLOCK

38-.8 DK BLU - TURN SIGNAL ■

MALE CONN FUSE FUSE COLOR HOT DESCRIPTION FUSE FUSE COLOR HOT
COLOR
LOCATION PART NO. AND CONDITION LOCATION PART NO. AND CONDITION DESCRIPTION
A BRN 12004887 AMPERE AMPERE
B BLK 12004886 ACC-RADIO 12004007 RED HOT IN ACC RADIO ACCESSORIES INJ 12004006 BRN HOT IN RUN INJECTORS
10 AMP OR RUN 7.5 AMP OR START
H GRN 12004885
ALT 12004009 YELLOW HOT IN RUN ALTERNATOR INSTR-LPS 12004005 TAN HOT W/ HEADLAMP IN INSTRUMENT PANEL LAMPS
1 NAT 12004888 20 AMP OR START 5 AMP PARK OR HEAD
L BLU 12004884 ECM-BAT 12004007 RED HOT AT ELECTRONIC CONTROL MODULE STOP-HAZ 12004008 LT BLUE HOT AT STOP LAMPS
10 AMP ALL TIMES 15 AMP ALL TIMES HAZARD FLASHER
ECM-CRNK 12004007 RED HOT IN RUN ELECTRONIC CONTROL TAIL LPS 12004009 YELLOW HOT AT TAIL LAMPS
10 AMP OR START MODULE IGNITION 1 20 AMP ALL TIMES
GAUGES 12004009 YELLOW HOT IN PROVISIONS FOR GAGES TRANS 12004007 RED HOT IN RUN TRANSMISSION
20 AMP RUN 10 AMP OR START
HORN-DM 12004008 LT BLUE HOT AT PROVISIONS FOR TURN-B/U 12004008 LT BLUE HOT IN RUN TURN SIGNALS
15 AMP ALL TIMES HORN AND DOME LAMPS 15 AMP OR START BACK-UP LAMPS
HTR 12004010 WHITE HOT IN HEATER WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS
25 AMP RUN 25 AMP ACC OR RUN

FUSE BLOCK B-11

GASOLINE ENGINE W/AUTO TRANS
 -8-1.0 GRA-

A
□ a-B
A“TA

GU 1)
a

a i a 0; m
a □
m a n

m □
a n

□
IGN HTR PWR
□s
□
o
b

350-.8 PNK/WHT - FUEL CYC MDL- £ l\

0
&
d I
0 nr
ii
□ q ' t ! □ tfe A i
0 in
F I i n i
240-1.0 ORN - HORN RLY • DOME LAMP
ACC SHUNT 12041235
8-.8 GRA - INSTRUMENT LAMPS
DPWRJP □ □ Okfl m
IB □□ w
I 8-1.0 GRA --------------------------------------------
— 50-3.0 BRN
0 □ □ □ □ □ [ID ■44-1.0 DK GRN - LT SW RHEOSTAT
-141-1.0 BRN/WHT
4-5.0 BRN - IGN SW
Pel [ I/© .40-1.0 ORN - TAIL LAMPS

93-3.0 WHT - WINDSHIELD WIPER

i □ ski 1 I k s -140-1.0 ORN - STOP LAMP SW - HAZ FLSHR

16-.8 PPL - TURN SIGNAL SW

75-.8 DK BLU - BACK-UP LAMP SW
□0 -3-5.0 PNK - IGN SW - ENG IGN
-39-.8 PNK/BLK - INSTRUMENT CLUSTER
□ □ B<1 -39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

FRONT REAR
12034359 - BLOCK MOLD
12089774 - PRINTED BLOCK

38-.8 DK BLU - TURN SIGNAL-

COLOR MALE CONN FUSE FUSE COLOR HOT DESCRIPTION FUSE FUSE COLOR HOT
LOCATION PART NO. AND CONDITION LOCATION PART NO. AND CONDITION DESCRIPTION
A BRN 12004887 AMPERE AMPERE
B BLK 12004886 ACC-RADIO 12004007 RED HOT IN ACC RADIO ACCESSORIES INSTR-LPS 12004005 TAN HOT W/ HEADLAMP IN INSTRUMENT PANEL LAMPS
10 AMP OR RUN 5 AMP PARK OR HEAD
H GRN 12004885
ALT 12004009 YELLOW HOT IN RUN ALTERNATOR STOP-HAZ 12004008 LT BLUE HOT AT STOP LAMPS
I NAT 12004888 20 AMP OR START 15 AMP ALL TIMES HAZARD FLASHER
L BLU 12004884 GAUGES 12004009 YELLOW HOT IN PROVISIONS FOR QAQES TAIL LPS 12004009 YELLOW HOT AT TAIL LAMPS
20 AMP RUN 20 AMP ALL TIMES
HORN-DM 12004008 LT BLUE HOT AT PROVISIONS FOR TURN-B/U 12004008 LT BLUE HOT IN RUN TURN SIGNALS
15 AMP ALL TIMES HORN AND DOME LAMPS 15 AMP OR START BACK-UP LAMPS
HTR 12004010 WHITE HOT IN HEATER WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS
25 AMP RUN 25 AMP ACC OR RUN

B-12 FUSE BLOCK

DIESEL ENGINE W/MAN TRANS
 8-1.0 GRA

240-1.0 ORN - HORN RLY - DOME LAMP

SHUNT 12041235
8-.8 GRA - INSTRUMENT LAMPS
8-1.0 GRA----------------------------------------------

44-1.0 DK GRN - LT SW RHEOSTAT

40-1.0 ORN - TAIL LAMPS

140-1.0 ORN - STOP LAMP SW - HAZ FLSHR

439-1.0 PNK/BLK - ECM (FUSED)

16-.8 PPL - TURN SIGNAL SW

3-5.0 PNK - IGN SW - ENG IGN
75-.8 DK BLU - BACK-UP LAMP SW
39-.8 PNK/BLK - INSTRUMENT CLUSTER
3-5.0 PNK - IGNITION
39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

38-.8 DK BLU - TURN SIGNAL-

COLOR MALE CONN FUSE FUSE COLOR HOT DESCRIPTION FUSE FUSE COLOR HOT
LOCATION PART NO. AND CONDITION LOCATION PART NO. AND CONDITION DESCRIPTION
A BRN 12004887 AMPERE AMPERE
B BLK 12004886 ACC-RADIO 12004007 RED HOT IN ACC RADIO ACCESSORIES HTR 12004010 WHITE HOT IN HEATER
10 AMP OR RUN 25 AMP RUN
H GRN 12004885
ALT 12004009 YELLOW HOT IN RUN ALTERNATOR INSTR-LPS 12004005 TAN HOT W/ HEADLAMP IN INSTRUMENT PANEL LAMPS
1 NAT 12004888 20 AMP OR START 5 AMP PARK OR HEAD
L BLU 12004884 ECM-BAT 12004007 RED HOT AT ELECTRONIC CONTROL MODULE STOP-HAZ 12004008 LT BLUE HOT AT STOP LAMPS
10 AMP ALL TIMES 15 AMP ALL TIMES HAZARD FLASHER
ECM-CRNK 12004007 RED HOT IN RUN ELECTRONIC CONTROL TRANS 142004007 RED HOT IN TRANSMISSION
10 AMP OR START MODULE IGNITION 1 10 AMP RUN OR START

GAUGES 12004009 YELLOW HOT IN PROVISIONS FOR GAGES TAIL LPS 12004009 YELLOW HOT AT TAIL LAMPS
20 AMP RUN 20 AMP ALL TIMES
HORN-DM 12004008 LT BLUE HOT AT PROVISIONS FOR TURN-B/U 12004008 LT BLUE HOT IN RUN TURN SIGNALS
15 AMP ALL TIMES HORN AND DOME LAMPS 15 AMP OR START BACK-UP LAMPS
WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS
25 AMP ACC OR RUN

FUSE BLOCK B-13

DIESEL ENGINE W/AUTO TRANS
 LAMP BULB DATA

AC Type Guide Lamps are recommended when replacement becomes necessary.

Lamp Usage Quantity Trade Power Rating

No. at 12V, Watts
Headlamp1 2 6014 50/60 W
Candle Power
Park and Signal Lamp2 2 2057 32-2
Tail and Stoplamp3 (Union City Body Co.) 2 1157 32-3
Tail and Stoplamp2 (Except Union City Body Co.) 2 2057 32-2
Front Side Marker Lamp 2 194 2
Rear Side Marker Lamp 2 194 2
License Lamp 2 67 4
Backup Lamp4 — — —

Instrument Cluster Illumination Lamp 6 PC194 2

Turn Signal Indicator Lamp 2 PC194 2
Headlamp High Beam Indicator Lamp 1 PC74 .7
Service Brake Warning Indicator Lamp 1 PC74 .7
Park Brake Warning Indicator Lamp 1 PC74 .7
Transmission Control Illumination Lamp 1 73 .3
Low Coolant Indicator Lamp5 1 PC74 .7
Glow Plug Indicator Lamp5 1 PC74 .7
Water in Fuel Indicator Lamp5 1 PC74 .7
Service Engine Soon Indicator Lamp 1 PC74 .7
Trans Indicator Lamp5 1 PC74 .7
Fasten Safety Belts Indicator Lamp6 1 PC74 .7
Door Ajar Indicator Lamp 1 PC74 .7
Daytime Running Lights Indicator Lamp7 1 PC118 .7

1. Double filament sealed beam: 50W low beam, 60W high beam.
2. Double filament lamp: 32 CP high, 2 CP low.
3. Double filament lamp: 32 CP high, 3 CP low.
4. Refer to body manufacturer’s specifications.
5. Diesel only.
6. When used by body manufacturer.
7. Canada only.

B-14 BULB DATA

& < z

RH HIGH-LOW [ 150-.8 BLK ■

HEADLAMP (DRIVEAWAY ONLY)
(SEE PAGE 23)

LH HIGH-LOW 150-.8 BLK |

HEADLAMP (DRIVEAWAY ONLY)
(SEE PAGE 23)

z
0 o

1
>
d
!
tr
o

■COPPER BRAID i

ENGINE SHEET FRAME SHEET SHEET FRAME SHEET SHEET FRAME

&
ENGINE DASH
GROUND METAL GROUND METAL METAL GROUND METAL METAL GROUND GROUND PANEL
G110 GROUND G106 GROUND GROUND G104 GROUND GROUND G104 G120 GROUND
G111 G107 G105 G106 G105 G121

GROUND DISTRIBUTION B-15

FORWARD LAMPS
 . ._ _ _ _ _ _ _ _ _ _ _ 486-.8 BRN -----CC ESC HYBRID
FUNCTION
(SEE PAGE 44)

r- 450-.8 BLKlWHT - -~
EVRV (L05 ONLy)
(SEE PAGE 46)

I
II r" 450-.8 BLKlWHT - . . -
FUEL PUMP RELAY
(SEE PAGE 54)

II
II
+r ...-.c
i
ECM
"-450-.8BLKlWHT _ _ - - - - - - -.r - - - - - - - 450-.8 BLKlWHT -
(SEE PAGE 45)

I ".-_.'mKIW""_ - - - - - - DRAC

-_
..-450-.8 BLKlWHT ___ ....
(SEE PAGE 64)
GT100

'"'' ~ .....- .. """""'- 12020107 (UPPER)

... 450-.8 BLKlWHT _ .... ECM
12020708 (LOWER)
(SEE PAGE 45)

,\'-
't '~_450-.8BLKlWHT_ -.r - - - -
. - 450-.8 BLKlWHT _ ... ALDL

,
- - - (SEE PAGE 45)

• \
\... --, - - ....,
"""""' ~_ _ 413-.8 TAN ----lICe ECM
(SEE PAGE 45)

•i ,,t
,,
m
C!

,,
~
~

,,
I
I
J
, \
ALTERNATOR
BRACKET ENGINE
GROUND
-- G101 -=-
GROUND
G100
B-16 GROUND DISTRIBUTION
GASOLINE ENGINE WIMAN TRANS
 ,
~ "..., ...., - 450-.8 BLK/WHT ~ - ...., ......
FUEL PUMP RELAY
I(SEE PAGE 54)

, r -, 450-.8 BLK/WHT • - - - --c EIIRV (L05, L19)

(SEE PAGE 46)

, I
, I
,I
,I ,. , - 450-.8 BLK/WHT - - - "..., - - - "..., - "..., -
... 450-.8 BLK/WHT.......... ALDL
(SEE PAGES 45, 47)

VI:~-~"~~-
DRAC
(SEE PAGE 64)

PCM
S102 • If _ "..., ... 450-.8 BLK/WHT ~ "..., - ...., ,...., - ~ - - -
... 450-.8 BLK/WHT.... .......
(SEE PAGE 51)

t,
, ,
, , ~_ - ~"'-"''''_'''O"'~-.- -
, - - --
GT100
- - 551-.8 TAN/WHT " . . . , ..... ;~~ PAGE 51)

,~ , , 120201071UPPER)
120201081LOWERI . ._ _ 413-.8 TAN - - - -. . . C PCM
(SEE PAGE 51)

, \.. ,- -.,.,""""'- -1 '

"
"
,, ''
"
i ',
,
,~ '.
'
* , i
.,
~
, ~
, ) l ;
, I '"'
~-
ALTERNATOR ENGINE
BRACKET GROUND
GROUND G100
G101
GROUND DISTRIBUTION B- 17
GASOLINE ENGINE W/AUTO TRANS
 RPO CODES

L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K

T61 ■ CANADIAN DAYTIME RUNNING LAMPS

l/P CLUSTER
CONNECTOR
(SEE PAGE 70)

l/P
GROUND
G200
B-18 GROUND DISTRIBUTION
GASOLINE ENGINE
 RPOCODES

T61 - CANADIAN DAYTIME RUNNING LAMPS

. .- _ _ _ _ _ _ 150-3.0 BLK _ PANEL DIMMER SWITCH

(SEE PAGE 72)

....I
~
0
()
150-.8 BlK 150-.8 BlK --C PARK BRAKE SWITCH
(SEE PAGE 70)
liP

C
Cl = D
. ._ _ _ _ 150-.8 BLK - - - -. . . FUEL HEATER
A
150-.8 BlK --II DRAC
(SEE PAGE 63) J (SEE PAGE 65)
B 150 39
K
C 3 419
0 2 31
L
E 439 35
~_ _ _ _ 150-.8 BlK -----CC WATER IN FUEL SENSOR
F 2 M 150-.8 BlK --C lOW COOLANT MODULE
(SEE PAGE 63) (SEE PAGE 70)
G 440 N

H 6

~1 2
3 5
Cl 0
~_ _ 150-.8 BlK --C WIPER SWITCH
(SEE PAGE 38)

Cl00
12020184

,
C
" '_ _ _ _ 150-.8 BlK - - - -. . GLOW PLUG CONTROllER DRl RELAY (T61)
(SEE PAGE 61)
(SEE PAGE 27)

ENGINE
' -_ _ _ _ 150-1.0 BlK '-_ 150-.8 BlK _ _ DRl MODULE (T61)
IS2I = (SEE PAGE 27)

I 6 1250148111 H
I I 440 1470 1 824 \I G ~

[, I 2 I 1ltD "" ~ F
1
I
I
439

3
35

2 I 311 ~@
1 1
E

1m -.:
\ 419 1 C
0
15O-.8BlK --II

150 I 39 11111 B

I I 1120 I A ? 150-.8 BlK --C

1 2 3 129 = liP CLUSTER
Cl00 CONNECTOR
12020183 (SEE PAGE 70)

150-.8 BlK --C

--C
-- 150-.8 BlK

ENGINE liP
GROUND GROUND
G100 G200

GROUND DISTRIBUTION B-19

DIESEL WIMAN TRANS
 ,..-..
,,
RPOCODES

~ ~ ..-.. ...-r ~ .... 551-.8 TAN/WHT ... 551-.8 TAN/wHT . . - . ....... TCM T61 - CANADIAN DAYTIME RUNNING LAMPS
(SEE PAGE 58)

,..-..
,,
~ ...- 450·.8 BLKlWHT'" "450-.8 BLKlWHT ~....c TCM

,,
(SEE PAGE 58)

. ._ _ _ _ 150,.8 BLK _ _. . . .- - - - 150-3.0 B L K " PANEL DIMMER SWITCH

150'.8 BlK ( ALDl (SEE PAGE 72)
(SEE PAGE 57)

,, ,, . ._ _ 150-.8 BLK _ _. .
GT100
12020107 (UPPER)
12020108 (LOWER) 150-.8 BLK ( DRAC
(SEE PAGE 65)
150-.8 BlK.... PARK BRAKE SWITCH
(SEE PAGE 70)

,, ,, . .- - - - - - - - - - - 150-.8 BlK ------------l1li(( FUEL HEATER

(SEE PAGE 63)
150-.8 BlK.... lOW COOLANT WARNING MODULE
(SEE PAGE 70)

,
150-.8 BlK.... WIPER SWITCH
(SEE PAGE 38)

,, 11_ _ _ _ _ _ _ _ _ _ _
1
50-.8 BlK _ _ _ _ _ _ _ _ _ _ _ _. (. WATER IN FUEL SENSOR

(SEE PAGE 63) DRL RELAY (T61)

(SEE PAGE 27)

,, S114
.1________________ '50-.8 Bll(" ------------1(( GLOW PLUG CONTROLLER
(SEE PAGE 61)
S203

DRl MODULE (TS1)

(SEE PAGE 27)

,, ' -_ _ _ _ _ _ _ _ _ _ _ 150-.SBlK _ _ _ _ _ _ _•
150-.S BLK _ _

,, . .- - - - -_ _ _ _ 150-.S BlK _ _. .
150-.S BLK _ _

lIP CLUSTER
CONNECTOR
(SEE PAGE 70)

,,
150-.BBlK . . . .

C100 Cl = D
~
12020183 A 0

= E!J 3 2
B
C
150
3
39
9 I:I~:~~ lS0-.SBlK· . . . .

,, 0
E
F
G
H
~1
2
439
2
440
6
31
35

420
250

2
3
Di::;;;;;:;;;;;:J0Cl
11
12

29

5
9
l
M
N

~-
ENGINE
--- ENGINE
Cl00
12010184

---
ENGINE lIP
GROUND GROUND GROUND
G102 G100 G200

B-20 GROUND DISTRIBUTION

DIESEL W/AUTO TRANS
 . ._ _ _ 150-1.0 BLK _ _ _ _ _ _.~'"
~.!IJi!t;.------- 150-.8 BLK - - - - •
r C
150-.8 BLK - -. . . PROVISIONS FOR
RH SIDE MARKER
(SEE PAGE 76)

S404 "-

" - 150-.8 BLK ---C. PROVISIONS FOR

LH SIDE MARKER
(SEE PAGE 76)
12065158 C402 12034342

-- ---
SHEET
FRAME
GROUND METAL
G400 GROUND
G402
GROUND DISTRIBUTION B-21
REAR
CIRCUIT OPERATION LOW BEAM LAMP(S) DO NOT OPERATE
TEST RESULT ACTION
Voltage is applied to the Light Switch at all times. current flow, the Circuit Breaker cools off and resets
The Light Switch includes a Self-Resetting Circuit automatically. When the Light Switch is in HEAD, the 1. Turn light switch ON and Test lamp does not light. GO to step 2.
Breaker. The Circuit Breaker opens when the Light Dimmer Switch directs voltage to either the Low Beams headlamp dimmer switch to LOW
or the High Beams. The HI Beam Indicator also receives BEAM position. Connect a test Test lamp lights. ISOLATE problem in body
Switch circuit draws too much current. When the Circuit
lamp from TAN (12) wire at builder’s installed wiring.
Breaker opens, it interrupts the current flow. With no voltage along with the High Beams.
connector C100 to ground.
2. Connect test lamp from TAN Test lamp does not light. GO to step 3.
(12) wire at headlamp dimmer
switch connector C210 to Test lamp lights. LOCATE and REPAIR open in TAN
DIAGNOSIS - HEADLAMPS ground. (12) wire from headlamp dimmer
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS » BOTH SIDES switch connector C210 to
TEST RESULT ACTION connector C101.

1. Connect a test lamp from RED Test lamp lights. GO to step 2. 3. Connect a test lamp from YEL Test lamp does not light. LOCATE and REPAIR open in YEL
(2) wire at light switch (10) wire at headlamp dimmer (10) wire from headlamp dimmer
connector C209 to ground. Test lamp does not light. LOCATE and REPAIR open in RED switch connector C210 to switch connector C210 to light
(2) wire from light switch ground. switch connector C209.
connector C209 to battery
junction block. Test lamp lights. REPLACE headlamp dimmer
switch.
2. With the light switch on and Test lamp lights. GO to step 3.
the dimmer switch to HIGH HIGH BEAM LAMP(S) DO NOT OPERATE
BEAM, connect a test lamp from Test lamp does not light. REPLACE light switch.
YEL (10) wire at light switch TEST RESULT ACTION
connector C209 to ground. 1. Place light switch to ON and Test lamp does not light. GO to step 2.
3. Connect a test lamp from LT GRN Test lamp lights. REPAIR open in LT GRN (11) wire dimmer switch to HIGH BEAM
(11) wire at headlamp dimmer from headlamp dimmer switch position. Connect a test lamp Test lamp lights. ISOLATE problem in body
switch connector C210 to connector C210 to connector from LT GRN (11) wire at builder’s installed wiring.
ground. C100. connector C100 to ground.

2. Place headlamp dimmer switch Test lamp does not light. GO to step 3.
Test lamp does not light. REPLACE headlamp dimmer
in HIGH BEAM position. Connect
switch.
a test lamp from LT GRN (11) Test lamp lights. LOCATE and REPAIR open in YEL
wire at headlamp dimmer switch (10) wire at headlamp dimmer
connector C210 to ground. switch connector C210 to light
switch connector C209.
3. Connect a test lamp from YEL Test lamp does not light. LOCATE and REPAIR open in YEL
(10) wire at headlamp dimmer (10) wire at headlamp dimmer
switch connector C210 to switch connector C210 to light
ground. switch connector C209.

Test lamp lights. REPLACE headlamp dimmer

switch.

B-22 HEADLAMPS
BASE
JUNCTION
BLOCK

S197

HEADLAMP
DIMMER
SWITCH

C210
8917693

BASE HEADLAMPS WIRING B-23

 0 1iL| VJJ C145
®L47 12077765
RH
SIDE MARKER
LAMP

HORN

115-.5 DK BLU |

.• S121

NOTE: This harness is shipped

along with the vehicle and is
LH installed by the body builder.
SIDE MARKER SHEET
METAL FRAME
LAMP
GROUND Q / GROUND

G105 G104
G106 G107 12077765

B-24 FORWARD LAMP HARNESS

CIRCUIT OPERATION LOW BEAM LAMP(S) DO NOT OPERATE
TEST RESULT ACTION
CANADIAN DAYTIME RUNNING LAMPS the DRL Indicator in the Instrument Panel and energizes
1. Turn light switch ON and dimmer Test lamp does not light.
the DRL Relay. When energized, the DRL Relay GO to step 4.
Battery voltage is applied to the Daytime Running switch to LOW BEAM position.
Lamps (DRL) Module from the BRN (50) wire and the disconnects the LT BLU/ORN (593) wire from ground and Connect a test lamp from TAN Test lamp lights. GO to step 2.
HTR fuse. internally connects it to the LT GRN/BLK (592) wire (12) wire at connector C100 to
causing it to be 12 volts. ground.
With the Headlamps on, the DRL Relay is not
energized and the LT BLU/ORN (593) wire is grounded The LT BLU/ORN (593) wire feeds the LH High beam 2. Connect a test lamp from LT Test lamp does not light. LOCATE and REPAIR open in LT
to BLK (150) wire inside of the relay. This serves as which is connected in series to the RH Headlamp BLU/ORN (593) wire at DRL relay BLU/ORN (593) wire from light
through the LT GRN (11) wire. Grounding of the entire connector C243 to ground. connector C100 to DRL relay
ground for the LH Headlamp.
DRL circuit is accomplished through the BLK (151) wire connector C243.
With Ignition in RUN, headlamps off and Parking at the RH Headlamp. This results in High beam
Test lamp lights. GO to step 3.
Brake released, the DRL Module applied battery voltage headlamps that are less intense for daytime driving and
to the LT GRN/BLK (592) wire. This action illuminates should provide longer service. 3. Connect a test lamp from BLK Test lamp does not light. REPLACE DRL relay.
(150) wire at the DRL relay
connector C243 to ground. Test lamp lights. LOCATE and REPAIR open in BLK
(150) wire from DRL relay
DIAGNOSIS - HEADLAMPS (WITH DRL) connector C243 to ground G200. If
not open is found, ISOLATE
problem in body builder’s installed
PRELIMINARY CHECKS: wiring.
Before checking the DAYTIME RUNNING LAMPS Lamp(s) are inoperative, refer to the HIGH BEAM
LAMP(S) DO NOT OPERATE test procedures. If the 4. Connect a test lamp from TAN Test lamp does not light. GO to step 5.
system, do the following:
High Beam Lamp(s) are operative, use the following (12) wire at headlamp dimmer
1. Place Park Brake in the OFF position.
switch connector C210 to ground. Test lamp lights. LOCATE and REPAIR open in TAN
2. Place Light Switch to ON and Headlamp Dimmer diagnostic procedures, after placing the Light Switch
(12) wire from connector C100 to
Switch to HIGH BEAM position. If the High Beam to OFF position.
headlamp dimmer switch
connector C209.
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS - BOTH SIDES 5, Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL
ACTION wire at headlamp dimmer switch (10) wire from headlamp dimmer
TEST RESULT
connector C210 to ground. switch connector C210 to light
1. Connect a test lamp from RED (2) Test lamp lights. GO to step 2. switch connector C209.
wire at light switch connector
C209 to ground. Test lamp does not light. LOCATE and REPAIR open in RED Test lamp lights. REPLACE headlamp dimmer
(2) wire from light switch connector switch.
C209 to fuse block.

2. Connect a test lamp from YEL (10) Test lamp lights. GO to step 3.
wire at light switch connector
C209 to ground. Test lamp does not light. REPLACE light switch.

3. Connect a test lamp from LT GRN Test lamp lights. REPAIR open in LT GRN (11) wire
(11) wire at headlamp dimmer from headlamp dimmer switch
switch connector C210 to ground. connector C210 to connector
C100.

Test lamp does light. REPLACE headlamp dimmer

switch.

CANADIAN DAYTIME RUNNING LAMPS (DRL) B-25

 HIGH BEAM LAMP(S) DO NOT OPERATE CANADIAN DAYTIME RUNNING LAMPS DO NOT OPERATE
TEST RESULT ACTION TEST RESULT ACTION

1. Connect a test lamp from LT GRN Test lamp does not light. GO to step 4. 1. With ignition in RUN, headlamps Test lamp does not light. LOCATE and REPAIR open in ORN
(11) wire at connector C100 to off and park brake released, (240) wire between DRL relay
ground. Test lamp lights. GO to step 2. connect a testlamp from ORN connector C242 and fuse block. If
(240) wire at DRL relay connector no open is found REPLACE DRL
2. Connect a test lamp from LT Test lamp does not light. LOCATE and REPAIR open in LT C242 to ground. fuse.
BLU/ORN (593) wire to ground at BLU/ORN (593) wire between
DRL relay connector C243. connector C100 and DRL relay Test lamp lights. GO to step 2.
connector C243.
2. Connect J 34029-A Multimeter Battery voltage at only one LOCATE and REPAIR open in BRN
Test lamp lights. GO to step 3. from BRN (50) wire at DRL module connector. (50) wire between splice S212 and
connector C243 and DRL relay connector with missing voltage.
3. Connect a test lamp from BLK Test lamp does not light. REPLACE DRL relay. connector C242 to ground.
(150) wire at DRL relay connector Measure voltage. No battery voltage at either LOCATE and REPAIR open in BRN
C243 to ground. Test lamp lights. LOCATE and REPAIR open in BLK connector. (50) wire between splice S212 and
(150) wire from DRL relay fuse block. If no open is found,
connector C243 to ground G200. REPLACE HTR fuse.
4. Connect a test lamp from LT GRN Test lamp does not light. GO to step 5.
Battery voltage at both GO to step 3.
(11) wire at headlamp dimmer connectors.
switch connector C210 to ground. Test lamp lights. LOCATE and REPAIR open in LT
GRN (11) wire from connector 3. Connect J 34029-A Multimeter No voltage. LOCATE and REPAIR open in BLK
C100 to headlamp dimmer switch from B R N (50) wire at DRL module (150) wire between suspect
connector C210. connector C243 and DRL relay connector and ground G200.
connector C242 to BLK (150) wire
5. Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL at each component connector. Battery voltage. GO to step 4.
wire at headlamp dimmer switch (10) wire at headlamp dimmer
Measure voltage.
connector C210 to ground. switch connector C210 to light
switch connector C209. 4. Connect J 34029-A Multimeter No voltage. LOCATE and REPAIR open in LT
from LT GRN/BLK (592) wire at GRN/BLK (592) wire between the
Test lamp lights. REPLACE headlamp dimmer DRL relay connector C242 to DRL relay and the DRL module. If
switch. ground. Measure voltage. no open is found, REPLACE DRL
module.

Battery voltage. GO to step 5.

5. Connect a test lamp from LT Test lamp does not light. LOCATE and REPAIR open in LT
BLU/ORN (593) wire at connector BLU/ORN (593) wire between DRL
C101. relay connector C242 and
connector C100. If no open is
found, ISOLATE problem in body
builder’s installed wiring.

Test lamp lights. Daytime running lamps are

operational.

B-26 CANADIAN DAYTIME RUNNING LAMPS (DRL)

 RH
SIDE MARKER
LAMP

~
C145
12077765

~"
~ _ _ _ 11-H) LTGRN

RH 11 C137
HIGH-LOW 12 12004267
HEADLAMP 151
z
a:
to
C144 ~
d>

-I
2973386

. ._ _ _ _ _ _ 151-.8BLK _ _

_15-.50KBLU _ _ _ _ _ _ _ _ __
15-.8 OK BLU_ _ _ . _ _ _•
15-.8 OK BLU
8124
z
a:
l!l
:.::

-
0
RH PARK AND
'--~-i'. BLK~
0
_______ • 8121
..,
C-
.,8 d>
TURN LAMP N
1'3

I
, r~.'"
11 ,I
C143
"WWHO' 12 ill~
2984855
z ~ 9 593 15
I-
a:
• 1- 29·~11

1--.. .
CO ..

------,
Ll)

14-.8LTBLU _ _
8123

- . ---.
'" 14-.5 LTBLU _14-.8 LT BLU
• ~ C101
12020100
-9-.8BRN 1-

LH PARK AND
TURN LAMP '--~~....,.8 BLKL®

- i ·8·12·2-- 9-.8 BRN - - - - - - - - - I :, 12-.8 TAN

,,
C142 z
a:
2984855 z l!l
a:
l!l S
S z C>
a:
o to

'"ch -

1H.OLTGRN _ _ _ __

12-.8TAN _ _ _ _ _ _. . - ------,, ~
LH 11
12
HIGH-LOW
150 --------~
~ ~ ~ ~
HEADLAMP
C140
2973386 ... . . . , AI 593-.8 OK BLU/WHT r r ..oj r . . . , .. --- . . . , . . . , . . . , . . . , .. r . . . , . . 593-.80KBLU/WHTr

151-3.0 BLK
...,
NOTE: This harness is shipped
along with the vehicle and is
installed by the body builder.

LH
SIDE MARKER SHEET
LAMP METAL FRAME
o GROUND
-- GROUND

C141
-
G105 G104
12077765

FORWARD LAMP HARNESS 8-27

W/DRL
 JUNCTION
BLOCK

HORN/OM ~ 1·------------------------.R.O.E.~·L·y--50-3.08AN - - .
15 AMP ~
HTR ~
25 AMP ~--. 50-3.0 8AN - - - -
_ _ _ _ ... ~ 592-.8LTGAN/8LK _ _ ~

~---2-1.0R8T-------.
~ . ._ _ _ _.240-1.0 DAN _ _ _ _ _ _ _ _ _ _ • 8298 8212
(FU818LE LINK) 8197 5O-3.08AN _ • _ 50-3.0 8AN _ _ _ _ _...~
(8EE PAGE 36)

C243
12052287

..J
:=
. ._ _ _ _ _ _ _ _ _ _ 240-.8 DAN _ _ _ _ _ _ _ _ _ _• , . ._ _ _ _ _ _ _ _ _ 150-.8 8LK _ _ _ _ _ IIj.~

o
u . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ , _ _ _ _ _ _ _ _ _ _ _ _ 12-.8TAN _ _ _ _ _........
oW C100 UP
~
0::
o 12020183
~ ENGINE Z
0::

= e2J 3 2 1 ~
m
~

lS A 1'20 1 1340 I <Xl

~r
B I 33 I 39 1450 I
C

~~@~
" ....
OJ 14191 3 I
I 31 1
135 1439
2

2
I
I
JJ~l=.*==~==:;-----------

-----
,-._____________ ~

11-1.0 LT GAN - - - - -

G II I 1440 I . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 11-1.0LTGRN _ _ _ _ _....

R H 11143419061 6 I
a
=
_________ 593-.8DKBLUIWHT_ ~

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2-3.0 AED _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2-3.0 RED _ _ _ _ _ ~~~

8-28 HEADLAMPS WIRING

W/DRL
 I/P CLUSTER
CONNECTOR
(SEE PAGE 69)
C205
12040744

44

LIGHT
SWITCH
LIGHT
SWITCH
l/P
(O ) GROUND
G200

HEADLAMPS WIRING B-29

W/DRL
 HAZARD WARNING LAMPS DO NOT OPERATE
CIRCUIT OPERATION
TEST RESULT ACTION
PARK AND MARKER LAMPS applied to both Front and Rear Turn Lamps. Alt of the 1. Place ignition switch in RUN and Turn signal lights operate. GO to step 2.
Voltage is applied through the TAIL LPS Fuse to the Turn Lamps and both Turn Indicators flash on and off. position turn signal lamps as if
Light Switch at all times. With the Light Switch in PARK making a turn. Turn signal lights do not operate. Refer to "Turn Signals Do Not
or HEAD, voltage is applied to the Park, Tail, Marker, and The Front Marker Lamps flash in HAZARD FLASH just Work On One Side" symptom.
License Lamps. The Front Marker Lamps are grounded as they did in TURN RIGHT and TURN LEFT, if the Lamp
2. Turn off turn signal lamps and put Test lamp lights. REPLACE turn signal switch.
through the LH and RH Park and Turn Lamps. Switch is in OFF, they flash on when the Hazard Lamps
hazard warning lamps ON.
are on. If the Lamp Switch is in either PARK or HEAD, Connect a test lamp from BRN Test lamp does not light. CHECK condition of STOP/HAZ
HAZARD SIGNAL LAMPS they flash on when the Hazard Lamps are off and off (27) wire at turn signal switch fuse. If fuse is good, LOCATE and
Voltage is applied at all times, through the STOP-HAZ when the Hazard Lamps are on. connector C206 to ground. REPAIR open in ORN (140) wire
Fuse and the Hazard Flasher to the normally open and B R N (27) wire. If fuse and
contact of the Hazard Switch in the Turn Signal Switch. In HAZARD, the circuit is always open, and the wiring are good, REPLACE hazard
With the Hazard Switch in HAZARD FLASH, voltage is Hazard Flasher Control the Lamps. flasher.

SIDE MARKER LAMP(S) DO NOT OPERATE

DIAGNOSIS - PARK, MARKER AND HAZARD LAMPS TEST RESULT ACTION
1. Place light switch in PARK Test lamp lights. GO to step 2.
PRELIMINARY CHECKS: position. Connect a test lamp from
If only one lamp is inoperative, inspect wire(s) to BRN (9) wire at connector C100 to Test lamp does not light. LOCATE and REPAIR open in BRN
affected lamp socket, check bulb-to-socket fit or replace ground. (9) wire from connector C100 to
bulb. light switch connector C209.
2. Remove bulb from socket, then Test lamp lights. ISOLATE problem in body builder’s
connect a test lamp between BRN installed wiring.
PARK LAMPS DO NOT OPERATE (9) wire and LT BLU (14) or DK
TEST RESULT ACTION BLU (15) wire(s) at connector Test lamp does not light. LOCATE and REPAIR open in LT
C100. BLU (14) or DK BLU (15) wire(s)
1. Place light switch in PARK Test lamp lights. GO to step 3. from connector C100 to turn signal
position. Connect a test lamp switch connector C206.
from O R N (40) wire at light Test lamp does not light. GO to step 2.
switch connector C209 to
REAR MARKER LAMP(S) DO NOT OPERATE
ground.
TEST RESULT ACTION
2. Connect a test lamp form RED Test lamp lights. CHECK condition of TAIL LPS
(2) wire at fuse block to fuse. If fuse is good, LOCATE 1. Place light in PARK position. Test lamp lights. GO to step 2.
ground. and REPAIR open in ORN (40) Connect a test lamp from BRN (9)
wire. wire at LH rear lamp harness Test lamp does not light. LOCATE and REPAIR open in BRN
connector C402. (9) wire(s) from rear lamp harness
Test lamp does not light. LOCATE and REPAIR open in RED connector C402.
(2) wire from fuse block to
battery junction block. 2. Connect a test lamp between BRN Test lamp lights. ISOLATE problem in body builder’s
(9) wire and BLK (150) wire(s) at installed wiring.
3. Connect a test lamp from BRN Test lamp lights. GO to step 4. rear lamp harness connector
(9) wire at light switch C402. Test lamp does not light. LOCATE and REPAIR open in BLK
connector C209 to ground. Test lamp does not light. REPLACE light switch. (150) wire from rear lamp harness
ISOLATE problem in body connector C402 to ground G400.
4. Connect a test lamp at BRN (9) Test lamp lights.
wire connector C100 to ground. builder’s installed wiring.

Test lamp does not light. LOCATE and REPAIR open in BRN
(9) wire from connector C100 to
light switch connector C209.

B-30 PARK, MARKER AND HAZARD SIGNAL LAMPS

 yvw w w w u
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TAIL LPS:
TAIL LPS 5
20
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140-1.0
- ,OORN - - - - - - - - - - - - - - - . PANEL DIMMER SWITCH
44
20 AMP
AMP —K A B c ° n
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—'Li’------ — 1
C297
12020030

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SWITCH 2

CIRCUIT \PARK
BREAKER ,
25AMP
10
HEAD
OFF
\
'PARK
40-1-_'-; 9

LIGHT
. ._ _ _ _ _ _ _ 40-1,OORN_-II-_ _ _
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REAR BODY
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REAR
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PARK AND MARKER SIGNAL LAMPS 8 ..31

B-31
 STOP-HAZ
15 AMP _ P I I - - - - - - - - · 1 4 0 - 1 . 0 0 R N - - - - - - - - -•
........_ _ _ _ _ _ _.140-1.0 ORN _ _ _ _ _ _ _ _ _ _ _ .1 (STEERING COLUMN SWITCHES)

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.
, ,_ _ _ _ 17-1.0 WHT
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G .5 BLK - - - - - - - - - .
F
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C206 KEY REAR

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NORMALLY
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HARNESS
PRNDL
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LAMP .........- - .5 GRA
m r-!. ~ (SEE PAGE 72)
BLU _ _ _ _ _ _ _. . . ~ lIP CLUSTER
14-.5 LT
BLU _ _ _ _ _ _. . . ~
CONNECTOR
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3:
0

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5
6

19-2.0 DKGRN ........- - - - - - -...- -...............- ......- -...- -...- ...- ......... .
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120 I!
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HAZARD
FLASHER
8-32 HAZARD SIGNAL LAMPS
 TURN SIGNALS DO NOT WORK ON ONE SIDE
CIRCUIT OPERATION
TEST RESULT ACTION
TURN SIGNAL LAMPS 1. Turn hazard warning system on. Lights flash. CHECK for improper bulb.
With the Ignition Switch in RUN or START, voltage is Lamp will find a path to ground through Splice S123 and Observe lights on side of turn REPLACE if necessary.
applied through the TURN/BU Fuse and Turn Flasher to the Park and Turn Lamp to ground. This Lamp provides signals that did not work.
the normally closed contact of the Hazard Flasher Switch low resistance paths to ground. The Marker Lamps will Lights do not come on. GO to step 2.
in the Turn Signal Switch. flash with the Turn Lamps.
2. Turn hazard warning system Test lamp lights. GO to step 4.
off. Place ignition switch to
With the Turn Signal Switch in LH Turn position, When the Light Switch is in either PARK or HEAD, RUN and turn signal to side Test lamp does not light. GO to step 3.
voltage is applied to both the LH Turn Indicator and the voltage is applied through the TAIL LPS Fuse, Lamp that does not work. Connect
LH Front Park and Turn Lamp LT BLU (14) wires. Switch, and Splice S122 to the Marker and Park Lamps. test lamp from LT BLU (14) or
Voltage is applied to the LH Tail, Stop and Turn Lamp If the Turn Signal Switch is in TURN LEFT, the LH Side DK BLU (15) wire (depending on
YEL (18) wire. Marker Lamp will have voltage at both connections and which side does not work) at
will go out. When the Flasher removes voltage to the turn signal switch connector
The Lamps go on immediately. They begin to flash Turn Lamp, the Marker Lamp will be grounded through C206 to ground.
when the current flow heats up the Timing Element in the the Turn Lamp and will go on. In this way, the LH Side 3. Connect test lamp from PPL Test lamp lights. REPLACE turn signal switch.
Flasher and it repeatedly opens and closes the circuit. Marker Lamp will flash on when the LH Park and Turn (16) at turn signal switch
Lamp goes off, and off when the Turn Lamp goes on. connector C206 to ground. Test lamp does not light. REPLACE turn signal flasher.
The voltage applied to the LH Park and Turn Lamp
will also be applied to the LH Side Marker Lamp. If the With the Turn Signal Switch in TURN RIGHT, voltage 4. Connect test lamp from LT BLU Test lamp lights. ISOLATE problem in body
Lamp Switch is in the OFF position, the LH Side Marker will be applied to the RH Lamps in the same way. (14) or DK BLU (15) wire builder’s installed wiring.
(depending on which side did
not work) at park and turn lamp Test lamp does not light. LOCATE and REPAIR open in
DIAGNOSIS - TURN LAMPS connector C142 or C143 to either LT BLU (14) or DK BLU
ground. (15) wires between turn signal
TURN SIGNALS DO NOT OPERATE switch connector C206 and
TEST RESULT ACTION connector C100.

1. Place hazard warning lamps to Hazard lamps operate. GO to step 2.

on position. TURN SIGNAL LAMPS FLASH RAPIDLY
Hazard lamps do not operate. REFER to "Hazard Lamps Do Not TEST RESULT ACTION
Operate" symptom.
Turn hazard lamp switch ON. One side of turn signal lamps flash REPLACE inoperative turn signal
2. Connect a test lamp from PPL Test lamp lights. REPLACE turn signal switch. Check front signal lamps and rear rapidly. bulb.
(16) wire at turn signal taillamps.
Only one side of turn signals light REFER to "Turn Signals Do Not
switch connector C206 to Test lamp does not light. CHECK condition of TURN/BU
but do not flash rapidly. Work On One Side" symptom.
ground. fuse and an open in PPL (16)
wire or DK BLU (38) wire. If
fuse and wiring are good,
REPLACE turn signal flasher.

TURN SIGNAL LAMPS B-33

 FUSE BLOCK
(STEERING COLUMN SWITCHES)
12103404

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27
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HORN/OM INSTR-LPS TRANS SIGNAL
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12004147
KEY I

NORMALLY
OPEN
PRNDL ~ 8-.5 GRA SWITCHES
LAMP
(SEE PAGE 72)
BACKUP
_ _...~ LAMP SWITCH
(SEE PAGE 78)

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(SEE PAGE 70)

TURN
FLASHER

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8-34 TURN SIGNAL LAMPS

CIRCUIT OPERATION
When the Horn Switch is depressed, one side of the
coil of the Horn Relay is grounded. The relay is
energized. Its contacts close and battery voltage is
applied to the Horn.

DIAGNOSIS - HORNS

PRELIMINARY CHECKS:
Check to see that the HORN D/M fuse is not blown.
REPLACE if blown.

HORN(S) W ILL NOT OPERATE

TEST RESULT ACTION
1. Connect a test lamp from DK GRN Test lamp lights. ISOLATE problem in body
(29) wire at connector C100 to builder’s installed wiring.
ground. Press horn switch.
Test lamp does not light. GO to step 2.

2. Remove horn relay. Connect a Test lamp lights. GO to step 3.

test lamp from ORN (240) wire
at horn relay connector C207 Test lamp does not light. LOCATE and REPAIR open in ORN
to ground. (240) wire between horn relay
connector C207 and fuse block.
3. Install horn relay. Horn does not sound. GO to step 4.
Disconnect turn signal switch
connector C206. Use a jumper Horn sounds. REPLACE horn switch.
wire to ground BLK (28) wire at
turn signal switch connector
C206.

4. Disconnect horn relay. Horn sounds. REPLACE horn relay.

Install a jumper wire from ORN
(240) terminal to DK GRN (29) Horn does not sound. LOCATE and REPAIR open in DK
terminal at horn relay GRN (29) wire from horn relay
connector C207. connector C207 connector C100.

HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSING HORN SWITCH

TEST RESULT ACTION
1. Disconnect turn signal switch Horn stops. REPLACE horn switch.
connector C206.
Horn continues to sound. GO to step 2.

2. Disconnect horn relay Horn stops. REPLACE horn relay.

connector C207.
Horn continues to sound. LOCATE and REPAIR open in BLK
(28) wire between horn relay
connector C207 and horn
switch.

HORN B-35
 S HOT A T A L L TIM ES C

HORN/DM
15 AMP 240-1.0 ORN I

HORN
RELAY

28-.5 BLK

z
PRNDL CL
LAMP ^ O
(SEE PAGE 72)
TURN
§
O SIGNAL
O SWITCH
S298

240-.8 ORN

340 120
! 450 39 33
PROVISIONS FOR
3 419
J % DOME LAMPS 240-.8 ORNl
2 31 (SEE PAGE 38)
( r
439 35
2
n
440
6 906 434

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B-36 HORN
CIRCUIT OPERATION WIPERS DO NOT OPERATE IN LO
TEST RESULT ACTION
WIPER 1. Place ignition in RUN and wipers Wiper m otor does not run. LOCATE and REPAIR open in GRA
The Wiper Motor is supplied battery voltage with the is through the PPL wire, the Wiper/Washer Switch and to LO. Connect a fused jum per (91) wire between wiper motor
Ignition Switch in START or RUN, with ground supplied the BLK wire to ground. from GRA (91) wire at wiper switch connector C188 and wiper switch
by the Wiper/Washer Switch. connector C221 to ground. connector C221. If no open is
WASHER found, REPLACE wiper motor.
When the Wiper Motors is in LO, Battery voltage is Battery voltage is applied to the washer pump
supplied to the motor through the WHT wire and the through the WHT wire, to the switch and to ground Wiper m otor runs. REPLACE wiper washer switch.
ground circuit is through the GRA wire, the through the BLK wire. The washers are operational as
WASHER MOTOR DOES NOT OPERATE
Wiper/Washer Switch and the BLK wire to ground. long as the paddle switch on the Wiper Switch arm is on.
TEST RESULT ACTION
When the wiper is in HI, battery voltage is supplied to
1. Place ignition switch in ACC Test lamp lights. GO to step 2.
the motor through the WHT wire and the ground circuit
from WHT (93) wire at Test lamp does not light. LOCATE and REPAIR open in WHT
connector C224 to ground. (93) wire between connector
C224 and fuse block.
DIAGNOSIS -- WIPER/WASHER
2. Connect a test lamp from WHT Test lamp lights. GO to step 3.
(93) wire at washer pump
PRELIMINARY CHECKS: connector C187 to ground. Test lamp does not light. LOCATE and REPAIR open in WHT
Check condition of WIPER fuse. If fuse is in good
(93) wire between washer motor
condition, use the following diagnostic procedures. connector C187 and connector
C224.
WIPERS DO NOT OPERATE IN ANY MODE 3. Connect test jum per from PNK Washer motor runs. GO to step 4.
TEST RESULT ACTION
connector C187 to ground. Washer motor does not run. REPLACE washer motor.
1. Place ignition in RUN and turn Test lamp does not light. LOCATE and REPAIR open in
wipers to HI. Connect a test lamp WHT (93) wire between wiper 4. Connect test jum per from PNK Washer motor runs. GO to step 5.
from WHT (93) wire at wiper motor motor connector C189 and fuse (94) wire at connector C224 to
connector C187 to ground. block. ground. Washer motor does not run. LOCATE and REPAIR open in PNK
(94) wire between washer motor
Test lamp lights. GO to step 2. connector C187 and connector
C224.
2. Connect a fused jumper from BLK Wiper motor runs. LOCATE and REPAIR open in BLK
(150) wire between wiper switch 5. Connect test jum per from PNK Washer motor runs. GO to step 6.
(150) wire at wiper switch
connector C221 to ground. connector C221 and ground G200.
washer switch connector C221. Washer motor does not run. LOCATE and REPAIR open in PNK
Wiper motor does not run. REPLACE wiper motor. (94) wire between connector
C224 and windshield wiper
WIPERS DO NOT OPERATE IN HI washer switch connector C221.

TEST RESULT ACTION 6. Connect test jumper from BLK Washer motor runs. LOCATE and REPAIR open in BLK
(150) wire at windshield wiper (150) wire between windshield
1. Place ignition in RUN and wipers Wiper motor does not run. LOCATE and REPAIR open in PPL washer switch connector C221 wiper washer switch connector
to HI. Connect a fused jumper (92) wire between wiper motor to ground. Press wash switch. C221 and ground G200.
from PPL (92) wire at wiper switch connector C189 and wiper switch
connector C221 to ground. connector C221. If no open is Washer motor does not run. REPLACE windshield wiper
found, REPLACE wiper motor. washer switch.

Wiper motor runs. REPLACE wiper washer switch.

WASHER MOTOR DOES NOT SHUT OFF

TEST RESULT ACTION

1. Place ignition switch in RUN and Washer motor stops pumping. REPLACE wiper washer switch.
wiper switch to WASH. Disconnect
wiper switch connector C221. Washer motor pumps. LOCATE and REPAIR short to
ground in PNK (94) wire between
wiper switch connector C221 and
washer motor connector C187.

WINDSHIELD WIPERS/WASHERS B-37

 WIPER
25 AMP

1 93-3.0 WHT |
PROVISIONS
FOR
DOME LAMPS

PANEL DIMMER
SWITCH
(SEE PAGE 72)

S298
(SEE PAGE 36)

WIPER 12010429

MOTOR

WASHER HORN RELAY

(SEE PAGE 36)
MOTOR

WINDSHIELD
WIPER/WASHER
SWITCH 0 S203
| (SEE PAGE 18)

l/P
GROUND
G200

B-38 WINDSHIELD WIPERS/WASHERS

 ENGINE DOES NOT CRANK AND STARTER SOLENOID DOES NOT CLICK
CIRCUIT OPERATION TEST RESULT ACTION

START 1. Place transmission in PARK (auto) Battery voltage. GO to step 2.

contacts to open simultaneously. As soon as the and depress clutch pedal (man).
When the Ignition Switch is moved to the START
Connect a voltmeter from PPL (6) No voltage. GO to step 3 (man trans).
position, battery is applied to the Starter Solenoid. Both contacts open, the starter circuit is turned off.
wire at starter solenoid to ground. GO to step 5 (auto trans).
solenoid windings are energized. The circuit through the Turn ignition switch to START
Pull-In Winding is completed to ground through the CHARGE position.
Starter Motor. The windings work together magnetically The Generator provides voltage to operate the
to pull in and hold in the Plunger. The Plunger moves vehicle’s electrical system and to charge its Battery. A 2. Connect voltmeter from PPL (6) Battery voltage. REPLACE starter solenoid.
the Shift Lever. This action causes the Starter Drive magnetic field is created when current flows through the wire to starter mounting bolts.
Assembly to rotate as it engages the Flywheel ring gear Rotor. This field rotates as the Rotor is driven by the Less than battery voltage. CLEAN starter motor mounting
on the engine. At the same time, the Plunger also closes engine, creating an AC voltage in the Stator windings. bolts, starter motor, and mounting
the solenoid switch contacts in the Starter Solenoid. Full The AC voltage is converted to DC by the rectifier bridge surface.
battery voltage is applied directly to the Starter Motor and is supplied to the electrical system at the Battery 3. Disconnect clutch start switch Battery voltage. GO to step 4.
and it cranks the engine. terminal. connector C219. Connect
voltmeter from YEL (5) wire at No voltage. GO to step 5.
As soon as the Solenoid Switch contacts close, This Generator’s regulator uses digital techniques to clutch start switch connector C219
voltage is no longer applied through the Pull-In Winding, supply the Rotor current and thereby control the output to ground. Ignition switch must be
since battery voltage is applied to both ends of the voltage. The Rotor current is proportional to the width of in START position.
windings. The Hold-ln Winding remains energized, and the electrical pulses supplied to it by the Regulator.
4. Depress clutch and put Engine cranks. REPLACE clutch start switch.
its magnetic field is strong enough to hold the Plunger, When the Ignition Switch is placed in RUN, narrow width
transmission in neutral. Apply
Shift Lever, and Drive Assembly Solenoid Switch pulses are supplied to the Rotor, creating a weak
parking brake. Connect a fused Engine does not crank. CHECK condition of CRNK fuse. If
contacts cranking the engine. magnetic field. When the engine is started, the jumper from YEL (5) to PPL (6) at fuse is good, LOCATE and REPAIR
Regulator sensor Generator rotation by detecting AC clutch start switch connector open in PPL (6) wire from clutch
When the Ignition Switch is released from the START voltage at the Stator through an internal wire. Once the C219. Turn ignition switch to start switch connector C219 to
position, battery voltage is removed from the PPL (6) wire engine is running the Regulator varies the field current START position. starter solenoid.
and the junction of the two windings. Voltage is applied by controlling the pulse width. This regulates the
from the Motor contacts through both windings to Generator output voltage for proper battery charging and 5. With ignition switch OFF, connect Battery voltage. REPLACE ignition switch.
ground at the end of the Hold-ln Winding. However, the electrical system operation. a voltmeter from cavity B terminal
voltage applied to the Pull-In Winding is now opposing at ignition switch connector C298 No voltage. LOCATE and REPAIR open in RED
to ground. (2) wires and fusible link from
the voltage applied when the winding was first energized. The digital regulator controls the VOLTS Indicator light
The magnetic fields of the Pull-In and Hold-ln Windings with a solid-state light driver. The light driver turns on battery junction block to ignition
the light whenever undervoltage, overvoltage or a switch connector C298.
now oppose one another. This action of the windings,
with the help of the Return Spring, causes the Starter stopped Generator is detected.
Drive Assembly to disengage and Solenoid Switch BATTERY IS UNDERCHARGED OR OVERCHARGED
TEST RESULT ACTION
1. Connect voltmeter from RED (2) Battery voltage. GO to step 2.
DIAGNOSIS - START AND CHARGE wire at generator connector
C107. No voltage. LOCATE and REPAIR open in RED
STARTER SOLENOID CL CKS, ENGINE DOES NOT CRANK OR CRANKS SLOWLY (2) wire and fusible link from
TEST RESULT ACTION generator connector C107 to
battery junction block.
1. Remove CRNK fuse. Connect a Voltage reading greater than 9.5 GO to step 2.
2. Connect generator connector Reading of 13-16 volts. PERFORM Generator Bench Test.
voltmeter to positive and negative volts after 15 seconds cranking.
C109 and terminal. Have all Refer to Section 6D in Service
battery terminals. Turn ignition
accessories turned off and Manual.
switch to START. Voltage less than 9.5 volts after 15 PERFORM a Battery Load Test.
engine running at fast idle.
seconds cranking. Refer to Section 6D in Service
Connect voltmeter from Reading of less than or REPAIR generator.
Manual.
battery terminal on generator greater than 13-16 volts.
2. Connect a voltmeter from negative Less than .5 volts. GO to step 3. to ground.
battery terminal to engine block.
More than .5 volts. REPLACE negative battery cable.

3. Connect voltmeter from positive Less than .5 volts. REPAIR starter motor.
battery terminal to starter solenoid
terminal at BLK (2) wire. More than .5 volts. REPLACE positive battery cable.

STARTIN G/C HAR GIN G B-39

 RPOCODES

, 2-32.0 BLK

1-19.0 BLK
r---------
., , ,
6-5.0PPL _ _ _ _ _ _ _ _ _~

eC219
6911921
CLUTCH
START
SWITCH
MTl
MT6 -_ AUTO TRANS HD, 4-SPD., WITH OVERDRIVE
MAN TRANS'
, 5-SPD., WITH OVERDRIVE

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2-3.0RST
(FUSIBLE LINK) ~6-5.0PPL _ _ _ _ _ _ _ _ _ __ ~ OFF
o
IGNITION LOCK
COIL eS207
_..•
' _ _ __ 6-5.0 PPL _ _ _ _ _ _ _ _ _ __
S196 e STARl ER MOTOR
(SEE PAGE 42) L ACC
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N~

1.___________~S:9-
2-5.0 RED IGNITION
SWITCH ---
ow 2-3.0 RED
.a:
o
~ '"z
D-
. ._ _ _ _ 3-5.0 PNK _ _ _ _ _ _ __ _e _ _ _ _ __
5111
(SEE
1 o
lIP

I
~
..J
- - 39-.6 PNK/BLK - D-
PAGE46f ENGINE D-
BATTERY o

/~-- = I

,•
E!J
JUNCTION e 3 1
~
BLOCK I
lS B
C
A

I:~ 13! 1150

UJIL419 I 3
I .-
..J~
:) 0 I
ro
@1: IL31 2
I J
3: 6

r
~~
~ E D
Z -..-:-p 135 1439
...u-_l _1 _--JJ L
D-
~ F m I 2
E
12 M
cD
M G 182414201440 I 9 N

S197 • R. H IL 431 I 350 I 6

G
29

~2-1.0RST = 3 IEiI 1 ..........- __ 5

c:=::JO ~ CRNK ALT

'H,
(FUSIBLE LINK) Cl00 2 20 AMP
12020163 ~ 10 AMP
:)------
~
Cl07 ClOD
GENERATOR 2-5.0 RED Z 12020164
D-
eD

. ._ _ _ 1-19.0BLK . ._ _ _" ~

J e __
5206
39-.6 PNK/BLK' _ _
---
(SEE PAGE 70)

906-.6 PPL _ _ _ _ _ _ _.~ ECM

(MT60NLy) , (SEE PAGE 45)
SHEET
ENGINE -
GROUND -
-=- METAL

G111 G110 GROUND

8-40 STARTING/CHARGING
GASOLINE ENGINE
 RPO CODES
RPOCODES

,
830 - SCHOOL BUS EQUIPMENT

e
MTl - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
6-3.0 PPL CLUTCH MT8 - MAN TRANS, 5-SPD., WITH OVERDRIVE

5-3.0 VEL START

SWITCH
C219 (MT8)
8911921

+ RH
+ LH
_ _ .6-3.0 PPl _ _ _ • _ _ _ _ _ _ _ _ _ _ _ _ _. .

. ._ _ _ _ _ 3-5.0 PNK _ _ _ _ _. .
BATTERY BATTERY
...J IGNITION
3: SWITCH
o
u Cl00

-------.1:3 -r
liP 12020184 3 4

~j~
~ '~'=~ '"
. .- - - - - - 1-50.0 BlK 5 2
1-32.0 BlK (B3D ONLy)

BATTERY ~~ 0
JUNCTION 2Z
00 START
BLOCK STARTER ~
1-1-
<Xl
RUN
~~
MOTOR ~
2 -'-' 0 0 0 OFF
<LW
<L <L>-
0 o LOCK
11 00
L
E
12 M
~ ~~ _L J ACC
0 0 0
9 N
S196 G
29

/
/ \ • -'
<L
<L
0
Iri ~1 C)
5
P

<b
=
~
1-2
~~
~ 2-1.0 RST _
(FUSIBLE LINK)
• _
S197
2-3.0 RED ~ ALT

r-
0-' 20 AMP
~ ~ ~ 39-.8 PNKlBlK • ~ _ 3-5.0 PNK.. S205

I~ GLOW PLUG
-' oW
2-5.0 RED _ _ _ _ _ _ _ _ _ 1_ · -----.
• S195 CONTROLLER it fa a: S206
a:

-- --
o 1!21 = (SEE PAGE 4)

I o
M

'" '"
M

_6-5.0PPL

I C L .. .-
- -
.. - -
. . . 2-3.0 RED

_2-3.0 RED

-
Sl13

-- -
_ • _ 3-3.0 PNK

....
C298 C299
12010966 6294641

A
~ Cl00

•
'"-'
",0
Z
a = 12020183

1_____
-'::<
WC')

GENERATOR Cl07 ~ o
N
o@.
N ~ a
Z 7 al ~

1 1 1
12045896 <L '? FUEL SHUT
<Xl 3-3.0 PNK - -_ _ _...~ OFF VALVE
di
C')
~

/~ ~ ~'"
(SEE PAGE 63)

'"
~
ENGINE ENGINE SHEET
GROUND GROUND METAL
LH CYLINDER RH GROUND
HEAD CYLINDER G110
G113 HEAD
G112
STARTING/CHARGING 8-41
DIESEL ENGINE
 RPO CODES
WVWVvVVVVVVVV/
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
< HOT IN START OR RUN <
m v v w v v v \v v \^
e c m -c r n k
5
10 AMP 439-.S PNK/BLK r 439-.8 PNK/BLK I

ALT I
20 AMP I _________________ ___________________________________________________________________________________________ _______ _______
“ i | ______
^ ^ 439-.a pn k/blk r ^
439-.8 PNK/BLK I

C120
I \ I
12078082

IGNITION MODULE I I
-ESI-------------------- - 423 | u mm 423-.8 WHT
439-.8 PNK/BLK . ■ 439-.8 PPUWHT
DISTRIBUTOR __ ,
430 | C ^ 430-.8 P P L y W H T iV '
REFERENCE HI

424 | B
IL 424-.8 TAN/BLK V ^ " I " """
453-.S BLK/REDBBT . 453-.8 BLK/RED'

DISTRIBUTOR
REFERENCE LO
453 | A
453-.S BLK/RED^ W
430-.8 PPL/WHT' h I 430-.8 PPL/WHT

423-.S WHT | I423-.8 W H T ^ H ELECTRONIC

CONTROL MODULE
--------------------------r r CONNECTORS
424-.S TAN/WHT . 424-,8 TAN/WHT
----------------------------------------------------------------h 4
C199
GT100
12020107 (UPPER)
12C15791 12010996 12020108 (LOWER)
i i
i i
k.
*
*
£
2
3
CD
£
z

I I
I \
^ 39-.8 PNK/BLK jm m
GENERATOR l/P

\
(SEE PAGE 40) ENGINE

DISTRIBUTOR c = l E 9 3 2 1

d
^
A
B
M
| S241 420
6 250 | '
440 | *1
29 _Q _
\ S208
C 2 | 14 f 1481 250 6 (SEE PAGE 70)
Hill 9
439 I 12 J UT 1824 420 440

E 31 2 I ] 11
r©
35
31
439
2

2 IGNITION
Lj J i SWITCH
i i 2° i 39 150 | JJ 120 (SEE PAGES 4, 5)
ra G
S112
i hi i
■4—
I
: 19
24
18
30
9¥
I
DRAC r ---- i
I 439-.8 PNK/BLK ■ 439-.8 PNK/BLK*
(SEE PAGE 64)
;* k C100
^ I 12020183
439-.8 PNK/BLK
ESC MODULE
(SEE PAGE 42) |

M tm 439-.S PNK/BLK ^ 1
PNK/BLK I

B-42 IGNITION
GASOLINE ENGINE
CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
465 .8 DK GRN/W HT A1 FUEL PUMP RELAY DRIVE C1 NO T USED
A2 NOT USED C2 NO T USED
A3 NOT USED 444 .8 LT GRN/BLK C3 STEPPER COIL B LOW
435 .8 GRA A4 EGR SOLENOID (LB4) EVRV (L05) 443 .8 LT G RN/W HT C4 STEPPER COIL B HIGH
419 .8 BRN/WHT A5 C H EC K ENGINE LAMP 441 .8 LT BLU/W HT C5 STEPPER CO IL A HIGH
439 .8 PNK/BLK A6 12V IGNITION FUSED 442 .8 LT BLU/BLK C6 STEPPER COIL A LOW
A7 NOT USED C7 NO T USED
461 .8 ORN A8 SERIAL DATA C8 NO T USED
451 .8 WHT/BLK A9 ASSEMBLY LINE DIAGNOSTIC LINK 906 .8 PPL/W HT C9 CRANK SIGNAL (FUSED)
437 .8 BRN A10 DRAC MODULE 410 .8 YEL C10 COOLANT TEMPERATURE
452 .8 BLK A11 5V RETURN B 432 .8 LT GRN C11 MANIFOLD ABSOLUTE PRESS.
450 .8 BLK/WHT A12 SYSTEM RETURN C12 NO T USED
417 .8 DK BLU C13 THROTTLE POSITION SENSOR
12V BATTERY FUSED 416 .8 GRA C14 5V SENSOR REFERENCE
440 .8 ORN B1
ELEC FUEL PUMP FUSED FEED 468 .8 DK GRN C15 INJECTOR B (2) DRIVE
120 .8 TAN/WHT B2
DISTRIBUTOR REF LOW 440 .8 ORN C16 12V BATTERY FUSED
453 .8 BLK/RED B3
B4 NOT USED 450 .8 BLK/W HT D1 SYSTEM GROUND
430 .8 PPL/WHT B5 DISTRIBUTOR REF HIGH 455 .8 PPL D2 5V RETURN A
B6 NOT USED D3 NOT USED
485 .8 BLK B7 SPARK RETARD CONTROL 423 .8 W HT D4 HEI SPARK TIM ING
B8 NOT USED 424 .8 TAN/BLK D5 HEI BYPASS
B9 NOT USED 413 .8 TAN D6 OXYGEN SENSOR LOW
B10 NO T USED 412 .8 PPL D7 OXYGEN SENSOR HIGH
B11 NOT USED D8 NOT USED
B12 NOT USED D9 NOT USED
D10 NOT USED
ELECTRONIC CONTROL MODULE CO NNECTOR D11 NOT USED
D12 NO T USED
D13 NOT USED
468 .8 DK GRN D14 INJECTOR B (2) DRIVE
467 .8 DK BLU D15 INJECTOR A (1) DRIVE
467 .8 DK BLU D16 INJECTOR A (1) DRIVE

ELECTRONIC CONTROL MODULE - GASOLINE ENGINES

ELECTRONIC CONTROL MODULE (ECM) - PINOUTS B-43

GASOLINE W/MAN TRANS
 452-.8 BLK I
MAP
SENSOR
r i 439-.S PNK/BLK I

1440-1.0 ORN |

I I 417-.8 DK BLU l

- 2 4 1 6 -.8 G R A ^ "

TP
SENSOR
455-.8 PPL 1

432-.8 LT GRN I ! 432*.8 LT GRN I

I 417-.8 DK BLU I

I 416-.8 GRA ^

417-.8 DK BLU I

COOLANT 416-.8 GRAI

TEMPERATURE
SENSOR

' 410-.8 YEL I 410-.8 YEL I

I 452-.8 BLK I • 1 I 452-.S BLK I

S101

485-.8 BLK I

i ESC KNOCK
SENSOR
m 412-.8 PPL I
£
2

486-.8 BRN

i 439-1.0 PNK/BLK I EVRV SOLENOID

(LOS)
(SEE PAGE 46)

439*.8 PNK/BLK
ESC
MODULE

p 94 | 420 440 2
29
N 9 39
15II
14 439
806 39 :
^ 5 0 /1 3 0 )
f l 140 120
M 33 12 J A 31 3 ^
L 93 11

440-.8 ORN
m <136
35 2
18 I 120 I 9 „ r
ll 9 3 97 422 :
L 92 6

OXYGEN C100
SENSOR 12020183
C124

12010996 12015791

I 440-.8 ORN I

B-44 ELECTRONIC CONTROL MODULE (ECM)

INPUTS - GASOLINE ENGINE W/MAN TRANS
~ _ 439-.8 PNK/BLK

_ _ _ _ _ 440-1.00RN
------- - - -
---------.£ ~~----- 44O-.80RN _ _. . .
44O-.80RN _ _ _ Ii
______ 439-.8PNK/BLK

. . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 440-.80RN _ _ _ _ _ _ _. .
_____ _

.I."~B,,,

4
illQ] 2
,, APO CODES

L05 - ENGINE. 5.7L (350 CID) V8 GAS ENGINE, VIN K

S104 C251
~ 04 ~3
45
(SEE PAGE 47) 12047946
-1 . ~419-.8BRNM'HT
_ .,,
@ill
43 I":M""-=:-"-'-'L.._ __
CJ
_465-.8BLK 46

-- ......
5
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-412020197 (UPPER) GT100 ,c 43
~_ 455-.8 PPL 455-.8 PPL I::::

----------------------------t
2020708 (LOWER
SERVICE

..

..
. .
432-.8 LTGRN

416-.8
417-.8 GRA ----------------------------t
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
DKBLU
432-.8 LT G RN

417-.8 DK BLU

.J"': -
r
-- -
'--

450-.8 BLK/WHT _
, ENGINE
SOON
LAMP
(SEE PAGE 70)

410-.8YEl _ _ _ _ _ _ _ _ ,
, _ _ _ 450-.8 BLK/WHT .... _ - -
416-.8 GRA

----.-T
- - .- '- -- -"= - r- 452-.8 BlK

461-.8 BAN
437-.8 ORN ======-!J
~
_
410-.8 VEL I- AI 451-.8 WHT/BlK - __

-
.. 452-.8 BLK _ _ _ _ _ _ _ _ _ _ _ _ _ __
452-.8 BLK

... 485-.8 BLK 1

_
_ ------ ,

--------t-t
_ c: ... 450-.8 BLK/WHT - - . . . . . . . . ....-
450-.8 BLK/WH T ' _ •

485-.8 BLK
-
--
.,-
AI
L.•
_A

- --
- .. .... ,-~ 455-.8 PPl ECM

...-. ....,
412-.8 PPl _ '_412-.8 PPl CONNECTORS

-
.. 412-.8PPl

~~.~:,::--: ~~
413-.8 TAN

450-.8 BLK/WH T _ ...

•
.... z
-
a::
_ .. _413-.8 TAN
~
..J

'"
p
C250
12045575

....
CAANK SIGNAL
(FUSED)
(SEE PAGE 40)

, ,,
J:
S102'-'- . . . 450-.8 BLK/WHT . , _ 0 ~
(SEE PAGE 16) ~ ~
..
<Xl

I- ~ ~

,,
J:

z..:
~
I- III 437-.8 BRN
I-
J:
'".:;
0)

-- =,
0)

M z '$f

-'
;;: ~

,,
0)

In
"' ..... -. : :440-.8
416-.8 OAN
GRA :==========~J
-t ,
--, -
_417-.8 DK BLU _ _ _ _ _ _ _ _ _ _ _. .
_432-.8 LTGAN _ _ _ _ _ _ _ _ _ _ _ _. .
_ _ _ _ _ _ 410-.8YEl _ _ _ _ _ _ _ _ _ _ _ _ _ _. .

,, DRAC MODULE
(SEE PAGE 64)
, ''
, ,, I
, I
486-.8 BRN

,,,- '"
l: :
c....a
-M....+--c=+-"--1I~

l ENGINE
GENERATOR
BRACKET
ALDL
C201
GROUND GROUND 12020043

G100
-- -- G101
ELECTRONIC CONTROL MODULE (ECM) 8-45
INPUTS - GASOLINE ENGINE WIMAN TRANS
 ECM-CRNK
ALT ~ L 10AMP
~
l/\AIVV\.IVV\J~ ~ r ..,..,. ..,..,. ..,." ..,..,.
'--439-1.0 PNK/BlK 439-1.0 PNK/BlK ..,..,...,..,...,..,. _ ..,..,. ..,..,. _ _ .. 439-1.0 PNK/BlK _ ..-.. •
20 AMP
ECM - BAT ~39-1.0 PNK/BlK - - - ..,..,. ..,..,. ..,..,. . . , . " ..,..,. ..,..,. ..,..,. . . , . " . . . 39-1.0 PNK/BlK - . . ..,..,. ..,..,. ..,..,. ..,..,. ~

~
481-1.0 RED
44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _•
10AMP 44O-1.00RN
•
"".....111!!11_ _ _ _ _ _ _ 423-.8 WHT _ _ _ _ _ _ _ _ _•
lAC Cl15
44O-.80RN ...
o
....
ELECTRONIC
SPARK
12V IGNITION FUSED
SPARK RETARD
ESC GROUND
-
-
-
423
424
430
c
-- 430-.8 PPlJWHT --.., ACTUATOR
STEPPER
12015798

- - . ... _
44O-.80RN

444-.8 LT GRN/BlK
........
~R
_ _ .-424-.8TAN/BlK _ _ ~ ~ ~
ESC SENSOR - 453 B
TIMING 120-.8 GRA

--
-I- ___ 453-.8 BlK/RED _ __ ~
A

lI"r"'\\m'~ ~:::: j 1 ... . - 443-.8 LT GRN/WHT F --....

C120
12040754
ra... _ ..,..,. 12010996
-,
,~
"..01

,...
F
F
_
_
441-.8 IT BlU/WHT
442-.B IT BlU/BlK ~
..--~

...

'a:=====~:::::~::~::==...=
424-.B TAN/BlK ..,..,. ~ , ~
EVRV
o ~. ~~ • _ .. _ _ 423-.8WHT ....

r . . . ,. .... 430-.8PPlJWHT.r ~
SOLENOID
w....______
C- - .,450-.8 BlK/WHT - - - ,

-- -
435-.8GRA _ _ _ _ _ _ _ _ _ _ , . , ~ .- ,... _ ..,..,. 424-.8 TAN/BlK r ....
(L05)
-"' _ . . , . " ..,..,. _ ..,..,. . . , . " 453-.8 BlK/RED,. _ ..,..,. ..,..,.
•• ,. _
. r ... 453-.8 BlK/RED..,..,. ~
_ 435-.8 GRA _ _ _ _ _•• ~

i :::::: ___________
L..--_I___ __::::m___ _ ....
-..,..,. 439-.B PNK/8lK . . , . " - -', •

r;;
• 467- 8 IT BLU
Cl14
1 •
...
· . .,
12047950
GT101 ''-'" ... r ... 450-.8 BlK/WHT ~
12010639
I i
_ _ 468-8lTGRN ..

o -_--._ _
S105 , S107
.I_______ ~. • _ 467-.8 IT BLU ....

I
481-1.0RED_ :::::::D _ S106

~
~
r:
1 _,...I
GRN 465-.8 DK GRN/WHT

468-.8_
DKGRN
..... ~
~
.... ..,..,. _
'l1li
'-'1_ ., - ..,." .-450-.BBlK/WHT-.. - - • ~--
.... r _ 450-.8 BlK/WHT--C

INJ-2
~, • _ -t_468-.8lTGRN ...

e
482- 8 WHT 1 ___ _ _ _ ___ 467-.B DK BLU _ _ _ _ _ _ _ _ __
•
~
467-.8 DK BLU _
. .,..... ..,..,...,." 1_ · . . F..., 1

, •
r ..,..,.

j------r
~ 439-.8 PNK/BlK ~ ..,..,. ..,..,. ..,..,. .
~. Sl12

INJ-1
ESC . . . . 439-.11rl
MODULE PNK/BlK
-.r _ , . . - . . _ _ _
1___. _
_ _ _ _ _ _ _ _. .
....
~ S109

o
N
0
'"
'"
'"

L
(SEE PAGE 44)

,--------.---I. . .-.. .
-t· - - .... !- - . . ''IF
. - - -

~-
- 120-1.0 GRA

I _ - 120-20 GRA
•

[19:
465-.8DKGRN/WHT_ ... ~ 465-.8DKGRN/wHT~ 7E - ......
FUEL
PUMP CYCLE
_ _ _ _ _ 120_2.0GRA _ _ _ _ _•

-I.
(!l ~ (!l
FUEL
PUMP ~ .." . - . . . 450-.B BlK/WHT· . . , . " _ _
... ~ • ~
RELAY ______11 _________ 1 _ • _E_NG_IN_E_ _ _ _...._ _ __
...
o
..
r- __
0
'" 440-.8 ORN ~

435-.BGRA_ . . . .
Cl03
12065169

I ,I
FUEL PUMP
OIL PRESSURE
~~ . . . ._ 1 2 0 - 1 . 0 G R A _ - - . . I

JI
.l
~ ,~S;
-il_+--fI
l
M

'.1~~~~~di~~~~11l ~~I~:-+--UN
SENSOR AND
SWITCH
II
481-1.0 R E D _

CD: " . .,.,.J:: .,""""' - - -·- ...".,.",.""'"'-

.A_ _ _ _ _ 44O-.80RN GENERATOR
(SEE PAGE 4 0 ) " 39-.8 PNK/BlK", Sl11 - III o
5
=
~
C118
12065401 =
Cl00
12020183 Cl00
ELECTRONIC CONTROL MODULE . ._ _ _ _ _ 440-1.0 ORN _ _ _ _•
C127 12020184
OUTPUTS (GASOLINE WIMAN TRANS) SOLENOID
1.______________________________________________ 12052641
490-.8RED _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. . . ~
(LB4)

8-46 ELECTRONIC CONTROL MODULE (ECM)

OUTPUTS - GASOLINE ENGINE WIMAN TRANS
 RPOCOOES
RPO CODES
- - - _ _ _ _ 439-1.0PNK/8LKr ____ _
_ _ _ _ _ _ _ .-439-.8PNK/BLK _ _ _ - - -

r
~

____ 450-.BBLK/WHT ____ ....., LB4 - ENGINE, 4.3L (262 CIO)

CID)

~
va
V6 GAS ENGINE, VIN Z

, S104
L05 - ENGINE, 5.7L (350 CIO)
CID)

:7i
V8 GAS ENGINE, VIN K
44O-1.00RN 44O-.80RN . . .- - - - - , ---44O-.80RN _ _ _ _ _ _. . .

• 44O-.B ORN 44O-.80RN

, _ _ _ 44O-.B ORN _ _ _ _ _ _•

• 44O-.80RN

. . . . _ _ _ _ _ _ _ 444-.8LTGRN/BLKr _ _ _ _
...... _ _ _ _ _ _ _ _ 120-.8GRA-... _ _ _ _ _ _
..... -- --~----
~ .....~.. r - ... · ~ 430-.8 PPLlWHT
.-:=.-.....1._. J~~ 419-.8 BRN/WHT
419-.B
TO SYSTEM

·
.r
[illJI....._ .. CHECK LAMP

~ 'L!~ t~ _ ...!!~ :::~~;=

(SEE PAGE 70)
~ _ _ _ _ _ _ _ 443-.8LTGRN/WHT _ _ _ _ _ _ _

...... _ _ _ _ _ _ _ 441-.BLTBLU/WHT _ _ _ _ _ _

...... _ _ _ _ _ _ _ 442-.8LTBLU/BLK _____ _ - - ~- - ,.~ ~ ~ ~ 12047946 ~:::::;B;I::::A:;:jL.J

~
•
_______
42~WHT
430-.8PPLlWHT· _ _ _ _ _ _ _
GT100 ::::~H:-:' ~ :- j ., ~" ,- 435-.8 GRA

...... _ _ _ _ _ _ _ _____ _
r~
~ ~~
~ ~
~
~
Lf - - 465-.80KGRN/WHT_
--~

1 ... .
424-.8TAN/BLK~

- 424-.B TAN/BLK - - , ..r _ _ _ 444-.B LT GRN/BLK _ ...,

ECM
-1
...... _ _ _ _ _ _ _ 453-.8BLK/REO' _ ....... _ _ _ _

rn ~ ~ III. -~. -- - . . 441-BLTBLU/wHT_ CONNECTORS

',= . - -(:.,. -- . : : :
. ,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 435-.8GRA _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,+---r:II___ 453-.BBLK/REOr
435-.BGRA_~ - ." ...... • ~ "'~I - 443-.BLTGRN/WHT.r - _, ,

.:~ ~~ :~~BLK tI
~-
...
•
-
........- - - - - - - - - - - - - - - - - - - 467-.B LT BLU - - - - - - - - - - - - - - - - - - - -. .

- 450-.B BLK/WHT,. - - - ..,

,
12020107 (UPPER)

120201~8 (LOWER)
467-.8 LT BLU

L
r- ,~
- .~
~ _ •

~ _467-.BLTBLU
- - ...

t, I
I, ~
~

8~
. .- - - - - - - - 46B-.B LTGRN -------------------.. -'

.....• - - -1-
.......- - - - - - - - 467-.B LT BLU - - - - - - - - - - - 467-.8 LT BLU _ • ~_ 468-.8 LT GRN _~. . . .~ ~ ~
~ ~:~S;N~ ~~ ~ .~ •• • ~
~- - _465-.80KGRN/WHT _ _ -

BBLK/WHT~
-

':1 •
... .. - - - - - --

46B-.BLTGRN_~_.illll!l~---..
.. - .J
--'-90a~-.8~PPLII IIIIj~
• 413-.8TAN-"'~ ~J i i ·
_450 - - rnn..... ..
' __ CRANK
SIGNAL
(SEE PAGE 40)
.....--.--.,.:",,,,," , -, - - - - - - - . "

•
•
•
•
~~.
~- .r_.::::~ ~=...~III
~ __
423-.8 WHT

I ,
• I ~
• ,.
450-.B BLK/WHT _ _ _ ,. _ 450-.B
BLK/WHT
J
, r
, ---- ~ 450-.8 BLK/WHT

C250
c

'- '1",.-
J. _
S102 • •
450-.8 BLK/WHT
450-.B BLK/WHT
-
-
-
-
-
..
_
•
_
413-.B T A N _
~ 450-.B BLK/WHT : . .
450-.8 BLK/WHT' _
12045575

GENERATOR ".
BRACKET
GROUND

Gl0l r'' .' ' ' ------,,----

-
r _450-1.0BLK/WHT,..J
~ •
•

413-.BTAN _ _ _ _ __

,... _ 450-1.0 BLK/WHT _

. ._ _ _ _ _ _ 486-.8 BRN _ _ _ _ _ _. . ,. ESC MODULE ow 11--t-:--1.L
o
u

~ ~ 450-.8 BLK/WHT _ .J
~-
SYSTEM (SEE PAGE 44)
c:
'"
ENGINE
~
GROUND
.2..
-
I
G100 C201
12020043

'~"" _ _ _ _ _ _ _ _ _ _ _.490-.8 REO _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .

ELECTRONIC CONTROL MODULE (ECM) B-47

8-47
OUTPUTS - GASOLINE ENGINE WIMAN
W/MAN TRANS
 .. 439-1.0PNKlBLK _ _ - - - - - - - - - - - _ - - - - - - - -
INJ
INJ

- 1,
7.5 AMP OAMP
OXYGEN
OXYGEN
SENSOR
('-_ _ _ _ _ _ _ _ _ _ _ _ _.481-.8 RED
r - - - --
,
.-

,
'- A ~

~-
D12~

~ 412-.8PPL

, R

IT]
CJ 11 452
!ml10 ~~
c:J 9 [IDJ

~l
,
412
MAP SENSOR
[IDa ~
@ill7 ~
..
>.::
(SEE PAGES 44,50)
439, .. - ~
+ ,
C124 ow z
12015791 a::

,,
CL
C>
~
(!)
co
cb
~
TP
GT100 C251
SENSOR :t . ._ _ _ _ _ 412-.8 PPL 12020107 (UPPER) 412-.8 PPL _ _ _ _ _ _ _ , 12047946

,,
12020108 (LOWER) B A

~
\ S100
___ ~416

r----:i~~",------.416-.8 GRA _ • _ _ _ _ _ _ _ 416-.8 GRA

416-.8 GRA _ •••••••••••••
: ••••
: •••• _ _

~.
, . ._ _ _ _ _ _ 417-.8 OK BLU _ _ _ _ _ _ _ _ _ _ 417-.8 OK B
LU 417-.8 OK BLU ~
"">oe---t- 417 t;Jr-,,_______ 452-.8 BLK _ .
S101_ _ _ _ _ _ _ 452-.8 BLK 452-.8 BLK _ _ _ _ _ _ _ , _
~
' - - - - t - 452
'-----" _ _ _ _ _ _• 467-.8 LT B

,,

~
ClOD LU 467-.8 LT BLU • _ _ _ _ _• • _ _
12078090
, _ _ _ _ _ _ 467-.8 LT BL
U 467-.8 LT BLU •
468-.8 LT GRN _ _ _ _ _ _ , _
co
(.Q;06 ...__- - - - 468-.8 LT GRN

cooJ
~

TEMPERATURE
~ ~
5 Ci
. .lIIIr-----·::~·.:
,
. ~TN:
RN

BLK
-- .... --
468-.8LTGRN______

439-.8 PNKlBLK _ _.J

_

,,
,,
SENSOR

INJECTOR 1
(SEE PAGE 44)

482-.8WHT
,
I

~~,
ll.,~ ECM
C250
12045575

,,
r -I~'
CONNECTOR

INJECTOR 2
~ L.. _ _
--. ,,
,----+481

~~
'''-_-+468'
o
w
a::
C>

~
S112

,
(SEE PAGE 52).

~
K

L
J

,,
= E2J 3 2 M

,,
A

ClOD
12020184

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 481-1.0 RED' _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _• ,

ClOD
12020183
. . . ~ . - . - . - ~.- . - . - . - . . 439-1.0
439-1.0PNKlBLK
PNK/BLK I. . . . _ .-.- _ .- .- .- ....a
B-48 THROTTLE BODY INJECTION
CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
465 .8 DK GRN/W HT A1 FUEL PUMP RELAY DRIVE 439 .8 PNK/BLK C1 12V IGNITION FUSED
1223 .8 YEL/BLK A2 SOLENOID B DRIVER 450 .8 BLK/W HT C2 SYSTEM GRO UND
1222 .8 LTG RN A3 SOLENOID A DRIVER 551 .8 TA N/W H T C3 SYSTEM GROUND
422 .8 TAN/BLK A4 TCC DRIVER 416 .8 GRA C4 5V SENSOR REFERENCE
A5 NOT USED 417 .8 DK BLU C5 TPS
A6 NOT USED 441 .8 LT BLU/W HT C6 STEPPER CO IL A HIGH
419 .8 BRN/WHT A7 SYSTEM C H EC K LAMP 442 .8 LT BLU/BLK C7 STEPPER COIL A LOW
A8 NOT USED 444 .8 LT GRN/BLK C8 STEPPER CO IL B LOW
A9 NOT USED 443 .8 LT G RN/W HT C9 STEPPER CO IL B HIGH
A10 NOT USED 432 .8 LTG RN C10 MAP
435 .8 GRA A11 EVRV SOLENOID 1061 .8 O RN/BLK C11 SERIAL DATA
420 .8 PPL A12 BRAKE SIGNAL C12 NO T USED
B1 NOT USED 413 .8 TAN C13 OXYGEN SENSOR GRO UND
B2 PRESSURE SW ITCH MANIFOLD C 412 .8 PPL C14 OXYGEN SENSOR
1226 .8 RED
B3 PRESSURE SW ITCH MANIFOLD B 468 .8 DK GRN C15 INJECTOR B (2) DRIVER
1225 .8 DK BLU
PNK B4 PRESSURE SW ITCH MANIFOLD A 467 .8 DK BLU C16 INJECTOR A (1) DRIVER
1224 .8
B5 NOT USED 440 .8 ORN D1 12V BATTERY FUSED
B6 NOT USED 455 .8 PPL D2 SENSOR GRO UND
1229 .8 LT BLU/WHT B7 FORCE M OTOR LOW 452 .8 BLK D3 SENSOR GROUND
1228 .8 BLK/RED B8 FORCE M OTOR HIGH 474 .8 GRA D4 5V SENSOR REFERENCE
1230 .8 DK BLU/WHT B9 INPUT SPEED HIGH 496 .8 DK BLU D5 KN O C K SIGNAL
1231 .8 GRA/RED B10 INPUT SPEED LOW 451 .8 W HT/BLK D6 ALDL
437 .8 BRN B11 DRAC MODULE 120 .8 TAN/W HT D7 ELECTRIC FUEL PUMP FEED
59 .8 DK GRN B12 AIR CO NDITIO NING (L05) FUSED
D8 NO T USED
POWERTRAIN CONTROL MODULE CO NNECTOR D9 NO T USED
D10 NO T USED
423 .8 W HT D11 HEI SPARK TIM ING
424 .8 TAN/BLK D12 HEI BYPASS
453 .8 BLK/RED D13 DISTRIBUTOR REFERENCE LOW
430 .8 PPL/WHT D14 DISTRIBUTOR REFERENCE HIGH
1227 .8 BLK/YEL D15 TRANSM ISSIO N TEMPERATURE
410 .8 YEL D16 COOLANT TEMPERATURE

POWERTRAIN CONTROL MODULE CO NNECTO R

POWERTRAIN CONTROL MODULE (PCM) PINOUTS B-

 439-.8 PNK/BLK

440-.8 ORN h

I 450-1,0 BLK/WHT w

r 551-,8TAN/WHTr -

-II- 417-.8 DK BLU

-n- 416-.8 GRA

:n: 432-.8 LT GRN

474-.8 GRA

I 496-.S DK BLU
-II- 496-.8 DK BLU

ii
M 455-.8 BLK 455-.S PPL

452-.8 BLK

1227-.8 BLK/YEL

I 410-.8 YEL 410-.8 YEL

412-.8 PPL

1226-.8 RED

1230-.8 DK BLU/WHT I

ESC KNOCK 1225-. SDK BLU

SENSOR
COOLANT 1231-.8 GRA/RED
TEMPERATURE
1224-.8 PNK ■■
SENSOR

C117
12015375

412-.8 PPL

OXYGEN
SENSOR

INPUT 1230-.8 DK BLU/WHT !

SPEED
SENSOR
0: 1231-.8 GRA/RED Jk
TRANSMISSION
ALTERNATOR ENGINE
BRACKET CONNECTOR GROUND
C173
12078084 G101 G100
B-50 POWERTRAIN CONTROL MODULE (PCM)
INPUTS - GASOLINE ENGINE W/AUTO TRANS
 F439-.8 PNK/BLK , RPO CODES

I 440- 8 ORN S f l
S102 1 L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN E

4
(SEE PAGE 17)
1450-1.0 BLK/WHT W • w m J M f 450-.8 BLK/WHT ' A 450-.8 BLK/WHT ^

I 551-.0 TAN/WHT W ^ 5 5 1 - .8 T A N /W H T -

I 417-.8 DK BLU I ■ 417-.8 DK BLU I 417-.8 DK BLU

I 416-.8 GRA | 416-.8 GRA ■ 416-.8 GRA

I 432-.8 LT GRN J I 432-.0 LT GRN

I 474-.B GRA I ■ 474-.8 G RA w m

I 496-.8 DK BLU I 496-.8 DK BLU

451-.8 W HT/BLK
S104
440-.8 ORN
(SEE PAGE 52) • ’

I 455-.8 PPL I 455-.S PPL

I 452-.8 BLK 452-.S BLK

I12 2 7 -.8 BLK/YEL I 1227-.8 BLK/YEL

I 410-.8 YEL | I 410-.8 YEL

I 412-.8 PPL I
412-.8 PPL

■ 1226-.8 RED I
1226-.8 RED H

I 1230-.8 DK BLU/WHT ^ 123 0-.8D K BLU/WHT V

I 1225-.8 DK BLU I m 1225-.8 DK BLU

■ 1231-.8 GRA/RED I ■ 1231 *.8 GRA/RED " ^

i 1224-.8 PNK ■ 1224-.8 p n k

450-1.0 BLK/WHT

413-.8 PPL 413-.8 PPL 413-.8 PPL

439-.8 PNK/BLK W

rf
420 440 2
r® 422
439 806 39 F
451
L 14Qf 120
E

J 3
436

3>i f 436 C
451 B
r 35 2
I - 450
-I A
93 97 422 :

J
91 92 6

ALDL
C201 PROVISIONS FOR
DRAC 12020043 AIR CONDITIONING
C100 (SEE PAGE 64)
12020183

POWERTRAIN CONTROL MODULE (PCM) B-51

INPUTS - GASOLINE ENGINE W/AUTO TRANS
 439-1.0 PNK/BLK

ECM-BAT ■ 480-1.0 ORN

10 AMP 450-.8 BLK/WHT
I 439-1.0 PNK/BLK tW

IDLE AIR IDLE AIR

CONTORL CONTROL
ACTUATOR ACTUATOR
(LB4/L05) 0-19)

EVRV i | v a r j a r ja m 424-.S ta n /i
(L05/L19)
■ V 453-,8 BLK/RED ’ * W * * 453-,8 BLK/RED

WW 430-.8 PPL/WHT -— I ^ 430-.8 PPIVWHT

EGR
— 1
H B 4 3 5 -.8 G R A ^ H | B B | B B k ■
M I - 1229-.8 LT BLU/WHT

^ ■ 4 3 5 - .8 GRA
(SEE PAGE 46)
465-.8 DK GRN/WHT ^ r . CO w r k ■ ■ B T 4 6 5 - . 8 D K G R N /W H T
I—
I "
Tz 5
^k 1^ -------------- ^"1 22 8 -8 BLK/RED * ■ - I A r . L ------ ------ -
.. l" 120-.8 TAN/WHT ■ K _ J . l, . r J
ELECTRONIC z ” “ I I i w i l l ? ohm
n. n I I ^ rn I >■? ™ 422-.8 TAN/BLK V <422-.8 TAN/BLK
SPARK 0
h-
5
m
I” 3
—
■ i H | B i ^ 'H l l k M i | | n M n 4 S 7 . . 8 DK BLI ■ 467-.8 DK BLU ■
TIMING - '
■■ .
9 ^ |
I ■
| H
1 ■ II ^ m
I' | ° ! ^
H 4 6 B -.8 D K Q R N ■ I 468-.S DK GRN I

M - M r - H -------------- -
r r ° z (

INJ-2 Lhtfc-
I

V
^

g « k -
■ |« 4 4 4 -.8 L T G R N /B L K

-
| a | M 1 2 2 2 -.8 LT GRN

H 1223-.8 YEL/BLK H |
t

INJ-1
-A —U '
“i r i t i

FUEL PUMP
OIL PRESS
SWITCH

FUEL PUMP
RELAY

oioa ALTERNATOR G100

I Jtmm ^m r
C103
C100 BRACKET ENGINE
12020183
12052287 120-2.0 GRA GROUND G101 GROUND
440-. 8 ORN M
B-52 POWERTRAIN CONTROL MODULE (PCM)
OUTPUTS - GASOLINE ENGINE W/AUTO TRANS
 RPO CODES
1481-1.0 RED
LB4 - ENGINE, 4.3L (262 CID) V6 GAS ENGINE, VIN Z
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N

19-.8 BRN/WHT

POWERTRAIN CONTROL MODULE (PCM) B-53

OUTPUTS - GASOLINE ENGINE W/AUTO TRANS
CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
A1 NO T USED 450 .8 BLK/WHT C1 SYSTEM GROUND
A2 NOT USED 551 .8 TA N/W H T C2 SYSTEM GROUND
1224 .8 PNK A3 PRESSURE SW ITCH MANIFOLD A 452 .8 BLK C3 SENSOR GROUND
1225 .8 DK BLU A4 PRESSURE SW ITCH MANIFOLD B 416 .8 GRA C4 5V SENSOR REFERENCE
1226 .8 RED A5 PRESSURE SW ITCH MANIFOLD C C5 NO T USED
1223 .8 YEL7BLK A6 SOLENOID B DRIVER C6 NO T USED
1222 .8 LTG R N A7 SOLENOID A DRIVER C7 NO T USED
451 .8 WHT/BLK A8 ALDL C8 NO T USED
A9 NOT USED C9 NOT USED
A10 NOT USED C10 NO T USED
A11 NOT USED C11 NO T USED
440 .8 ORN A12 12V BATTERY FUSED C12 NO T USED
B1 NOT USED C13 NOT USED
B2 NOT USED C14 NOT USED
B3 NOT USED 1229 .8 LT BLU/WHT C15 FORCE M OTOR HIGH
420 .8 PPIVBLK B4 BRAKE SIGNAL 439 .8 PNK/BLK C16 12V IGNITION FUSED
422 .8 TAN/BLK B5 TCC D1 NOT USED
B6 NOT USED 437 .8 BRN D2 DRAC MODULE
B7 NOT USED 1231 .8 DK BLU/W HT D3 INPUT SPEED LOW
B8 NO T USED 1230 .8 GRA/RED D4 INPUT SPEED HIGH
1234 .8 GRA/RED B9 SYSTEM C H EC K LAMP D5 NO T USED
1061 .8 ORN/BLK B10 SERIAL DATA 121 .8 W HT D6 ENGINE SPEED
1233 .8 DK GRN/YEL B11 OUTPUT SPEED SENSOR LOW 476 .8 BLK/PNK D7 SENSOR GROUND
1232 .8 LT BLU B12 OUTPUT SPEED SENSOR HIGH 417 .8 DK BLU D8 TPS
D9 NO T USED
TRANSMISSION CONTROL MODULE CONNECTOR D10 NOT USED
D11 NO T USED
D12 NO T USED
1227 .8 BLK/YEL D13 TRANSM ISSIO N TEMPERATURE
433 .8 GRA/BLK D14 MAP
D15 NO T USED
1229 .8 LT BLU/WHT D16 FORCE MOTOR HIGH

TRANSM ISSION CO NTRO L MODULE CO NNECTO R

TRANSMISSION CONTROL MODULE (TCM) - PINOUTS B-55

6.2L V8 HD DIESEL ENGINE W/HD AUTO TRANS AND OVERDRIVE
Y M A / v m /v w v / yvw w vw w W VW W W W W VV I 250-1.0 BRN I
S HOT IN STAR T OR RUN ^ I 250-1.0 BRN.I
^ HOT A T A L L TIMES < > HOT IN STAR T >

^VVWVWWWN Za /WVWWV^ >VVVVVVWV\Wv^A

ECM-BAT ECM-CRNK y
A.
TRANS 3 f
250-1.0 BRN ■ ■ A M
1223-.8 YEL/BLK

1 0 AMP 250- 1.0 b r n |

10 AMP 10 AMP ^ a a r 439-.S p n k / b l k v \

i
TP SENSOR
1440-1.0 ORN I 1

• 476 C
Q ® jm m r 476-.S b lk /p n k ^
BLK/PNK

• 417 B I 417-.8 DK BLU

1416-.8 GRA

I 455-.S PPL ^

1433-.S GRA/BLK m A V

l416-.8GRA'*™*i^» • I "
MAP S1°° i l k
SENSOR M ^ H 4 1 6 -.8 G R A H ■ H IH H

-1231

C173 1230-.8 DK BLU/WHT ,

INPUT 12078084
1231-.8 G R A / R E D ^
SPEED
SENSOR
452~ )

A
452-.S BLK I

It 121-.8 W H T l
B £2
C126 121 )
12015792
ENGINE
SPEED
SENSOR

ENGINE
GROUND
G100
B-56 TRANSMISSION CONTROL MODULE (TCM)
DIESEL ENGINE W/AUTO TRANS
CIRCUIT OPERATION W AIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME W HEN
ENGINE IS BELOW NORMAL OPERATING TEMPERATURE
The heating of the Glow Plugs is controlled by the After the initial time period the relay will be de-energized
TEST RESULT ACTION
Glow Plug Relay in the Glow Plug Controller. Battery for five seconds then will cycle ON/OFF for approximately
voltage is applied to the relay contacts through the RED 10 seconds. 1. Place ignition switch in RUN Test lamp lights. GO to step 2.
wire from Junction Block. The relay is operated by a position. Connect test lamp from
Solid-State Controller. The Controller responds to engine When the Glow Plug Controller receives the Start RED (2) wire at glow plug Test lamp does not light. LOCATE and REPAIR open in RED
temperature and also to an Ignition Switch Start Input. Input, the Glow Plugs and WAIT Indicator will cycle controller connector C190 to (2) wire and fusible link from glow
ON/OFF after the Ignition Switch is returned to RUN. ground. plug controller connector C190 to
When the Ignition Switch is turned to RUN, battery battery junction block.
voltage is applied to the Enable Input of the Controller. After approximately 25 seconds the Controller will 2. Connect test lamp from PNK (3) Test lamp lights. GO to step 3.
The Glow Plug Relay within the Controller will be open the Glow Plug Relay and the heating of the plugs wire at glow plug controller
energized for approximately five seconds during which it stops. connector C128 to ground. Test lamp does not light. LOCATE and REPAIR open in PNK
applies voltage to the Glow Plugs and WAIT Indicator. (3) wire from glow plug controller
connector C128 to ground terminal
G102.

DIAGNOSIS - GLOW PLUGS 3. Connect test lamp from PNK (3) Test lamp lights. GO to step 4.
wire to BLK (150) wire at glow
plug controller connector C128. Test lamp does not light. LOCATE and REPAIR open in BLK
PRELIMINARY CHECKS: (150) wire from glow plug
A check of the glow plug system should be Turn ignition switch to OFF and then momentarily to controller connector C128 to
performed before doing diagnostic procedures. START and return to RUN position. The WAIT indicator ground terminal G102.
should flash for approximately 25 seconds and then go
4. Connect test lamp from PPL (906) Test lamp lights. GO to step 5.
With engine below normal operating temperature, turn out. wire at glow plug controller
ignition switch to RUN. The WAIT indicator should light. connector C128 to ground. Move Test lamp does not light. LOCATE and REPAIR open in PPL
After approximately 10 seconds, the WAIT indicator must With engine at normal operating temperature, turn ignition switch to START position. (906) wire from glow plug
begin to flash for an additional 10 seconds and then go ignition switch to RUN. The WAIT indicator should flash. controller connector C128 to
out. starter motor.
5. Place ignition switch to OFF Test lamp lights. REPLACE glow plug controller.
position. Connect test lamp from
ORN (503) and ORN/BLK (509) Test lamp does not light. GO to step 6.
wires at glow plug controller
connector C191 to ground.
6. Disconnect glow plug controller Reading of 2 ohms or less. GO to step 7.
connector C128. Using a positive
polarity ohmmeter, check Reading greater than 2 ohms. LOCATE and REPAIR open in ORN
continutity between ORN (503) (503) wires from glow plug
and BLK (150) wires. controller connector C128 to splice
S116.
7. Reconnect glow plug controller Test lamp cycles on and off for GO to step 8.
connector. Connect test lamp from approximately 25 seconds then
ORN (503) and ORN/BLK (509) goes off.
wires at glow plug controller
connector C191 to ground. Turn Test lamp does not light or cycles REPLACE glow plug controller.
ignition switch momentarily to for the incorrect time.
START and then release to RUN
position.

8. Remove all connectors from glow Test lamp lights for all glow plugs. LOCATE and REPAIR open in ORN
plugs. Connect one lead of test (503) and ORN/BLK (509) wires
lamp to battery voltage and other from glow plug to glow plug
lead to each glow plug. controller connector C191.

Test lamp does not light for one or REPLACE glow plug(s) where test
more glow plugs. lamp did not light.

GLOW PLUGS B-59

 I 1-32.0 BLK

RIGHT BANK GLOW PLUGS

a: eg
O 0)
ci p

505-.5 RST I
o
1 I LEFT BANK GLOW PLUGS (FUSIBLE LINK)

LEFT BANK SHEET RIGHT BANK 6-5.0 PPL I 6-5.0 P P L !

GLOW PLUGS METAL GLOW PLUGS

2-3.0 RED I
GROUND GROUND GROUND
G113 G111 G114

B-60 GLOW PLUGS

 RPO CODES

B3D - SCHOOL BUS EQUIPMENT

MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
MT8 - MAN TRANS, 5-SPD., WITH OVERDRIVE
2-8.0 RED

*z
CL
C190

CLUTCH START SW
(MTS ONLY)
(SEE PAGE 41)
GLOW PLUG
CONTROLLER

I 509-5.0 ORN/BLK
S114
(SEE PAGES 19, 20)
I 503-5.0 ORN

503-1.0 ORN

l/P C299
12010966
S205
ENGINE

3
CD
0
1
3-3.0 PNK I
508

: 450 503

3 68 J
2

:
430

24
35

94
i
<

93
r

, 7
15
11

12

593 9

14 29 821 :
6 508
5

C100
12020184

1505-1.0 YEL1

ENGINE
GROUND 6-5.0 PPL
G102
2-5.0 RED

GLOW PLUGS B-61

CIRCUIT OPERATION WATER IN FUEL INDICATOR LIGHTS WITH NO WATER IN FUEL
TEST RESULT ACTION
The Diesel Fuel Filter System combines six functions therm ostatic switch. The switch opens or closes, to turn
1. Place ignition switch in RUN Water in fuel indicator stays LOCATE and REPAIR open in
into a single package: the heater off or on, depending on the temperature of position. Disconnect water in on. YEL/BLK (508) wire between
1. It heats diesel fuel to prevent wax-plugging of the the fuel. fuel sensor connector C130. water in fuel sensor connector
filter; C130 and water in fuel
2. It combines very small droplets of water in the fuel The fuel then passes through the Primary and indicator.
into larger drops and separates the water from the Secondary filters. Next the fuel flows through the water
fuel; coalescer. Here the droplets of water in the fuel are Water in fuel indicator goes REPLACE water in fuel sensor.
3. It filters the diesel fuel; combined into larger drops, the drops fall to the water out.
4. It detects an excessive pressure drop indicating filter reservoir in the filter. When fuel flows from the Fuel Filter
plugging; (Vacuum Switch) Assembly to the injection pump, it is clean and free of WATER IN FUEL INDICATOR DOES NOT LIGHT BRIEFLY WITH
5. It detects the presence of excess water in the fuel; water. ____________ IGNITION SWITCH TURNED TO RUN
and TEST RESULT ACTION
6. It provides a means to drain the water it has The Solid-State Water In Fuel Sensor applies voltage
separated. to a Probe. When the Probe touches water, the Module 1. Disconnect water in fuel Battery voltage. GO to step 2.
closes a switch. This completes a circuit to ground to sensor connector C130 and
The Fuel Filter Assembly consists of the following light the SERVICE FUEL FILTER Indicator. place ignition switch in RUN. No voltage. CHECK condition of ALT fuse. If
main parts: Fuel Heater, the Water In Fuel Sensor, the Connect a voltmeter from fuse is good, LOCATE and REPAIR
Fuel Pressure Switch, and a Filter. The Filter contains A times delay circuit in the Water In Fuel Module PNK/BLK (39) wire at water in open in PNK/BLK (39) wire from
the "coalescer" (the device that combines small droplets grounds the Indicator bulb briefly to test the bulb each fuel sensor connector C 130 to water in fuel sensor connector
ground. C130 to fuse block.
of water into larger ones) and the filter/separator. time the system is turned on.
2. Connect voltmeter from Battery voltage. GO to step 3.
An electric fuel pum p delivers diesel fuel from the tank The Fuel Heater is operated by a built-in thermostatic PNK/BLK (39) to BLK (150) wire
to the fuel filter. As fuel enters the filter, it passes first switch. When the switch is closed, battery voltage is at water in fuel sensor No voltage. LOCATE and REPAIR open in BLK
through the Fuel Heater. The heater contains a applied to the heater from the ALT Fuse. connector C130. (150) wire from water in fuel
sensor connector C 130 to
ground G102.
3. Connect voltmeter from Battery voltage. REPLACE water in fuel sensor.
DIAGNOSIS - DIESEL ENGINE FUEL CONTROLS YEL/BLK (508) wire at water in
fuel sensor connect or C130 to No voltage. CHECK water in fuel lamp. If
ground. lamp is good, LOCATE and REPAIR
FUEL HEATER DOES NOT O P E R A TE _____________
open in YEL/BLK (508) wire
TEST RESULT ACTION between water in fuel sensor
connector C130 and water in
1. Disconnect fuel heater Battery voltage. GO to step 2. fuel indicator.
connector C132. Place
ignition switch to RUN No voltage. CHECK condition of ALT fuse. If
position. Connect voltmeter fuse is good, LOCATE and REPAIR
from PNK/BLK (39) wire at fuel open in PNK/BLK (39) from fuel
heater connector C132 to heater connector C132 to fuse
ground. block.

2. Connect voltmeter from Battery voltage. REPLACE fuel heater.

PNK/BLK (39) wire to BLK (150)
wire at fuel heater connector No voltage. LOCATE and REPAIR open in BLK
C132. (150) wire from fuel heater
connector to ground G102.

B-62 FUEL CONTROLS

DIESEL ENGINE
 ALT
20 AMP I 39-. 8 PNK/BLK

FAST IDLE
SOLENOID

C135
12004267
39-.8 PNK/BLK GENERATOR
(SEE PAGE 41)

WATER IN
FUEL SENSOR

FUEL
HEATER

WATER IN
508-.8 YEL FUEL LAMP
(SEE PAGE 70;

I ----------------

FUEL SHUT I
OFF VALVE
ENGINE S208
(SEE PAGE 70)
GROUND
l/P CLUSTER
G102 3 9 ,8 PNK/BLK *
(SEE PAGE 69)

FUEL CONTROLS
DIESEL ENGINE
 RPO CODES

M Tt - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE

MT8 - MAN TRANS, 5-SPD., WITH OVERDRIVE

ECM-CRNK
10 AMP $
I 439-1.0 PNK/BLK I

o S203
CO B A (SEE PAGE 18)
D
_i IZZI 1 HiHl
O 5
11226 2 11223!
_/
< o
Ui 1 Ii23a ' 3 1222'
z
o 1224) 4 14 2 2 1
ECM/PCM
p
DRAC uu 5
6
CONNECTOR
C251
□ n
11229 7 rrm 12052175
(l2 2 £ 8 □
y o fisa 9 CZ3
x X > O X
tU
> ?! § g 1123-f 10 C=J
< 4 3 7 ] 11 L«bJ

CZI 12 [4 2 0 ]

437-.8 BRN
GT100
12020107 (UPPER)
12020108 (LOWER)

1233-.8 DK GRN/YEL

ENGINE
vss 150-.8 BLK
I
(MT8) 439-.S PNK/BLK

1232-.8 LT BLU

824-.8 LT BLU/BLK
4
W/YEL
■ 1233-.8 DK GRN/YEL mS B
j:
1232-.8 LT BLU
" i ! i

OUTPUT
T
SPEED « a r 1233-.8 DK GRN/YEL I ____________ i
12020183
SENSOR
■ 1232-.8 LT B L U ^ ^ ^ M M B M
(MT1)
l/P
GROUND
G200

64 DIGITAL RATIO ADAPTER CONTROLLER (DRAC)

GASOLINE ENGINES W/MAN OR AUTO TRANS AND DIESEL ENGINES W/AUTO TRANS
 ALT
39-.8 PNK/BLK
20 AMP 39-.S PNK/BLK

I I
\ I
\ f
_\_L
ll
M:
t I!
30
18
24
19
:

68
DRAC
), r 11
12
S24-.8 LT BLU/BLK
VEHICLE SPEED SIGNAL CLUSTER
3. 15 9
1233
14 29
T 505
1232 VEHICLE SPEED INPUT
1232-.8 LT BLU
CC

39 12 VOLT (IGNITION)
C100 I _______ 39>.8 PNK/BLK V 150 GROUND
12020184
150-.8 BLK 1233 VEHICLE SPEED SIGNAL INPUT

♦
SPEEDOMETER
(SEE PAGE 71) C292
12066130

1233-.8 DK GRN/YEL I

r S203
(SEE PAGE 19)

VSS

1233-.8 DK GRN/YEL -

1232-.8 LT BLU ■ ■ ■

*•1232 C185 3 GE3

12020600
C100
12020183 l/P
GROUND
G200

DIGITAL RATIO ADAPTER CONTROLLER (DRAC) B-65

DIESEL ENGINE W/MAN TRANS
CIRCUIT OPERATION DIAGNOSIS - INSTRUMENT PANEL: GAGES AND INDICATORS
The operation of an individual Indicator is described TEMPERATURE GAGE PRELIMINARY CHECKS:
along with its circuit. Refer to the schematic and text for The Temperature Gage is also operated by two coils. Check condition of GAUGES and INST LPS fuses. If
the circuit that is indicated below each of the Indicators. Battery voltage is applied to both coils. One is grounded fuses are in good condition use the following diagnostic
directly and the other is grounded through the procedures.
PARK BRAKE WARNING LAMP Temperature Sender. This has 55 ohms resistance at
Battery voltage is applied to the Park Brake Warning 127°c (260°F) (hot coolant) and its resistance becomes FUEL GAGE INDICATES FULL OR BEYOND AT ALL TIMES
Lamp when the Ignition Switch is in RUN or START. The greater at lower temperatures. It is approximately 1400
TEST RESULT ACTION
Park Brake Switch provides a ground when the Park ohms at 38°C (100°F). This causes the current through
Brake is applied. The Park Brake Warning Lamp the Sender and one coil to increase as the coolant 1. Disconnect fuel pump connector Fuel gage indicates full. LOCATE and REPAIR open in PNK
illuminates to alert the driver. temperature increases. This m oves the pointer. C400 and place ignition switch to (30) wire between fuel pump
RUN. Connect a fused jumper connector C400 and fuel gage. If
LOW COOLANT INDICATOR (DIESEL) from PNK (30) wire at fuel pump no open is found, REPLACE fuel
SERVICE BRAKES WARNING LAMP connector C400 to ground.
The Low Coolant Indicator comes on to warn the gage-
Battery voltage is applied to the Service Brakes
Warning Lamp when the Ignition Switch is in RUN or driver when a low level of coolant exists in the radiator.
Fuel gage indicates empty. GO to step 2.
START. The Brake Pressure Switch closes to provide a Battery voltage is applied to the Low Coolant Module.
ground and illuminate the lamp when there is a loss of When a low coolant condition exists, a signal is sent to 2. Connect fused jumper form PNK Fuel gage indicates full. LOCATE and REPAIR open in BLK
brake fluid pressure in one of the two brake systems. the Low Coolant Module from the Low Coolant Sensor. (30) wire to BLK (150) wire at fuel (150) wire between fuel pump
This could be caused by a leak in one of the brake lines. The Low Coolant Module will provide a ground to the pump connector C400. connector C400 and ground G400.
Low Coolant Indicator. If no open is found, REPLACE fuel
pump.
FUEL GAGE
The Low Coolant Sensor is not a switch that opens
The pointer of the Fuel Gage is moved by the Fuel gage indicates empty. REPAIR/REPLACE fuel pump.
magnetic fields of two coils. The coils are at right angles and closes. It has a very high resistance to ground,
to each other. Battery voltage is applied to the E-coil more than 50,000 ohms, when the engine coolant level
is low. This causes the Low Coolant Module to light the FUEL GAGE INDICATES EMPTY WHEN THERE IS FUEL IN THE TANK
and the circuit divides at the opposite end of the coil.
One path continues to ground through the F-coil. Low Coolant Indicator. With more of the Sensor covered TEST RESULT ACTION
Another goes to ground through the variable resistor of by coolant, its resistance decreases. When the fluid level
is good, the resistance will be less than 10,000 ohms. 1. Disconnect fuel pump and place Fuel gage indicates full. REPAIR/REPLACE fuel pump.
the Fuel Gage Sender. ignition switch to RUN.
With the Sensor resistance between 10,000 and 50,000
ohms, the Sensor is partly covered and the fluid is not Fuel gage indicates empty. LOCATE and REPAIR an open in
When the tank is low, the resistance of the Sender is PNK (30) wire between fuel pump
low. A large flow of current passes through the E-coil low enough to cause the warning to be displayed.
connector C400 and fuel gage. If
and the Fuel Gage Sender resistor. This moves the no open is found, REPLACE fuel
pointer toward E on the scale. When the tank is full, the CHECK ENGINE (GASOLINE) INDICATOR gage.
Sender resistance is high. More current now flows Refer to Light Duty Truck Fuel, Driveability and
through the F-coil, moving the pointer toward F on the Emissions Service Manual, Section 3. FUEL GAUGE IS INACCURATE
scale.
TEST RESULT ACTION
WATER IN FUEL WARNING INDICATOR
With two coils operating the pointer, the Gage is not Refer to Fuel Controls (Diesel), Page 62 1. Disconnect fuel pump connector Gage responds correctly. CHECK BLK (150) wire for high
affected by changes in the system’s battery voltage. C400. Connect one RED lead of J resistance. If wire is good,
GLOW PLUG INDICATOR 34029-A Multimeter to PNK (30) REPAIR/REPLACE fuel pump.
OIL PRESSURE GAGE Refer to Glow Plugs (Diesel), Page 59 wire and other to ground. Set
The engine oil pressure is displayed by the Oil resistance dials to 0 ohms and Gage does not respond correctly. CHECK for high resistance in PNK
then to 90 ohms. Fuel gage (30) wire. If wire is good, REPLACE
Pressure Gage. The pointer of the Gage is moved by RH/LH TURN SIGNAL INDICATORS should indicate empty and then
two coils, and its operation is similar to that of the Fuel fuel gage.
Refer to Front Exterior Lamps, Page 33 full. (Allow time for gage to reach
Gage.
full due to anti-slosh device.)
HIGH BEAM INDICATOR
The Oil Pressure Sender is connected to the junction Refer to Headlamps, Page 22
of the two coils. It has low resistance when the oil TEMPERATURE INDICATOR STAYS ON AT ALL TIMES WITH IGNITION SWITCH IN RUN
pressure is low, and 90 ohms resistance when the oil DRL INDICATOR TEST RESULT ACTION
pressure is high. This changing resistance changes the Refer to Headlamps with Canadian Daytime Running 1. Disconnect temperature sender Indicator stays on. LOCATE and REPAIR short in DK
current flow through coils. The magnetic fields of the Lamps, Page 25 connector C108 (Gasoline) or GRN (35) wire. If wire is good,
coils move the pointer from low to high.
C106 (Diesel) and place ignition REPLACE instrument cluster.
switch to RUN. Observe
temperature indicator. Indicator goes off. REPLACE temperature sender.

B-66 INSTRUMENT PANEL

 TEMPERATURE GAGE INDICATES COLD ALL THE TIME OIL PRESSURE GAGE INDICATES HIGH PRESSURE AT ALL TIMES
TEST RESULT ACTION TEST RESULT ACTION
1. Disconnect temperature sender Temperature gage indicates hot. REPAIR/REPLACE temperature Disconnect oil pressure sender Oil pressure gage indicates low REPLACE oil pressure sender.
connector C108 (Gasoline) or sender. connector C118 and place ignition pressure or indicator lights.
C106 (Diesel). Ground the OK switch to RUN. Connect a fused
Oil pressure gage indicates high
GRN (35) wire at temperature Temperature gage does not lOCATE and REPAIR open in DK jumper from TAN (31) wire at oil
pressure or indicator does not lOCATE and REPAIR open in
sender connector C108 (Gasoline) indicate hot. GRN (35) wire between pressure sender connector C118 light. TAN (31) wire and bUlb. If wire and
or C106 (Diesel). temperature sender connector to ground.
bulb are good, REPLACE oil
C108 (Gasoline) or C106 (Diesel) pressure gage.
and temperature gage. If wire is
good, REPLACE temperature OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN OIL PRESSURE IS GOOD
gage.
TEST RESULT ACTION
TEMPERATURE GAGE IS NOT ACCURATE 1. Disconnect oil pressure sender Oil pressure gage indicates high REPLACE oil pressure sender.
connector C118 and place ignition pressure or indicator light goes
TEST RESULT ACTION
switch to RUN. out.
1. Disconnect temperature sender Gage indicate correctly. REPLACE temperature sender.
connector C108 (Gasoline) or Oil pressure gage indicates no or lOCATE and REPAIR open in TAN
C106 (Diesel). Connect RED lead Gage is not correct. lOCATE and REPAIR open in DK low pressure or indicator light (31) wire between oil pressure
from J 34029-A Multimeter to DK GRN (35) wire between stays on. sender connector C118 and oil
GRN (35) wire and other lead to temperature sender connector pressure gage. If wire is good,
ground. Adjust resistance dials to C108 (Gasoline) or C1 06 (Diesel) REPLACE oil pressure gage.
1400 ohms and then to 55 ohms. and temperature gage. If wire is
Temperature gage should indicate good, REPLACE temperature LOW COOLANT INDICATOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLy)
cold then hot. gage. TEST RESULT ACTION
1. Disconnect low coolant warning low coolant indicator lights. REPLACE low coolant warning
TEMPERATURE GAGE INDICATES HOT WITH ENGINE COOLANT switch connector C150 and place switch.
BELOW OPERATING TEMPERATURE AND IGNITION SWITCH IN RUN ignition switch to RUN. Observe
TEST RESULT ACTION low coolant indicator light. Low coolant indicator does not GO to step 2.
light.
1. Disconnect temperature sender Temperature gage indicates cold. REPLACE temperature sender.
connector C108 (Gasoline) or 2. Disconnect low coolant warning Battery voltage. GO to step 3.
C106 (Diesel) and place ignition Temperature gage does not lOCATE and REPAIR an open in module connector C236. Connect
switch to RUN. indicate cold. OK GRN (35) wire between voltmeter from PNK/BLK (39) wire No voltage. lOCATE and REPAIR open in
temperature sender connector at low coolant warning module BlK/ORN (550) wire. If no open is
C108 (Gasoline) and 106 (Diesel) connector C236 to ground. found, CHECK condition of
and temperature gage. If no open GAUGES fuse.
is found, PERFORM diagnostic
procedures under symptom 3. Connect voltmeter from BlK/ORN Battery voltage. GO to step 4.
"Temperature Gage Is Not (550) wire to BlK (150) wire at low
Accurate. coolant warning module connector No voltage. lOCATE and REPAIR open in BlK
C236. (150) wire between low coolant
warning module connector C236
OIL PRESSURE GAGE IS NOT ACCURATE and ground G200.
TEST RESULT ACTION 4. Connect voltmeter from GRA (69) Battery Voltage. GO to step 5.
1. Disconnect oil pressure sender Oil pressure gage indicates REPLACE oil pressure sender. wire at low coolant warning
connector C118. Connect one correctly. module connector C236 to No voltage. lOCATE and REPAIR open or
RED lead of J 34029-A Multimeter ground. short to ground in GRA (69) wire
to TAN (31) wire at oil pressure from low coolant warning module
Oil pressure gage does not lOCATE and REPAIR open in TAN
sender connector C118 and other connector C236 to low coolant
indicate correctly. (31) wire between oil pressure
lead to ground. Set resistance warning lamp.
sender connector C118 and oil
dials to 0 ohms and then to 90 pressure gage. If wire is good, 5. Connect voltmeter from BlK/ORN Battery Voltage. LOCATE and REPAIR open in
ohms. The oil pressure gage REPLACE oil pressure gage. (550) wire to YEL/BlK (68) at low VEL/BlK (68) wire from low coolant
should indicate low pressure and coolant warning module connector warning module connector C236 to
then high pressure. C236. low coolant warning switch
connector C1 50.

No voltage. REPLACE low coolant warning

module.

INSTRUMENT PANEL 8-67

/

LOW COOLANT INDICATOR IS LIT WHEN COOLANT LEVEL IS GOOD

TEST RESULT ACTION
Connect a fused jumper from low Low coolant indicator goes out. REPLACE low coolant probe.
coolant warning switch connector Low coolant indicator stays lit. LOCATE and REPAIR open in
C150 to ground. Place ignition YELlBLK (68) wire. If wire is good,
switch to RUN and observe low follow diagnostic procedures listed
coolant indicator light. under symptom "Low Coolant
Indicator Does Not Light With
Coolant Level Low."

8-68 INSTRUMENT PANEL

I ILLUM ILLUM ILLUM ILLUM ILLUM ILLUM
ILIUM

I 8
-150
I
I
I HIGH
BEAM
LEFT
TURN (....
~:;
f--
14
RIGHT
TURN
®
50

1,5
r------f---,
,CANADIAN

:
,
I
:
~~~II~~Er--
,LAMP ~v~
'-
150

593:
I
:I

~ L _ _ _ _ _ _ _ _ .J

G--:[)-
I
11
SERVICE
TRANSMISSION -
(629W/DRL)
1234
r-

I
t--
39
-39
f--
39

I 508 68 419

'f-""'"
WATER
IN
LOW
--
COOLANT
'-
'-~
SERVICE
ENGINE
SERVICE
BRAKE
PARK
BRAKE
GLOW
PLUG

I
FUEL SOON (DIESEL SPEEDO- FUEL OIL
(DIESEL ONLY) METER
ONLy)

I VOLT TEMP

I
I /, .~ " C205
c::::
•p "'" g
= .", ~.
~ ..
F= ~
12040746

I ..--~------------~~----------------~---------------t----------~--+-t1~ · - F== .~
39 --...t-i=:::::ttt-e",
F== .M .."'.
_30 --_IHtt_IIfft..
'" I ~
:<S '" .;j'i-"",*~-!iiJ7---+-""'"
508 -
68-----~

- ~
.=
824 - ......__;t+t-.:iS ....
.~ CDO
~fF=HI-15O----I--.J

I --------+---------__11_--------+---__1t--+--+-
~8
15O - _ ~ .~ ~ 33
~ ~~~--~--~3---__11_---_+~
_-+----+--39 _= .l!l co"'--+tF=H-41~1
... :::; '" 9:==t===t:S~r'
O~ ~. I ~
:::.
I -----35--~--~1t_e::::
r--
CDe..fIfF=I-fI-15 ----1----""1
31
_~1_--15O
1""'"1234
'"
~
co
~. F
I ~
~
~fF=I-fI-15O - - - f - - - - '

---------~~--------+----~I__+--+-i_llro29--~E:~~~~~~;~
... ~::11~14-----1~

I '-.. ,.....
'-----'\....::J....r="\"--
.......-.J

l\.""t" JJ I
~

I
I INSTRUMENT PANEL B-69
8-69

I
 W 'A W W W W W V /
% HOT IN STAR T O R RUN <

m vw vw w vm
ALT
20 AMP L _______ 39-.8 PNK/BLK 1
GAUGES
20 AMP I 550-.8 BLK/ORN |
FROM SWITCH 1
TO LAMP

GROUND -1 5 0 LOW COOLANT

IGNITION -5 5 0 WARNING PARK
MODULE BRAKE
LOW COOLANT (DIESEL ONLY)
SWITCH
WARNING
SENSOR
(DIESEL ONLY) (CLOSED WHEN
PARK BRAKE
IS APPLIED)
H I 5 5 0 - . 8 BLK/ORN

68-.S YEL/BLK

508-.8 YEL/BLK a m

508 120
| 120 30 24 :
: 450 111
18
3 68 J 19 ;

2 31
[C
n ,7
11
439 35
12
2
15 593 9
: 440
14 29
6 906 505

CT

l/P CLUSTER
GLOW PLUGS ] CONNECTOR
(SEE PAGE 61) (SEE PAGE 69)

PCM
(SEE PAGE 53) 1
ENGINE

BRAKE PRESSURE
WARNING SWITCH
(SEE PAGE 74) 1234-.8 GRA/RED

a
RH TURN SIGNAL
(SEE PAGE 32) TCM
(SEE PAGE 57)
LH TURN SIGNAL
(SEE PAGE 32)
I■ ■ 68-. 8 YEL7BLK B ■

WATER
IN FUEL
SENSOR
(DIESEL ONLY) I 508-.8 YEL/BLK I
HEADLAMP
C205 DIMMER SWITCH
12040744 (SEE PAGE 23)

~ GROUND
C130
12015793
G200
B-70 INDICATOR LAMPS
 HOT IN START
OR RUN

ALT I _______ 39*.8 PNK/BLK I

20 AMP

ENGINE
FUEL PUMP
TEMPERATURE COOLANT OIL PRESSURE FUEL PUMP
SENSOR OIL PRESSURE
SWITCH TEMPERATURE
CLOSES W HEN ENGINE (DIESEL) SENSOR & SWITCH
TEMPERATURE EXCEEDS
260°F

k REAR BODY
J CONNECTOR

30-.5 PPL

31-.5 TAN

35-.5 DK GRN

FRAME
CO)
_
,/p
GROUND
GROUND
G200

INSTRUMENT PANEL GAGES B-71

 PANEL DIMMER
SWITCH

A B C D
9 [1 5 0 (1 5 6 44
"S i
INST LPS
5 AMPS
44-1.0 DK G R N * I T
PROVISIONS FOR
I1 5 6 -.8 WHT DOME LAMPS
(SEE PAGE 38)

i 8-.5 GRA

zi
q IJ
m
“ o
9 n
d> §

TURN

/ SIGNAL
SWITCH

\ 8-.5 GRA I

44
LIGHT
SWITCH

A B C d E F 39
*

30

150 824
150- ,s . • 156
DOME l/P CLUSTER 419 39
33
I OFF
CONNECTOR
11,1 150 |1 5 0 -.8 B L K |
(SEE PAGE 69)
CIRCUIT / 'PARK
BREAKER' ----/ I f— _
25 AMP
35
HEAD 31
OFF 1S0 .150

40- I': ' PARK 15

14 11

HEAD S203
(SEEPAG E 18)

LIGHT'
SWITCH

■ 150-3.0 BLK I

l/P
GROUND
G200
B-72 INSTRUMENT PANEL LAMPS
CIRCUIT OPERATION ALARM W ILL NOT SOUND
TEST RESULT ACTION
Vehicles equipped with the Hydro-Boost Brake system 1. Connect a test lamp from Test lamp lights. GO to step 2.
have an optional warning harness that plugs into the l/P PNK/BLK (39) wire at alarm
harness. Refer to Section 5A1 of the 1991 R/V, P Light connector C217 to ground. Test lamp does not light. LOCATE and REPAIR open in
Truck Service Manual for further description and PNK/BLK (39) wire between
operation of the Hydro-Boost System. alarm connector C217 and fuse
block.
DIAGNOSIS - BRAKE WARNING SYSTEM 2. Connect test jum per from BLK Alarm sounds. GO to step 3.

C217 to ground. Alarm does not sound. REPLACE alarm.

PRELIMINARY CHECKS: 3. Connect test jum per from BLK Alarm sounds. GO to step 4.
1. Check condition of GAUGES fuse. Replace if system, verify hydraulics as described in Section (11) wire at delay module
needed. 5A1 of the 1991 R/V, P Light Truck Service connector C116 to ground. Alarm does not sound. LOCATE and REPAIR open in BLK
2. Place Ignition Switch in RUN. Manual. If alarm continues to malfunction, use (11) wire between alarm
3. For vehicles equipped with Hydro-Boost Brake the following procedures. connector C217 and delay
module connector C216.

BRAKE INDICATOR REMAINS ON WITH IGNITION SWITCH IN RUN AND PARK BRAKE OFF 4. Connect test jum per from TAN Alarm sounds. REFER to Section 5A1 of the
(966) wire at hydro-boost 1991 R/V, P Light Truck Service
TEST RESULT ACTION
pressure switch connector Manual.
Brake indicator lamp does not go GO to step 2. C148 to ground.
1. Disconnect park brake switch
out. Alarm does not sound. LOCATE and REPAIR open in TAN
connector C204.
(966) wire between hydro-boost
Brake indicator lamp goes out. CHECK adjustment of park brake pressure switch connector C148
switch. If adjustment cannot be and delay module connector
corrected, REPLACE park brake C216. If no open is found,
switch. REPLACE delay module.

2. Disconnect brake pressure Brake indicator lamp does not go LOCATE and REPAIR short to ALARM WILL NOT SHUT OFF
warning switch connector C105. out. ground in BLK (111) wire between
brake pressure switch connector TEST RESULT ACTION
C105 and indicator lamp. 1. Disconnect brake pressure Alarm stops. GO to step 2.
warning switch connector
Brake indicator lamp goes out. CHECK for a possible leak or loss C105. Alarm continues to sound. CHECK for possible leak or loss
of brake fluid.
of fluid in the brake system.
2. Disconnect delay module Test lamp lights. GO to step 3.
connector C216.
Test lamp does not light. LOCATE and REPAIR short to
ground in BLK (11) wire between
delay module connector C216
and alarm connector C217.
3. Disconnect hydro-boost Alarm continues to sound. LOCATE and REPAIR short to
pressure switch connector ground in TAN (996) wire
C148. Connect a test lamp from between hydro-boost pressure
TAN (996) wire at hydro-boost switch connector C148 and
pressure switch connector delay module connector C216.
C148 to positive battery If no short is found, REFER to
terminal. Section 5A1 of the 1991 R/V, P
Light Truck Service Manual.

Alarm stops. REPLACE delay module.

BRAKE WARNING SYSTEM B-73

SCHOOL BUS
 C218 _ _ _ 39-.8PNK/BLK_ - - - - - - - - - - - - - - - - -
12004888

I
~BA~ L I
[iJpUJ
~ S
lEI 0 1.5 OHM
RESISTOR
L liP
l/P CLUSTER
lID lID 00 [iJ~ill lEI 0 CONNECTOR
rID lID [ru 0 ill ALARM (SEE
(SEE PAGE
PAGE 69)
€
ACC
GAUGES C217
20 AMP 8905825

GAUGES
u0 PWR
Ou . ._ _ _ _ _ _ _ _ _ 966-.8 TAN _ _ _ _ _ _ _ _ _..

~[AJ~~
HORN/OM INSTR-LPS TRANS ECM-BAT
~

~DO~OO
TAIL LPS INJ HTR ACC-RADIO

~OODD[)£]
~P-HAZ E~r [jUXO WIPER

Jib Pu::g FUSE BLOCK REAR ...J

HYDRO IOGST SWITCH

AlARM
HI

111

FRONT
12089776 ~ C216
o FLASHER 8900655
o UNIT
::s<D
<Xl
..
...-_......:;
••0
HYDRO­
HYDRO-
BOOST f1~~~....---- 860-.8 YEL - - - - - -.. C205
12040744
PRESSURE r;tiil!"'~---- 966-,8 TAN - - - - - - C255
SWITCH HI
(CLOSED
(CLOSED
WITH LOSS C148
C298 C299
OF PRESSURE) 12004827 GT100 12015987 12015952 12010966 6294841
12020107 (UPPER)
A
12020108 (LOWER)

::s<D C
<Xl
..
...J

FLOW
4iiM------- 860-.8 YEL - - - - - -. .
~
o
SWITCH . ._ _ _ _ _ _ 111-.8 BLK _ _ _ _ _ _ _. . .
(CLOSED
C149 lIP
WITH LOSS
OF FLUID 6288440
FLOW)
--
ENGINE
A 340 2
J
= B 450 39
K
C 3 419
(CLOSES WHEN 0
D 2 31
UNEQUAL PRESSURE L STA
E 439 35
EXISTS BETWEEN M 0 RUN
F 2
G 440 N
0 0 0 0 0 OFF
H 6 P
LOC
~1 2 0
3 5
D L ACC
111-.8 BLK
0 0

123 = C100
12020184
C100 IGNITION
12020183 SWITCH
SWITCH
B-74 BRAKE WARNING SYSTEM
SCHOOL
SCHOOL BUS
BUS
CIRCUIT OPERATION BACKUP LAMPS DO NOT OPERATE

TEST RESULT ACTION

BACKUP LAMPS PARK, TAIL, MARKER, AND LICENSE LAMPS
With the Ignition Switch in RUN or START, voltage is Voltage is applied through the PARK LP Fuse to the 1. Place transmission in reverse. Test lamp lights. ISOLATE problem in body builder’s
applied through the TURN/BU Fuse to the Transmission Light Switch at all times. With the Light Switch in PARK Connect test lamp from LT GRN installed wiring.
or HEAD, voltage is applied to the Park, Tail, Marker, and (24) wire at rear lamp harness
Position Switch or the Backup Lamp Switch. Whenever
connector C402 to ground. Test lamp does not light. GO to step 2.
the gear selector lever is shifted to REVERSE the License Lamps.
Transmission Position Switch or the Backup Lamp Switch 2. Connect test lamp from DK BLU Test lamp lights. GO to step 3.
closes and voltage is applied to the Backup Lamps and (75) wire at backup lamp switch
the lamps turn on. connector C214 (auto) or C146 Test lamp does not light. CHECK condition of TURN/BU
(man) to ground. fuse. If fuse is good, LOCATE and
REPAIR open in DK BLU (75) wire
from backup lamp switch
DIAGNOSIS -- REAR EXTERIOR LAMPS connector C214 (auto) or C146
(man) to fuse block and DK BLU
(38) wire.
PRELIMINARY CHECKS:
The rear lamp systems taillamps, backup lamps, and 3. Connect test lamp from LT GRN Test lamp lights. LOCATE and REPAIR open in LT
license plate lamp(s) all receive voltage from same wire (24) wire at backup lamp switch GRN (24) wire from backup lamp
circuit (BRN 9) and are grounded at the bulb socket(s). connector C214 (auto) or C146 switch connector C214 (auto) or
(man) to ground. C146 (man) to connector C408.
If only one system is not working, LOCATE and REPAIR
an open in the wiring and/or bulbs that pertain to that
Test lamp does not light. Adjust backup lamp switch. If
system.
backup lamp switch will not adjust
properly, REPLACE backup lamp
NONE OF THE REAR LAMP SYSTEMS OPERATE switch.

TEST RESULT ACTION

1. Connect test lamp from ORN (40) Test lamp lights. GO to step 2.
wire at light switch connector
C209 to ground. Test lamp does not light. CHECK condition of TAIL LPS fuse.
If fuse is good, LOCATE and
REPAIR open in RED (2) wire from
light switch connector C209 to
battery junction block and/or ORN
(40) wire from light switch
connector C209 to fuse block.

2. Place light switch to PARK Test lamp lights. GO to step 3.

position. Connect test lamp from
BRN (9) wire at light switch Test lamp does not light. REPLACE light switch.
connector C209 to ground.

3. Connect test lamp from BRN (9) Test lamp lights. LOCATE and REPAIR open in BLK
wire at rear lamp harness (150) wire.
connector C402 to ground.
Test lamp does not light. LOCATE and REPAIR open in BRN
(9) wire from rear lamp harness
connector C402 to light switch
connector C209.

REAR EXTERIOR LAMPS B-75

 1 24-.8 LTG R N I

RH
PROVISIONS FOR
BACKUP
RH SIDE MARKER
LAMP

F ~ ) l - . 8 BLK

C408 C406
2977107

RH TAIL STOP AND

TURN LAMP

M— 8blK'
U I I t V - S BLK.
■ 19-.8 DK G R N l

C404
2984855

.
d>

Q D yf ia i

19 )
A
9-.8 BRN w a rn •
S402
RH LICENSE
LAMP
NOTE: This harness is shipped
I9 -.8 BRN I • S400 along with the vehicle and is
c4oo |kg) I ■ 24-.8 LT G RNa 2977107 installed by the body builder.
12034342

9-.S BRN
S401 < § h - .8 BLK-= ® LH LICENSE
C150
LAMP

I 1 5 0 - .8 BLK | M
S404

.8 BLK*
I 18-.8 YEL« M b it * .8 b l k -
© LH
C403
BACKUP
2984855 LAMP
LH TAIL, STOP AND
TURN LAMP ^ B ^ - S BLK ^

C405
2977107

PROVISIONS FOR
LH SIDE
MARKER
24-.8 LT GRN

B-76 REAR LAMP HARNESS

 RPO CODES

TRANSMISSION MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE

BACKUP MT8 - MAN TRANS, 5-SPD., WITH OVERDRIVE
LAMP SWITCH
(AUTO TRANS ONLY)

C214
2973407

REAR
JD)H l a m p
24-1.0 LT GRN HARNESS

BACKUP
LAMP SWITCH
(4 SPEED MAN
TRANS ONLY)

>
1
1C
O1

C100
12020183

BACKUP LAMPS B-77

 y^AVW V'W W Vf
S HOT AT ALL TIMES <
i^VWVVVWVV^T
LIGHT
SWITCH
TAIL LPS 44
20 AMP

PANEL DIMMER
140-1.0 ORN
150- ,x DOME
■ 156

2
SWITCH LIGHT -

SWITCH
I l S l r i 11 so 11 se I 4 4 lC ^ CIRCUIT .PARK
BREAKER
25 AMP
I HEAD
OFF
* PARK
r -.
HEAD

REAR
BODY
CONNECTOR
■ 9-2.0 BRNI

REAR
LAMP
jj HARNESS

12065158 C402

340 120
I 30 24 J
: 450 39 33
18 19 K
3 419 J I9
2 31
439 35 [C ) r
11
12
L
M
2
440 94
n93
, 15 593 9 N
14 29
6 906 434 P

o
o

B-78 TAILLAMPS, REAR MARKER AND LICENSE LAMPS

CIRCUIT OPERATION

VACUUM SYSTEMS EGR VALVE VACUUM SYSTEM

A vacuum-operated component uses the force of the throttle is opened beyond idle and inlet manifold A leak in the EGR (exhaust gas recirculation) vacuum
normal air pressure working against the lower air vacuum is normal. This reduces combustion system can upset the ECM’s programmed control of
pressure of a partial vacuum to operate the component. temperatures in the engine to control oxides of nitrogen exhaust gas recirculation and adversely affect engine
The vacuum created within the inlet manifold when the emissions. operation. Too much exhaust gas recirculation at idle or
engine is running is stored in a vacuum tank in the cruise can result in the engine stalling after closed
engine compartment. A check valve in the line feeding The EGR valve is operated by an integral vacuum throttle deceleration, surging during steady throttle
vacuum to the tank keeps the stored vacuum from actuator that controls a pintle within the valve. The pintle cruising, or a rough idle. Too little exhaust gas flow
weakening when inlet manifold vacuum drops during allows combustion temperatures to become too high and
remains closed to prevent exhaust gas recirculation until
bring about detonation ("spark knock") or an overheated
high speed or high power operation. vacuum is applied to the actuator. The vacuum causes
engine. In addition, nitrous oxide emissions may be high
the pintle to open, allowing a measured flow of exhaust
enough to cause the vehicle to fail an emissions test.
Vacuum is routed through hoses (and in some cases, gas to enter the inlet manifold.
tubing) to a mechanical or electric valve that provides a
The EGR system remains closed during periods of Because the source of an EGR system symptom
means of controlling the vacuum-operated component.
engine idle and deceleration to prevent rough idle from might be traced to a mechanical or electrical condition
When the valve is open, it allows vacuum to go to an
excessive dilution of the fuel-air mixture. It also remains as well as a faulty vacuum system, an effective
actuator that actually operates the component. When
closed at wide-open throttle to prevent voltage loss. At systematic diagnosis procedure should examine all three
the component is to be returned to its original position,
other times, it rapidly cycles open and closed to categories of components - not just the vacuum system
the valve cuts off the vacuum to the actuator hose and
modulate the flow of exhaust gas as required. Under alone. Therefore, no exclusive vacuum system diagnosis
vents the hose to normal air pressure.
certain circumstances, it may remain fully open to procedures are provided here. For more information on
provide the maximum EGR. the EGR system, refer to the 1991 "Fuel and Emissions
A typical actuator is a metal shell with a movable shaft
Service Manual."
that retracts and extends to mechanically operate the
component. A flexible diaphragm separates the interior A manifold absolute pressure (MAP) sensor measures
of the shell into two chambers - a sealed chamber to the strength of the vacuum in the EGR vacuum circuit DIAGNOSIS
which vacuum can be admitted, and an open chamber and sends a signal back to the electronic control module
exposed to normal air pressure. The movable shaft is (ECM). If actual vacuum differs from the preferred Condition most likely to cause vacuum system
attached to the center of the diaphragm and extends vacuum as calculated by the ECM, the ECM will adjust problems include hoses that leak or become
from the open chamber. the on-off intervals of the EGR valve to correct the flow disconnected. With the engine running, either condition
of exhaust gas into the cylinders. This provides the is easily detected from the hiss of air at the opening.
When the vacuum is directed to the sealed chamber, required control of oxides of nitrogen emissions while Other common vacuum problems are kinked or
normal air pressure presses on the other side of the retaining engine performance under all operating obstructed hoses, hoses connected incorrectly or
diaphragm and causes it to retract the shaft. When the conditions. The ECM also uses the signal from the MAP binding components.
vacuum is cut off, the sealed chamber is vented to sensor to control fuel delivery and ignition timing.
outside air to balance the air pressure on both sides of A vacuum pum p can be used as a vacuum source to
the diaphragm and eliminate the force that retracted the Vacuum for the EGR system is taken from the throttle operate com ponents and test the system. The built-in
shaft. A coiled spring within the sealed chamber body and routed through a hose to the electronic vacuum gage of the pump provides a means of checking
expands to push the diaphragm back to its original vacuum regulator valve (EVRV) solenoid (V8 engine) or for a vacuum leak as well. Once vacuum is applied to
positions. This extends the shaft. to the EGR valve solenoid (V6 engine). The solenoid is operate the component, the gage should hold steady
controlled by the 435 circuit from the ECM. When the until the vacuum is purposely released.
EXHAUST GAS RECIRCULATION solenoid opens the electronic vacuum regulator valve or
VACUUM SYSTEM the EGR valve, vacuum reaches the EGR actuator On vacuum systems that are controlled by electrical
All 1991 P-Truck gasoline engines are equipped with through another vacuum hose and opens the EGR pintle or electronic switches, check for a blown fuse, wiring that
an exhaust gas recirculation (EGR) system. The EGR valve to allow exhaust gas to flow into the inlet manifold. is cracked, frayed or burned, and high resistance in
system allows a small amount of exhaust gas to flow When the EVRV solenoid or the EGR valve solenoid is connectors of the control circuit(s) before checking for a
from the exhaust manifold into the inlet manifold when released, the valve vents the EGR actuator to outside air suspected vacuum system problem.
to close the EGR pintle valve.
 S102
(SEE PAGES 42, 52)

I 45O-.0 BLK/W HT ■ •

S 111 (SEE PAGE 46)

PCM
P39-.8 PNK/BLK I • H T 39-.8 PNK/BLK I
(SEE PAGE 51)

ENGINE
GROUND
G100

B-80 EXHAUST GAS RECIRCULATION (EGR)

 C 134 C 135

12H-25

12A3
12A5

1. Cold Advance Control

2. Fast idle Solenoid
3. Fuel Shut-Off Valve
4. Generator
5. Glow Plug (RH)
6. Cold Advance and Fast Idle
1. RH Batteries
Temperature Switch
2. LH Battery
3. Starter Motor

Figure 1 - Batteries and Cables (6.2L V8 HD Diesel Engine) Figure 2 - Engine Wiring Harness - RH Side (6.2L V8 HD Engine)

COMPONENT LOCATOR VIEWS B-81

 FRONT
OF VEHICLE

S116 VIEW [ a ]

1. Glow Plug Controller

C106 2. Water in Fuel Sensor
3. Fuel Heater
4. Back Up Lamp Switch
5. Speed Sensor
6. Oil Pressure Switch

Figure 4 - Engine Wiring Harness - Rear (6.2L V8 HD Diesel Engine)

FRONT
OF
VEHICLE

C195
C100

C116

1. Glow Plug (LH)

2. Coolant Temperature Sender 1. Battery Junction Block
2. Map Sensor
3. Low Coolant Sensor
12H24

Figure 3 - Engine Wiring Harness - LH Side (6.2L V8 HD Diesel Engine) Figure 5 - Engine Wiring Harness to Cowl/Radiator (6.2L V8 HD Diesel Engine)

B-82 COMPONENT LOCATOR VIEWS

 C117

FRONT
OF VEHICLE

1. Idle Air Control Actuator

2. Injectors
3. EVRV
4. Starter Motor
1. Ignition Coil 5. Knock Sensor
2. Distributor 6. TP Sensor
3. Electronic Spark Module Coolant Temperature Sensor
4. Transmission 8. Generator
5. Engine Temperature Switch 9. Map Sensor
4 SPD., MAN TRANS 6. Transmission Backup Lamp Switch
12H22

Figure 6 - Engine Wiring Harness, LH Side (7.4L V8 Gas Engine) Figure 7 - Engine Wiring Harness, RH Side (7.4L V8 Gas Engine)

COMPONENT LOCATOR VIEWS B-83

 2

FRONT
OF VEHICLE
VIEW

1. Map Sensor
2. Idle Air Controller
3. TP Sensor
4. Injectors
5. ESC Hybrid
6. Knock Sensor
7. Starter Motor
8. EVRV

Figure 9 - Engine Wiring Harness, RH Side (5.7L V8 Gas Engine)

C118

C174
C108

Coolant Temperature Sensor

1. Distributor
Coil
2. Electronic Spark Module
Distributor
3. Oil Pressure Sender
Electronic Spark Module
4. Output Speed Sensor
Oil Pressure Sender
C146 Output Speed Sensor
5. Transmission
6. Input Speed Sensor
Transmission
7. Knock Sensor
Input Speed Sensor
C185 8. Engine Temperature Switch
Engine Temperature Switch
Vehicle Speed Sensor
4 SPD., MAN TRANS Backup Lamp Switch 12
C174 12H16

Figure 8 - Engine Wiring Harness, LH Side (5.7 V8 Gas Engine) Figure 10 - Engine Wiring Harness to Cowl (7.4L V8 Gas Engine)

B-84 COMPONENT LOCATOR VIEWS

 C110
cm C 112

GT101

S189

1. EGR Solenoid
2. TP Sensor
S190 3. Injectors
4. Starter Motor
5. Map Sensor
6. Coil
C224
7. Idle Air Control C206 12C2
8. Coolant Temperature Sensor
Figure 12 - Steering Column Switches

S199

12H17

GlgO G101
FRONT
OF VEHICLE FRONT
OF VEHICLE

G111

C116 C121

C115
VIEW B VIEW A

Figure 11 - Engine Wiring Harness, RH Side (4.3L V6 Gas Engine)

COMPONENT LOCATOR VIEWS B-85

 C100

4.3L ENGINE

S197 [¥ ]

1. Battery Junction Block

2. Fuel Pump Relay C113
3. ESC Hybrid Function (MAN TRANS ONLY)
4. Brake Pressure Warning Switch S109 GT100 12H4
G110

Figure 15 - Battery and Leads (4.3L V6 and 5.7L V8 Gas Engines W/ School Bus Equipment)

G110
S101 G111

(5.7L ENGINE)
VIEW

(7.4L ENGINE)

1. Battery Junction Block GT100 FRONT 1. Battery

2. Fuel Pump Relay OF VEHICLE 2. Starter Motor
(4.3L ENGINE)
12H6
VIEW B

Figure 14 - Engine Wiring Harness to Cowl (4.3L V6, 5.7L and 7.4L V8 Gas Engines Figure 16 - Battery and Leads (4.3L V6, 5.7L and 7.4L V8 Gas Engines)

B-86 COMPONENT LOCATOR VIEWS

COMPONENT LOCATION Page - Figure COMPONENT LOCATION Page - Figure
Backup Lamp S w itc h ....................... . . Top LH front of tra nsm issio n ............................................. 82 4 Ignition C o i l ...................................... . . . Top of engine near d is trib u to r........................ ................. 83 6
83 6 84 8
84 8 85 11
Battery, L H .......................................... . . LH front behind radiator s u p p o rt...................................... 81 1 . . . Top center of engine ...................................... ................. 83 7
Battery, RH ........................................ . . RH front behind radiator support ................ ................... 81 1 84 9
86 15 85 11
86 16 . . . Top center of engine ...................................... ................. 83 7
Battery Junction B lo c k ..................... . . RH side of shipping panel .......................... ................... 82 5 84 9
86 14 85 11
Brake Pressure Warning Switch . . . . . Near master cylinder ......................................................... 86 14 Input Speed S e n s o r........................ . . . LH side of transmission ................................. ................. 84 8
Cold Advance Control ..................... . . Top front of e n g in e .......................................... ................... 81 2 84 10
Cold Advance Fast Idle . . . RH side of e n g in e ............................................. ................. 83 7
Temperature Switch ..................... . . RH rear of e n g in e ........................................... ................... 81 2 84 9
Coolant Temperature Sensor 85 11
(G asoline)........................................ . . Top front of e n g in e ........................................ ................... 83 7 Low Coolant Sensor (Diesel) . . . . . . . RH side of ra d ia to r........................................... ................. 82 5
Coolant Temperature Sensor MAP Sensor (Diesel) ..................... . . . LH side of shipping p a n e l............................... ................. 82 5
(D ie s e l)............................................ , . . Top RH front of e n g in e ................................. ................... 84 8 MAP Sensor (Gasoline) ................. . . . Top rear of e n g in e ........................................... ................. 83 7
Distributor .......................................... . . Top rear of e n g in e ........................................ ................... 83 6 84 9
84 8 85 11
84 10 Oil Pressure Sender (D iesel)......... . . . Top rear of e n g in e ........................................... ................. 84 8
EGR Solenoid ..................................., . . Top RH side of e n g in e ................................. ................... 85 11 84 10
Engine Temperature S w itc h ........... . . . LH side of e n g in e ........................................... ................... 83 6 Oil Pressure Switch (Gasoline) . . . . . . Top LH side of tra n sm is sio n .......................... ................. 82 4
84 8 84 8
84 10 Output Speed Sensor ................... . . . LH side of transmission ................................. ................. 84 8
ESC H y b r id ....................................... . . . Top RH side of e n g in e ................................. ................... 84 9 84 10
86 14 Starter M o t o r .................................... . . . Lower RH side of engine ............................... ................. 81 1
ESC Module ..................................... . . . Top of engine at d istrib u to r.......................... ................... 83 6 83 7
84 8 84 9
84 10 85 11
E V R V ................................................... , . . Top RH front of e n g in e ................................. ................... 83 7 86 15
84 9 86 16
Fast Idle Solenoid ............................. . . Top LH side of engine ................................. ................... 81 2 TP Sensor ......................................... . . . Top RH side of e n g in e .................................... ................. 83 7
Fuel Gage S e n d e r ............................. . . In fuel t a n k ...................................................... ................... 85 13 84 9
Fuel Heater ....................................... . . . Top rear of e n g in e ........................................ ................... 82 4 85 11
Fuel Pump R e la y .............................. , . . Top LH side of shipping panel ................... ................... 86 14 Turn Signal S w itc h .......................... . . . LH side of steering c o lu m n ............................ ................. 85 12
Fuel Shut Off Valve ......................... . . . Top front of e n g in e ........................................ ................... 81 2 V S S .................................................... . . . Top LH side of tra n sm issio n .......................... ................. 82 4
Generator (Diesel) ............................. . . Front of e n g in e ............................................... ................... 83 7 84 8
84 9 Water in Fuel S e n s o r ..................... . . . Top rear of e n g in e ........................................... ................. 82 4
85 11 . . . LH side of steering c o lu m n ............................ ................. 85 12
Generator (Gasoline) ........................ . . Front of e n g in e ............................................... ................... 81 2 Connectors:
Glow Plug #1 ................................. . . . LH side of e n g in e ........................................... ................... 81 3 C100 ............................................. . . . Top left side of left cowl ................................. ................. 82 5
Glow Plug # 2 ................................. . . . RH side of e n g in e ........................................... ................... 81 2 86 14
Glow Plug # 3 .................................... . . LH side of e n g in e ........................................... ................... 81 3 C102 ............................................. . . . Top left side of left cowl ................................. ................. 82 5
Glow Plug # 4 ................................. . . . RH side of e n g in e ........................................... ................... 81 2 86 14
Glow Plug # 5 ................................. . . . LH side of e n g in e ........................................... ................... 81 3 C103 ............................................. . . . At fuel pump relay ........................................... ................. 86 14
Glow Plug # 6 ................................. . . . RH side of e n g in e ........................................... ................... 81 2 C105 ............................................. . . . At brake pressure warning s w itc h ................. ................. 86 14
Glow Plug # 7 ................................. . . . LH side of e n g in e ........................................... ................... 81 3 C106 ............................................. . . . At coolant temperature sensor ..................... ................. 81 3
Glow Plug # 8 ................................. . . . RH side of e n g in e ........................................... ................... 81 2 C107 ............................................. ................. 81 2
Glow Plug Controller ..................... . . . Top LH rear of engine ................................. ................... 82 4 83 7
Idle Air Control A c tu a to r................ . . . Top rear of e n g in e ........................................ ................... 83 7 84 9
84 9 85 11

COMPONENT LOCATER INDEX B-87

COMPONENT LOCATION Page - Figure COMPONENT LOCATION Page - Figure
C108 ................................................ .......................... At engine temperature s w itc h ................................. . . . . 82 5 C172 ............................ ........................ LH center of transm ission..................................... ......... 83 6
83 6 84 8
84 8 84 10
84 10 C173 ............................ ........................ Input speed sensor ............................................... ......... 83 6
C109 ........................ .......................... At coolant temperature sensor ............................... ___ 83 7 84 8
84 8 84 10
84 10 C174 ............................ ....................... Output speed s e n s o r ............................................ ......... 83 6
C110 ........................ ..................................................... At throttle position s e n s o r ................................................................................. ______ 83 7 84 8
84 9 84 10
85 11 C175 ............................ ....................... EVRV ........................................................................ ......... 83 7
cm ................ ..................................................... At RH in je c to r.............................................................. ___ 83 7 84 9
84 9 C185 ............................ ......... 82 4
85 11 84 8
C112 ........................ .......................... At LH in je c to r.............................................................. ___ 83 7 C186 ............................ ..................... LH top of LH cowl (near support) ........................ ......... 86 14
84 9 C192 ............................ ..................... #1 glow p l u g .......................................................... ......... 81 3
85 11 C193 ............................ ......... 81 3
C113 ........................ .......................... At ESC hybrid ........................................................... . . . . 84 9 C194 ............................ ..................... # 5 glow p l u g .......................................................... ......... 81 3
86 14 C195 ............................ ......... 81 3
C115 ........................ .......................... At idle air control a c tu a to r......................................... ___ 83 7 C196 ............................ ..................... # 2 glow p l u g .......................................................... ......... 81 2
84 9 C197 ............................ ..................... # 4 glow p l u g .......................................................... ......... 81 2
85 11 C198 ............................ ......... 81 2
C116 ........................ .......................... At MAP s e n s o r ........................................................... ___ 82 5 C199 ............................ ....................... # 8 glow p l u g .......................................................... ......... 81 2
83 7 C206 ............................ ..................... Base of serving column ........................................ ......... 85 12
84 9 C224 ............................ ..................... Base of serving column ........................................ ......... 85 12
85 11 C400 ............................ ....................... At fuel t a n k ............................................................... ......... 85 13
C117 ........................ .......................... At knock s e n s o r ......................................................... ___ 83 7 C401 ............................ ....................... At fuel level s e n d e r................................................. ......... 85 13
84 9 C402 ............................ ....................... At rear lamp harness ............................................ ......... 85 13
84 10 Grommets:
C118 ........................ .......................... At oil pressure sender (gasoline) .......................... ___ 84 8 GT100 .......................... ....................... LH lower side of c o w l............................................ ......... 86 14
84 10 GT101 .......................... ..................... Center of injector b o d y .......................................... ......... 83 7
C199 ........................ .......................... At oil pressure switch (d ie s e l)................................. ___ 82 4 84 9
C120 ................................................ ..................................................... At electronic spark m o d u le ............................................................................. ______ 83 6 85 11
84 8 Grounds:
84 10 G100 ............................. ..................... Top LH rear of engine .......................................... ......... 83 7
C121 .................................................... ..................................................... At ignition coil ........................................................................................................................ ______ 83 6 84 8
84 8 85 11
85 11 G101 ............................ ..................... At alternator b ra c k e t............................................... ......... 84 9
C125 .................................................... .................................................... LH side of distributor ................................................................................................ ______ 83 6 85 11
84 8 G102 ............................. ..................... RH front top of engine .......................................... ......... 81 2
84 10 G110 ............................ ..................... RH side of radiator support above b a tte ry .......... ......... 81 1
C127 .......................... . . . . 85 11 86 15
C128 ...................................................... ; ..................... At glow plug c o n tro lle r............................................. ___ 82 4 86 16
C129 .................................................... ______ 81 2 G111 ............................ ......... 84 11
C130 ......................................................................................................... At water in fuel sensor ........................................................................................... ______ 82 4 86 16
C131 .................................................... .................................................... At cold advance fast idle temperature switch . . . ______ 81 2 G112 ............................. ......... 81 1
C132 ......................................................................................................... At fuel h e a te r ............................................................................................................................ ______ 82 4 G113 ............................ ......... 81 1
C134 .......................................................................................................... Top of cold advance c o n tro l ........................................................................ . . . . 82 4 G402 ............................. ......... 85 13
C135 .................................................... .................................................... Fast idle s o le n o id .............................................................................................................. ______ 81 2 Splices:
C146 ......................................................................................................... At backup lamp s w itc h ........................................................................................... ______ 82 4 S 1 0 1 ............................... ......... 84 9
83 6 85 11
84 8 86 14
C150 ......................................................................................................... At low coolant s e n s o r ................................................................................................ ______ 82 5 S 1 0 2 ............................... ......... 86 14

B-88 COMPONENT LOCATER INDEX

COMPONENT LOCATION Page -- Figure
S 1 0 4 .......................................... Top LH side of c o w l........................................................... 86 14
S 1 0 9 .......................................... Top LH side of LH cowl .................................................... 86 14
5 11 1 Top LH side of LH cowl .................................................... 86 14
511 2 Top LH side of LH cowl .................................................... 86 14
511 3 Front RH top of e n g in e ....................................................... 81 2
511 4 RH top corner of e n g in e .................................................... 81 2
511 5 RH top center of e n g in e .................................................... 81 2
511 6 LH top rear of e n g in e .........................................................81 3
511 7 RH top rear of e n g in e .........................................................81 2
S 1 8 9 .......................................... Top LH center of e n g in e .................................................... 83 6
84 8
84 9
85 11
5190 Top LH side of engine ....................................................... 85 11
5191 LH side of transmission .................................................... 83 6
84 8
5195 LH side of cowl .................................................................. 82 5
86 14
5196 LH side of cowl .................................................................. 82 5
86 14
5197 LH side of cowl .................................................................. 82 5
86 14
5198 Lower RH side of engine .................................................. 83 7
84 9
85 11
S199 Lower RH side of engine .................................................. 83 7
84 9
85 11

COMPONENT LOCATER INDEX B-89

 SECTION C
P MODEL
(MOTORHOME)

SECTION C - P-MOTORHOME C-1

 DRL RELAY FUEL PUMP
(SEE PAGE 18) STEERING
SENDER
COLUMN
(SEE PAGE 38)
SWITCHES
l/P CONNECTOR
(SEE PAGES 4

BATTERY
(SEE PAGES 4

REAR LAMPS
HARNESS
(SEE PAGE 61)

PROVISIONS FOR
WIPER/WASHER
(SEE PAGE 28)

REAR BODY
CONNECTOR
(SEE PAGE 38)

C-2 PHANTOM VIEW

 SYMPTOMS INDEX REAR EXTERIOR LAMPS
PAGE None of the rear lamps operate ...................................................................................................................... C-60
SYMPTOM
Backup lamps do not o p e ra te ........................................................................................................................... C-60

AUXILIARY COOLING FAN START AND CHARGE

Auxiliary cooling fan does not r u n ................................................................................................................... C-48
Battery is undercharged or o v e rc h a rg e d ........................................................................................................ C-29
Auxiliary cooling fan runs c o n tin u o u s ly .......................................................................................................... C-48
Engine does not crank and starter solenoid does not click ....................................................................... C-29
Starter solenoid clicks, engine does not crank or cranks s lo w ly ................................................................ C-29
CRUISE CONTROL
Cruise control does not disengage when brake pedal is depressed ...................................................... C-51 TURN LAMPS
Cruise control does not operate ......................................................................................................................C-51 Turn signals do not work on one s id e ............................................................................................................. C-23
Turn signals do not operate ..............................................................................................................................C-23
DIESEL ENGINE FUEL CONTROLS Turn signal lamps flash r a p id ly .........................................................................................................................C-23
Service fuel filter indicator does not light briefly with ignition switch turned to RUN ............................ C-46
Fuel heater does not operate .......................................................................................................................... C-46 WIPER/WASHER
Water in fuel indicator lights with no water in fuel ....................................................................................... C-46 Wipers do not operate in any mode ............................................................................................................... C-27
Wipers do not operate in HI ..............................................................................................................................C-27
GAGES AND INDICATORS Wipers do not operate in L O ..............................................................................................................................C-27
Fuel gage indicates full or beyond at all tim e s .............................................................................................. C-53
Fuel gage indicates empty when there is fuel in the ta n k ............................................................................C-53
Fuel gage is inaccurate ................................................................................................................................... C-53
Oil pressure gage indicates low pressure when oil pressure is g o o d ...................................................... C-53
Oil pressure gage indicates high pressure at all tim e s ................................................................................ C-54
Temperature gage indicates hot with engine coolant below operating temperature and ignition
switch in R U N ................................................................................................................................................. C-54
Temperature gage indicates cold all the time .............................................................................................. C-54
Temperature gage is in a c c u ra te ..................................................................................................................... C-54
Low coolant indicator is lit when coolant level is g o o d ................................................................................ C-54
Low coolant indicator does not light with coolant level low (diesel o n ly ) ..................................................C-54

GLOW PLUGS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is
below normal operating te m p e ra tu re .......................................................................................................... C-43

HEADLAMPS
Headlamps do not illuminate high or low beams - both sides .................................................................. C-13
Low beam lamp(s) do not operate .................................................................................................................C-13
High beam lamp(s) do not o p e ra te .................................................................................................................C-13

HEADLAMPS (WITH DRL)

Headlamps do not illuminate high or low beams - both sides .................................................................. C-16
Low beam lamp(s) do not operate .................................................................................................................C-16
High beam lamp(s) do not o p e ra te .................................................................................................................C-17
Canadian daytime running lamps do not operate ....................................................................................... C-17

HORNS
Horn will not operate ........................................................................................................................................C-25
Horn sounds continuously without depressing horn switch .......................................................................C-25

PARK, MARKER AND HAZARD LAMPS

Park lamps do not o p e ra te ...............................................................................................................................C-21
Side marker lamp(s) do not o p e ra te ...............................................................................................................C-21
Hazard warning lamps do not operate .......................................................................................................... C-21

SYMPTOM INDEX C-3

 _ _ _ _ _ _ _ 2-5.0 RED _ _ _ _. .

sr
2_
2
·P.iJ::'
ow
a::
o
~
BAlTERY 0

0 0 0
•
START

RUN
OFF
44

1
lOCK
. ._ _ _ _ _ _ 1-50.0 BlK C f- _L J ACC
C200 C201 I
6294641 ~
0 0 0
12010966
IGNITION ;::
COil 156
Z AUTO APPLY 150
(SEE PAGE 32) aw IGNITION
-'
(L
(L a::
>::
z
(L
Hi
~
PARK BRAKE
SWITCH _ ..._ __
SWITCH - 2
DOME

t i·'"'"' ' _::::"

0 0 0 OFF
~
~ N
'9 LIGHT
'" CIRCUIT
SWITCH
I S205
BREAKER
25 AMP I I

• HEAD
10

PPNK

STARTER

,
40

MOTOR _2-5.0 RED_

HEAD
DIESEL

.S103
S100

• -- 2-3.0 RED

I~ •
S101 aw
a:: C202

I~
o 12020029
~ PANEL DIMMER
~~ SWITCH
a::rn
om
"'::J
NbS

~
51
a::
o
•
M
N GT100
12085003 (UPPER) " ___11_ 9-1.0 BRN
_ .300-5.0 ORN1
12085002 (lOWER)
.1 ___ 2-5.0 RED _ _ _ __

a
w aw -.r-. =~OO-5.0
S201 ORN

~~·-I-I
a:: a::
o o
M
~

I ~
~

§».-
o
I S102
2-2.0 R S T _ •
(FUSIBLE LINK)

COOLING FAN J ~BA~ ~

rn:J rn:J ~
[g ~ ill
L
ill ~ ill
[ill 0

0
~
~
0
~
C!
q
6

LL"~-
RELAY [ill
(SEE PAGE 49)
rn:Jrn:J~DillDD
o
C106 ~ AOCC 0 ~R jW: I
~
12045896 OA
GENERATOR GAUGES PWR STOP-HAl

r'i5flrstlnotl~
15AMP

4i HORN/OM ~ ECM-BAT
L..r;J ~
L.r;j INSTR-LPS
f""";;;-{l AlT
------ Z
a::
f10tl ~ ~ ~ rn 20 AMP

JF i -m
m L...r;J
TAIL LPS ~
INJ r::::l
HTR r';;;;-;l
ACC-RADIO TURN/BU
^TURN/BU
V yT I» ;r 11
~n-otl~~
l.J.=W ~ AUX
* 115AMP
5 AMP
I----- fcl-----*---- kH i M -
STOP-HAZ
WIPER
~K DD
Fsjn m o ALT CRNK

nsr.t
T~
n 0
k/S/PLR
10AMP
WIPER
G110 25 AMP INJ

C-4 POWER DISTRIBUTION 7.5 AMP

GASOLINE ENGINE
 2-5.0 RED

'Jj~'.
_6-5.0PPL
C201

o
S200 44
START
• _2-5.0 RED
RUN

+ RH
+ LH C200
0 0 0
OFF
LOCK
_L J
12010966 ACC
BATTERY BATTERY 4-5.0BRN_ 0 0 0

1 z
IGNITION
-
150

2
DOME
156

. .-.. '"
-'
0.
0.
Z
0.
a:
CD
SWITCH LIGHT
0 0 0
to
~ ...to . SWITCH

.
300-5.00RN CIRCUIT '-PARK
906-.5 RST ----z~
W
(FUSIBLE LINK) I S150 BREAKER
25 AMP

~ -'
[[
0.
HEAD
10

8: C! ., OFF
,PARK
~
w (])~ 40-+-.......- .

L.. HEAD

.@::z' :;r.,
-
S101

Ir------------ 2-3.0 RED

I
2-2.0 RST 2-5.0 RED

p----------
( (FUSIBLE LINK)

I :~:.:;E~RN-------. ---.,
C202
12020029

• z
a:
PANEL DIMMER
SWITCH

"~l
C203
.~-·II-------3-5.0PNK-------. . o
o 12020030
to
~~~~~~ID41-~==~~I[I:~~-~!~/P~---
6
AJ- 2 150 24011111 439 17 2 g

GT100
12085003 (UPPER)
• 3 16 350
C 140 15 120
D 9 508 331
E 35 8 397
3001301 sol
420 440 592 J

0 593 11 K
68 2501419 L 481
10 505 MI
W/GASOLINE
901 93 75 NJ-l0 W/DiESEL
1
o
w
a:
12085002 (LOWER)
G 39 1234 31 59 50 l 1 /824T 141 4 p o
to _ 9-1.0BRN
•
~, .
1 2 3 4 5 10 9 8 7 6 12015964 N

L,.... ----~-
.S100
2-1.0 RST _ _ _ __

(FUSIBLE LINK)
• 12015764 2-5.0 RED
GAUGES

~~i-i=r~~"o~
-'
ow GLOW PLUG ~ 0. 20AMP
a:
CONTROLLER '""-Z "-'"Z W
a: q 0.
o
oj
N
0 0
.., ..,tri
tri
0
..; :b0 i_ TRANS
10AMP

-----.....--
;(; (])

INSTR-LPS

[-J- J .l.BAT.l
[!!J
L
l!!J @ !IJ ~ CD [ffi D
D~

D~
A

z
a:
CD
'"
Z
0.
o
o
w
a:
a:
o
o
to
5AMP

HORN/DM
15AMP

t
o
L
...tri ..,tri 6
g
S~5 - 3-3.0 P N K - , lID lID @ ill ~ CD [ill D HTR

Lb.~11.1
3-3.0 PNK t
FUEL SHUT
lID@@DOJDDO
ACC IGN HTR PWR

SHEET
OFF VALVE
(SEE PAGE 47)
~OO~G GAUGES PWR ECM-CRNK

~OO~~
10AMP
./ METAL GENERATOR
0 , GROUND ow HORN/OM INSTR-LPS TRANS ECM-BAT

-= -: -= G110
a:
o ~~~~

~1~ENG1NE
..; TAIL LPS INJ HTR ACC-RADIO
N
~~~OO

'~J
ENGINE ENGINE ST P- l~~]K OAUXO WIPER .T U R N /B U
15 A M P
GROUND GROUND ALT CRNK

~ PuS/P~
LH CYLINDER RH CYLINDER
10AMP
HEAD HEAD WIPER
G113 G112 25 AMP
POWER DISTRIBUTION C-5
DIESEL ENGINE
 — €< 0)

1-50.0 BLK

d.

I
r /n
.-------- y
If

GT100
12085003 (UPPER)
12085002 (LOWER)

COOLING
FAN RELAY
(SEE PAGE 48)

SHEET INJECTORS ECM IGN

7.5 AMP 10 AMP 20 AMP
METAL
GROUND
G110

C-6 POWER DISTRIBUTION

GASOLINE DRIVEAWAY
 1-32.0 BLK I I 6-5.0 PPL

J" r^3—
[ □ □ b e
[M o
+ - + -
RH LH
BATTERY BATTERY

IGNITION -^=r
SWITCH
300*5.0 ORN |

DIESEL ONLY
E ONLY | G ASO LINE ONLY
3-3.0 PNK

3 9 | 1 » 4 3 1 1Y59 ! 50 I
481 W /G ASOLINE
! 300 30 P 50 I
35 fl 397-j*----- !---------
9 508
33 ,
140 15 120j«-----j--------7
o
( N
250 419
.... 593 11
10 W /DIESEL
1 4i- |4 2 0 |4 4 0 | 592
2 |1 5 0 | 2 4 0 |1 1 1 |/ I 439 f 17 I 2

G ASO LINE O NLY DIESEL ONLY

J
2 ! 150 | 240 |111| I 14 3 9 1 17 I 2 l/P
3 | 16 |3 5 0 | | I 14 2 0 1440 I 592
140 15 120 593 11
— I /"-\ L _

S
9 508 33 68 250 419 -481 W /G ASO LINE
O i—
35 8 397 ^ ^ 10 505
[300 30 | 50 I I 19011 93 75 ■10 W /D IESEL
39 11234 3 1 1 59 | 50 | | | |824| 14 4
12015964
5 10
—

I 3-3.0 PNK ■

VAM AW W W VVV^
% HOT IN START OR RUN ?

V W W W W V W A ^C

ECM
10 AMP

REAR
S I ■CD-
__
r in h f| o r h d h DS on
© o FUSE BLOCK
12052472
c ] [ ] c ] t —] BOT

£5

ENGINE ENGINE
GROUND GROUND
LH CYLINDER RH CYLINDER
HEAD HEAD
G113 G112
POWER DISTRIBUTION C-7
DIESEL DRIVEAWAY
 8-1.0 GRA-
1— 1 I

1
KC>
r BAT

□
L
11 fB WE:lu ED u

CD O
□
L

e ; 0 □
350-.8 PNK/WHT - FUEL CYC MDL
o
GO HI 0 □ m □ □
300-5.0 ORN - IGNITION 240-1.0 ORN - HORN RLY - DOME LAMP
ACC IGN HTR PW R 250-1.0 BRN - TRANSMISSION SHUNT 12041235
440-1.0 ORN - ECM 8-.8 GRA - INSTRUMENT LAMPS
0 □ GXA UI
G ES
1PW
30,R1 1 2-5.0 RED - BATTERY 8-1.0 GRA---------------------------------------------
- 50-3.0 BRN
tK ] I
_ Xi
_ K 1 d c
H O RN /D M IN S T R -L P S
TRANS E C M -B A T 300-5.0 ORN - IGNITION 44-1.0 DK GRN - LT SW RHEOSTAT
-141-1.0 BRN/WHT 40-1.0 ORN - TAIL LAMPS
K l'
TA IL L P S
£ INJ3 KHTR] K l
A C C -R A D IO 4-5.0 BRN - IGN SW 481-1.0 RED - INJECTORS

30A~1 93-3.0 WHT - WINDSHIELD WIPER 140-1.0 ORN - STOP LAMP SW - HAZ FLSHR
B“ ] K l
S T O P -H A Z E C M -C R N K
DW IPd
AUX ER 76-3.0 PNK - AUXILIARY 439-1.0 PNK/BLK - ECM (FUSED)
20A
o ALT
0C R N K0 16-.? PPL - TURN SIGNAL SW
3-5.0 PNK - IGN SW - ENG IGN
75-.8 DK BLU - BACK-UP LAMP SW
39-.8 PNK/BLK - INSTRUMENT CLUSTER
K ]
TURNm i
□ □
FU S/PLR
3-5.0 PNK - IGNITION
39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

FRONT
12034359 - BLOCK MOLD
12089776 - PRINTED BLOCK

-38-.8 DK BLU - TURN SIGNAL

MALE CONN FU SE FU SE COLO R HOT D E S C R IP T IO N FU SE FU SE COLOR HOT

COLOR
L O C A T IO N P A R T NO. AND C O N D IT IO N L O C A T IO N P A R T NO. AND C O N D IT IO N D E S C R IP T IO N
A BRN 12004887 AM PERE AM PERE

B BLK 12004886 A C C - R A D IO 12004007 RED H O T IN A C C R A D IO A C C E S S O R IE S HTR 12004010 W H IT E H O T IN H EATER

10 A M P O R RUN 25 A M P RUN
H GRN 12004885
ALT 12004009 YELLO W H O T IN R U N ALTERNATO R IN J 12004006 BRN HO T IN R U N IN J E C T O R S
1 NAT 12004888 20 A M P O R START 7.5 A M P O R START
L BLU 12004884 AUX C IR C U IT GRN H O T IN R U N B O D Y B U IL D E R IN S T R -L P S 12004005 TA N H O T W/ H E A D L A M P IN IN S T R U M E N T P A N E L L A M P S
BREAKER 30 A M P O R STA RT IN S T A L L E D A C C E S S O R IE S 5 AMP PARK O R HEAD

E C M -B A T 12004007 RED HO T AT E L E C T R O N IC C O N T R O L M O D U L E S T O P -H A Z 12004008 LT B L U E H O T AT STOP LAM PS

10 A M P A L L T IM E S 15 A M P A L L T IM E S HAZARD FLA SH ER
E C M -C R N K 12004007 RED H O T IN R U N E L E C T R O N IC C O N T R O L PW R C IR C U IT GRN H O T AT B O D Y B U IL D E R
10 A M P O R STA RT M O D U L E IG N IT IO N 1 BREAKER 30 A M P A L L T IM E S IN S T A L L E D A C C E S S O R IE S
G AUGES 12004009 YELLO W H O T IN P R O V IS IO N S F O R G A G E S T A IL L P S 12004009 YELLO W H O T AT TA IL L A M P S
20 A M P RUN 20 A M P A L L T IM E S
H O R N -D M 12004008 LT B L U E H O T AT P R O V IS IO N S F O R TRANS 12004007 RED HOT IN R U N T R A N S M IS S IO N
15 A M P A L L T IM E S HORN AND DOME LAM PS 10 A M P O R ST A R T

TURN-B/U 12004008 LT B L U E HOT IN R U N T U R N S IG N A L S

15 A M P O R START B A C K -U P L A M P S

W IP E R 12004010 W H IT E HO T IN W IN D S H IE L D W IP E R S
25 A M P A CC O R RUN

C-8 FUSE BLOCK

GASOLINE ENGINE
 8-1.0 G RA-
n I—

x c >
□
iT A 0 [L ]P tD ® □

□ b

0 W i i m ® □

[§] @] □ 240-1.0 ORN - HORN RLY - DOME LAMP

0 m □ □
ACC IG N HTR PW R SHUNT 12041235
° 1
IshV n t ] | 30A | 8-.8 GRA - INSTRUMENT LAMPS
II n r s i 8-1.0 G R A ---------------------------------------------
G AUG ES

K l E l
HORN/DM INSTR-LPS
KTRANSl ECM-BAT 44-1.0 DK GRN - LT SW RHEOSTAT

K ]
TAIL LPS
□ 0 [jd
INJ
25A
HTR
D 3
ACC-RADIO
40-1.0 ORN - TAIL LAMPS

30A 140-1.0 ORN - STOP LAMP SW - HAZ FLSHR

u§]
STOP-HAZ ECM-CRNK AUX
DWIPER
§] '439-1.0 PNK/BLK - ECM (FUSED)

ALT CRNK 3-5.0 PNK - IGN SW - ENG IGN

39-.8 PNK/BLK - INSTRUMENT CLUSTER
D d
TURN-B7U FUS/PLR
□ □ 39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID

FRONT
12034359 - BLOCK MOLD
12089776 - PRINTED BLOCK

38-.8 DK BLU - TURN SIGNAL-

COLOR MALE CONN FUSE FUSE COLOR HOT DESCRIPTION FUSE FUSE COLOR HOT
LOCATION PART NO. AND CONDITION LOCATION PART NO. AND CONDITION DESCRIPTION
A BRN 12004887 AMPERE AMPERE
B BLK 12004886 ACC-RADIO 12004007 RED HOT IN ACC RADIO ACCESSORIES HTR 12004010 WHITE HOT IN HEATER
10 AMP OR RUN 25 AMP RUN
H GRN 12004885
ALT 12004009 YELLOW HOT IN RUN ALTERNATOR INSTR-LPS 12004005 TAN HOT W/ HEADLAMP IN INSTRUMENT PANEL LAMPS
1 NAT 12004888 20 AMP OR START 5 AMP PARK OR HEAD
L BLU 12004884 AUX CIRCUIT GRN HOT IN RUN BODY BUILDER STOP-HAZ 12004008 LT BLUE HOT AT STOP LAMPS
BREAKER 30 AMP OR START INSTALLED ACCESSORIES 15 AMP ALL TIMES HAZARD FLASHER
ECM-BAT 12004007 RED HOT AT ELECTRONIC CONTROL MODULE PWR CIRCUIT GRN HOT AT BODY BUILDER
10 AMP ALL TIMES BREAKER 30 AMP ALL TIMES INSTALLED ACCESSORIES
ECM-CRNK 12004007 RED HOT IN RUN ELECTRONIC CONTROL TAIL LPS 12004009 YELLOW HOT AT TAIL LAMPS
10 AMP OR START MODULE IGNITION 1 20 AMP ALL TIMES
GAUGES 12004009 YELLOW HOT IN PROVISIONS FOR GAGES TRANS 12004007 RED HOT IN RUN TRANSMISSION
20 AMP RUN 10 AMP OR START
HORN-DM 12004008 LT BLUE HOT AT PROVISIONS FOR TURN-B/U 12004008 LT BLUE HOT IN RUN TURN SIGNALS
15 AMP ALL TIMES HORN AND DOME LAMPS 15 AMP OR START BACK-UP LAMPS
WIPER 12004010 WHITE HOT IN WINDSHIELD WIPERS
25 AMP ACC OR RUN

FUSE BLOCK C-9

DIESEL ENGINE
 LAMP BULB DATA

AC Type Guide Lamps are recommended when replacement becomes necessary.

Lamp Usage Quantity Trade Power Rating

No. at 12V, Watts
Headlamp1 2 6014 50/60 W
Candle Power
Park and Signal Lamp2 2 2057 32-2
Tail and Stoplamp3 (Union City Body Co.) 2 1157 32-3
Tail and Stoplamp2 (Except Union City Body Co.) 2 2057 32-2
Front Side Marker Lamp 2 194 2
Rear Side Marker Lamp 2 194 2
License Lamp 2 67 4
Backup Lamp4 — — —

Instrument Cluster Illumination Lamp 6 PC194 2

Turn Signal Indicator Lamp 2 PC194 2
Headlamp High Beam Indicator Lamp 1 PC74 .7
Service Brake Warning Indicator Lamp 1 PC74 .7
Park Brake Warning Indicator Lamp 1 PC74 .7
Transmission Control Illumination Lamp 1 73 .3
Low Coolant Indicator Lamp5 1 PC74 .7
Glow Plug Indicator Lamp5 1 PC74 .7
Water in Fuel Indicator Lamp5 1 PC74 .7
Service Engine Soon Indicator Lamp 1 PC74 .7
Trans Indicator Lamp5 1 PC74 .7
Fasten Safety Belts Indicator Lamp6 1 PC74 .7
Door Ajar Indicator Lamp 1 PC74 .7
Daytime Running Lights Indicator Lamp7 1 PC118 .7

1. Double filament sealed beam: 50W low beam, 60W high beam.
2. Double filament lamp: 32 CP high, 2 CP low.
3. Double filament lamp: 32 CP high, 3 CP low.
4. Refer to body manufacturer’s specifications.
5. Diesel only.
6. When used by body manufacturer.
7. Canada only.

C-10 LAMP BULB DATA

 RPO CODES

T61 - CANADIAN DAYTIME RUNNING LAMPS

p
A 2 1150 I 240 11111 I I 4 3 9 1 17 I 2 H l/P
B 3 16 350| | 14 2 0 1440 592 J
C 140 15 120 -J /~N L 593 11 K
D 9 508 33 68 250 419 L .481 W /G ASOLINE
E 35 8 397 ^ w n 10 505 M
S113 ^ A/C COMPRESSOR PCM I 413-. 8 TAN I F 1300 30 I 50 I I 19011 93 75 N'■10 W /D IESEL

CO
CM
(SEE PAGE 50) (SEE PAGE 34) _ __ G 39 11234 31 | 59 | 50 | | 14 4 P
12015964
PCM
1454-.8 BLK/WHT I 1 2 3 4 5 10 9 8 7 6
J — N J--------
(SEE PAGE 34)
COOLING FAN ALDL ■ 450-.8 BLK/WHT )
PRESSURE SWITCH (SEE PAGES 35, 37)
(SEE PAGE 49) PCM ■ 450-.8 BLK/WHT I
(SEE PAGE 34) DIESEL ONLY
G ASO LINE ONLY | -G A j ? LINE ONLY

,481 W /G ASOLINE

“ 10 W /D IESEL

----------------1 l/P CLUSTER

S 112
rrs::: /ti ■ 150-1.0 BLK
(SEE PAGE 56)

PANEL DIMMER 150-3.0 BLK

SWITCH
1 (SEE PAGE 58)

GT 100 CD
CO
CD
CO
DRL MODULE
12085003 (UPPER) (T61 ONLY
12085002 (LOWER) (SEE PAGE 18)

WIPER SWITCH L _____- « DRL RELAY

(SEE PAGE 28) (T61 ONLY)
(SEE PAGE 18)

DRAC
(SEE PAGE 42)

ENGINE ENGINE ALTERNATOR l/P FRAME

GROUND GROUND BRACKET GROUND GROUND
G102 G100 GROUND G200 G400
G103

GROUND DISTRIBUTION C-11

GASOLINE ENGINE
 150-.8 BLK ^ ALDL
(SEE PAGE 41)

DRAC
150-.8 BLK I
(SEE PAGE 42)

WIPER SWITCH
(SEE PAGE 28)

GLOW PLUG PANEL DIMMER

DRL RELAY
1150-.8 BLK I CONTROLLER
(SEE PAGE 18)
(SEE PAGE 47)

GT100
WATER IN FUEL 12085003
1150-. 8 BLK I SENSOR (UPPER)
(SEE PAGE 47) 12085002
(LOWER)

1150-.8 BLK I

EF71

150-.8 BLK
1150-.8 BLK I

FUEL
HEATER p i i —. i i r\
(SEE PAGE 47) A 2 115 0 I 240 11111 | J439 i 1 7 I 2 H l/P
B 3 I 16 |350| | | 14 2 0 1440 592 J
C 140 15 120 593 11 K
- J L _
D 9 508 33 68 250 419 L .481 W /G ASOLINE
E 35 8 397 ^ ^ 10 505 M
F 1300 30 | 50 | | {901| 93 75 N | ■10 W /DIESEL
551-1.0 TAN/WHT G 39 1234 3 1 1 59 | 50 | | | 824) 14 4 P
12015964
TCM 1 2 3 4 5 10 9 8 7 6
------- v --------
(SEE PAGE 41) I 450-1.0 BLK/WHT r
DIESEL ONLY
G ASO LINE ONLY | GASO LINE ONLY
2
£ 1 2 3 4 i 5
ENGINE
G 3 9 | 1234 311^591501 , |824| 14
481 W /G ASOLINE
F 30 P 50

I
E 35 I I 10. ■■*1iA
D ,-----^ Z Z 1 > 8 250 419 L
O 10 W /D IESEL
C 140 "T T 593 11 K
B 16 I3 5 0 f |420| 440 | 592 J
2 ^ 150 I 24011111, t 4 3 9 1 17 I 2 H

G ASO LINE ONLY DIESEL ONLY

9*
G109
G101 SHEET G108 G200
ENGINE METAL ENGINE
GROUND O GROUND l/p
GROUND GROUND

C-12 GROUND DISTRIBUTION

DIESEL ENGINE
CIRCUIT OPERATION HIGH BEAM LAMP(S) DO NOT OPERATE
TEST RESULT ACTION
Voltage is applied to the Light Switch at all times. current flow, the Circuit Breaker cools off and resets Test lamp does not light. GO to step 2.
1. Place light switch to ON and
The Light Switch includes a Self-Resetting Circuit automatically. When the Light Switch is in HEAD, the headlamp dimmer switch to HIGH
Breaker. The Circuit Breaker opens when the Headlamp Headlamp Dimmer Switch directs voltage to either the BEAM position. Connect a test Test lamp lights. ISOLATE problem in body builder’s
circuit draws too much current. When the Circuit Low Beams or the High Beams. The Hi Beam Indicator lamp from LT GRN (1.1) wire at installed wiring.
Breaker opens, it interrupts the current flow. With no also receives voltage along with the High Beams. connector C101 to ground.
2. Place headlamp dimmer switch in Test lamp does not light. GO to step 3.
HIGH BEAM position. Connect a
DIAGNOSIS - HEADLAMPS test lamp from LT GRN (11) wire Test lamp lights. LOCATE and REPAIR open in LT
at headlamp dimmer switch GRN (11) wire from headlamp
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS - BOTH SIDES connector C215 to ground. dimmer switch connector C215 to
connector C101.
TEST RESULT ACTION
3. Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL
1. Connect a test lamp from RED (2) Test lamp lights. GO to step 2.
wire at headlamp dimmer switch (10) wire at headlamp dimmer
wire at light switch connector
connector C215 to ground. switch connector C215 to light
C202 to ground. Test lamp does not light. LOCATE and REPAIR open in RED
switch connector C202.
(2) wire from light switch connector
C202 to battery junction block.
Test lamp lights. REPLACE headlamp dimmer
2. With the light switch on and the Test lamp lights. GO to step 3. switch.
headlamp dimmer switch to HIGH
BEAM, connect a test lamp from Test lamp does not light. REPLACE light switch.
YEL (10) wire at light switch
connector C202 to ground.
3. Connect a test lamp from LT GRN Test lamp lights. REPAIR open LT GRN (11) wire
(11) wire at headlamp dimmer from headlamp dimmer switch
switch connector C215 to ground. connector C215 to connector
C101.

Test lamp does not light. REPLACE headlamp dimmer

switch.

LOW BEAM LAMP(S) DO NOT OPERATE

TEST RESULT ACTION

1. Turn the light switch to ON and Test lamp does not light. GO to step 2.
headlamp dimmer switch to LOW
BEAM position. Connect a test Test lamp lights. ISOLATE problem in body builder’s
lamp from TAN (12) wire at installed wiring.
connector C101 to ground.
2. Connect a test lamp from TAN Test lamp does not light. GO to step 3.
(12) wire at headlamp dimmer
switch connector C215 to ground. Test lamp lights. LOCATE and REPAIR open in TAN
(12) wire from headlamp dimmer
switch connector C215 to
connector C101.

3. Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL
wire at headlamp dimmer switch (10) wire from headlamp dimmer
connector C215 to ground. switch connector C215 to light
switch connector C202.

Test lamp lights. REPLACE headlamp dimmer

switch.

HEADLAMPS C-13
BASE
 RH
SIDE MARKER
LAMP

HORN

u C137
12004267

1 15-.5 DK BLU

• S121

I 11-1.0 LTGRN

S122

LH
HIGH-LOW
HEADLAMP
NOTE: THIS H A R N E SS IS
SHIPPED ALONG WITH THE
VEHICLE AND IS INSTALLED
BY THE BODY BUILDER.

LH
SIDE MARKER SHEET
LAMP METAL FRAME
GROUND Q j GROUND

G105 G104
G107 G106

C-14 FORWARD LAMP HARNESS

 BATTERY JUNCTION
C101
BLOCK 12059472

FORWARD
LAMP
9 0 0 0 o y HARNESS

REAR LAMP
HARNESS
(SEE PAGE 62)

I 111-1.0 LT GRN I l/P CLUSTER

(SEE PAGE 56)

I 11-1.0 LT GRN ■ ■ ■
C203
14(M 15 120 _ J ^ L_ 593 12020030
11T
9 # 5 0 8 33
35 [ 8 397 ^
— n O
^
68 250 419
10 505 A W /G ASOLINE

10 W /DIESEL
PANEL DIMMER SWITCH
39 11234 3 1 1 59 j 50 | [82 4 j 14
2015964
5 10

DIESEL ONLY
G ASO LINE ONLY | ^GASO LINE ONLY

ENGINE
9 I 50 |
50 |
T \ i 824i 14 481 W /G AS O U N E
150- ■ 156
I I I P . 505L 3 DOME
2
o —1
-
use 10 W /D IESEL
1 [59 iil OFF
3 | 16 13501 |4 2 0 |440 m
150 I 2 4 0 11 T l]/ 1439) 1 7 j 12015113 CIRCUIT »PARK

HEADLAMP G ASO LINE ONLY DIESEL ONLY

I BREAKER
25 AMP

DIMMER HEAD
SWITCH I 10-1.0 YEL I OFF
LIGHT 'PARK
I 11-1.0 LT GRN I SWITCH 40'
HEAD

LIGHT
SWITCH

HEADLAMPS C-15
BASE
CIRCUIT OPERATION LOW BEAM LAMP(S) DO NOT OPERATE
TEST RESULT ACTION
CANADIAN DAYTIME RUNNING LAMPS 1. Turn light switch ON and Test lamp does not light. GO to step 4.
Battery voltage is applied to the Daytime Running Relay. When energized, the DRL Relay disconnects the
headlamp dimmer switch to LOW
Lamps (DRL) Relay Switch at all times through the BRN DK BLU/WHT (593) wire from ground and internally BEAM position. Connect a test Test lamp lights. GO to step 2.
(50) wire and the HTR fuse. connects it to the ORN (240) wire, causing it to be 12 lamp from TAN (12) wire at
volts. connector C101 to ground.
With the Headlamps on, the DRL Relay is not
energized and the LT BLU/ORN (593) wire is grounded The DK BLU/WHT (593) wire feeds the LH High 2. Connect a test lamp from DK Test lamp does not light. LOCATE and REPAIR open in DK
to BLK (150) wire inside of the relay. This serves as Beams which are connected in series to the RH BLK/WHT (593) wire at DRL relay BLU/WHT (593) wire at connector
Headlamp through the LT GRN (11) wire. Grounding of connector C208 to ground. C101 to DRL relay connector
ground for the LH Headlamp.
the entire DRL circuit is accomplished through the BLK C208.
With Ignition in RUN, headlamps off and Park Brake (151) wire at the RH Headlamp. This result in High
Test lamp lights. GO to step 3.
released, the DRL Module applies battery voltage to the Beam headlamps that are less intense for daytime
LT GRN/BLK (592) wire. This action illuminates the DRL driving and should provide longer service. 3. Connect a test lamp from BLK Test lamp does not light. REPLACE DRL relay.
Indicator in the Instrument Panel and energizes the DRL (150) wire at DRL relay connector
C208 to ground. Test lamp lights. LOCATE and REPAIR open in BLK
(150) wire from DRL relay
connector C208 to ground G200.
DIAGNOSIS - HEADLAMPS
(WITH DRL) 4. Connect a test lamp from TAN Test lamp does not light. GO to step 5.
(12) wire at headlamp dimmer
switch connector C215 to ground. Test lamp lights. LOCATE and REPAIR open in TAN
PRELIMINARY CHECKS: (12) wire from headlamp dimmer
Before checking the DRL system, do the following: HIGH BEAM LAMP(S) DO NOT OPERATE test switch connector C215 to
1. Place Park Brake in the OFF position. procedures. connector C101. If no open is
2. Place Light Switch to ON and Headlamp Dimmer If the High Beam Lamp(s) are operative, use the found, ISOLATE problem in body
Switch to HIGH BEAM position. following diagnostic procedures, after placing the builder’s installed wiring.
If the High Beam Lamp(s) are inoperative, refer to the Light Switch to OFF position. 5. Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL
wire at headlamp dimmer switch (10) wire from headlamp dimmer
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS - BOTH SIDES connector C215 to ground. switch connector C215 to light
switch connector C202.
TEST RESULT ACTION
Test lamp lights. REPLACE headlamp dimmer
1. Connect a test lamp from RED (2) Test lamp lights. GO to step 2.
switch.
wire at light switch connector
C202 to ground. Test lamp does not light. LOCATE and REPAIR open in RED
(2) wire from light switch connector
C202 to fuse block.

2. With the light switch on and the Test lamp lights. GO to step 3.
headlamp dimmer switch to HIGH
BEAM. Connect a test lamp from Test lamp does not light. REPLACE light switch.
YEL (10) wire at light switch
connector C202 to ground.

3. Connect a test lamp from LT GRN Test lamp lights. REPAIR open in LT GRN (11) wire
(11) wire at headlamp dimmer from headlamp dimmer switch
switch connector C215 to ground. connector C215 to connector
C101.

Test lamp does not light. REPLACE headlamp dimmer

switch.

C-16 HEADLAMPS
W/DRL
 LOW BEAM LAMP(S) DO NOT OPERATE CANADIAN DAYTIME RUNNING LAMPC I NOT OPERATE
TEST RESULT ACTION TEST RESULT ACTION

Turn light switch ON and Test lamp does not light. GO to step 4. 1 With ignition in RUN, headlamps Test lamp does not light LOCATE and REPAIR open in ORN
headlamp dimmer switch to LOW off and park brake released, (240) wire between DRL relay
BEAM position. Connect a test Test lamp lights. GO to step 2. connect a test lamp from ORN connector C208 and fuse block or
iamp from TAN (12) wire at (240) wire at DRL relay connector REPLACE HORN/DM fuse.
connector C101 to ground. C208 to ground.
Test lamp lights. GO to step 2.
Connect a test lamp from DK Test lamp does not light. LOCATE and REPAIR open in DK
BLK/WHT (593) wire at DRL relay BLU/WHT (593) wire at connector 2, Connect J 34029-A Multimeter Battery voltage at only one LOCATE and REPAIR open in BRN
connector C208 to ground. C101 to DRL relay connector from BRN (50) wire at DRL module connector. (50) wire between splice S211 and
C208. connector C217 and DRL relay connector with missing voltage.
connector C208 to ground.
Test lamp lights. GO to step 3. Measure voltage. No battery voltage at eithc LOCATE and REPAIR open in BRN
connector. (50) wire between splice S211 and
Connect a test lamp from BLK Test lamp does not light. REPLACE DRL relay. fuse block or REPLACE HTR fuse.
(150) wire at DRL relay connector
C208 to ground. Test lamp lights. LOCATE and REPAIR open in BLK Battery voltage at both GO to step 3.
(150) wire from DRL relay connectors.
connector C208 to ground G200.
3. Connect J 34029-A Multimeter No voltage. LOCATE and REPAIR open in BLK
Connect a test lamp from TAN Test lamp does not light. GO to step 5. from BRN (50) wire at DRL module (150) wire between suspect
(12) wire at headlamp dimmer connector C217 and DRL relay connector and ground G102 or
switch connector C215 to ground. Test lamp lights. LOCATE and REPAIR open in TAN connector C208 to BLK (150) wire G200.
(12) wire from headlamp dimmer at each component connector.
switch connector C215 to Measure voltage. Battery voltage. GO to step 4.
connector C101. If no open is
found, ISOLATE problem in body 4 Connect J 34029-A Multimeter No voltage. LOCATE and REPAIR open in LT
builder’s installed wiring. from LT GRN/BLK (592) wire at GRN/BLK (592) wire between DRL
DRL relay connector C20§ to relay connector C208 and DRL
Connect a test lamp from YEL (10) Test lamp does not light. LOCATE and REPAIR open in YEL ground. Measure voltage. module connector C217. If no
wire at headlamp dimmer switch (10) wire from headlamp dimmer open is found, REPLACE DRL
connector C215 to ground. switch connector C215 to light module.
switch connector C202.
Battery voltage. GO to step 5.
Test lamp lights. REPLACE headlamp dimmer
switch. 5 Connect a test lamp from DK Test lamp does not light LOCATE and REPAIR open in DK
BLU/WHT (593) wire at connector BLU/WHT (593) wire between DRL
C101. relay connector C208 and
connector C101. If no open is
found, ISOLATE problem in body
builder’s installed wiring.

Test lamp lights. DRL are operating.

HEADLAMPS C -1 7
W/DRL
 BATTERY y W M A /W W v / V A A M /W W V W 'M
< HOT A T A L L TIMES C < HOT IN START OR RUN Z
JUNCTION
>vWVVWVVV\N W /M A M W V W 'C
BLOCK
15528797
HTR
25 AMP
~
. . . ._ _ _ _ _ _ _ _• 50·2.0 BRN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _•

o o o o
~.2.1.0RST
~ (FUSIBLE LINK)

. ._ _. . . . . ._ _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240.1.00RN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .

• S100

I
0
w
a:
0
Iri •
l>ClJocm."c;>
_ _ _ _ _ _ _ _ _ _ _ 2-5.0 REO _ _ _ _ _ _ _ _ _ _ _~N eN CQ ~ ~ i .....

~~Q~Lj~------- 2·3.0 RED _ _ _ _ _ _ _ _. , .

'" U;~Q)~NN
• _________________ °WNt1~www
:g 0t- ... ~~
...L .....
(II 0) ~t:-:- 0

~~l.o-
~
~~SL~LINE ~~-----. 24O·1.00RN _ _ _ _ _ _ _ ~
I
. . . . . . . . . 11·1.0LTGRN _ . . . . . . . . . . . . 1 . ._ _ _ _ _ _ l"'.OLTGRN . . . . . . . . . . . ._ 1_
)"1
:111
GASOLINE ONLY !:::::::.
",1$ '"
0
'-:: :g1-
en
f- DIESEL ONLY
"""11_ _ _ _ _. . 24O.1.00RN -.J
_1 ......._ .. 50·3.0 BRN -----~~~~y~~;:~t GASOLINE - ....- _ _ _ _ 50.3.0BRN _ _ _ _ _ _ __
DIESEL ONLY 0 I,.. ONLY
r
,/~
, ,_ _ 10·1.0YEL _ ..._ _ _ _ 10·1.0YEL _ _ _ _ .1 ____ .1_
f- _ 593·.8 DK BLU/WHT ....
I--' - 593-.8 DK BLU/WHT _ ...
- .... ....- --....-...
1

_:=-
_ 33-.5 TAN/WHT _ ....-... _ ...~

: ~f i ,,~;7=~ ..-__.. 150.1.0BLK. . . . . . . . . . . . _1··S2.1.S_ _ _ _.11•.1•.0LTGRN ENG

12015113
:......_ _ _ 10-1.0YEL _ _ _ _ _ _ _ __

~ I 1_________ l 1 . 0 L T G R N - - - - - - -. . . . .

, ~ , ffi ,
, ,~
I
'" S112 •

1_._ . .
(SEE PAGE 11) q •
- . _. ._ _ _ _ 150.2.0BLK-, L,. _ _ _ .. 592.. 8LTGRN/BLK _ _ _......

......+~ ................................ _12 •. 8TAN _ _ _ _ _ _ _ _ _ _ _ _ _ _

• ~ _ _ _ _. . . ._ _ _ _ • _ _ _ _ _ _ _ _ _ _ _ _ _ _ 12•. 8TAN _ _ _ _ _.........

i ..___________________~I~------.I-,-
, ,
S204 • _______ •
,_____________________ ::::::~:~R.N
_ _ _ _.150•. 8BLK . ._ _ _ _ _ _ _ _ _. .
_ _ _ _ _ _ _. :

(SEE PAGE 11) • •

, ~,- , -_ _ _• 50-3.0BRN _ _ _. .

'"
... 593-.8 DK BLU/wHTr
- 0

0 l.QJ
~Oh
~
m Cl0l

,""Mn
,

• r11 24O.1.00RN

24O•2.0 0RN
~
HORN RELAY
(SEE PAGE 26)
'" 592-.8LTGRN/BLK C208
12052287
2 4 0 + - -_ _-,

50 ....._ _--.
12-.8 TAN
G102 /~rr~I?~r'~ ........J
-
til t- :: • . . . . 24O-1.00RN _ . 240-1.0 ORN _ _. . . ._ . ._ _ 593
l>
ENGINE S214
o GROUND , (SEE PAGE 18)
DRL
592

FORWARD LAMP
-- _ ....-... _ _ _ 593-.8DKBLU/WHT _ _ _ _ _
RELAY
150-+-----....

• _ _ _ _ _ _ _ 11-1.0 LT GRN _ _ _ _ _ _ _. .
HARNESS

C-18 HEADLAMPS
W/DRL
 l/P CLUSTER
CONNECTOR
(SEE PAGE 55)

DOME LAMP DRL

(SEE PAGE 59)
MODULE

I 2*3.0 RED i

I 240-1.0 ORN I

I 50-3.0 BRN I

I 33-. 5 TAN/WHT I

110-1.0 YEL I

' 593-.S DK BLU/WHT ,

i n - 1.0 l t g r n m am

* 592-.0 LT GRN/BLKI

1 12-.8 TAN |

LIGHT
SWITCH
LIGHT
SWITCH

l/P GROUND
IQ) G200

HEADLAMPS C-19,
W/DRL |
 0
RH
SIDE MARKER
LAMP

151
HORN
12077765
11-1.0 LT G R N *

RH
C137
HIGH-LOW 12004267
HEADLAMP 12-.8 TAN I ID
_J
CO
*

15-.8 DK BLU * ■ 15-.5 DK BLU

■ 29-1.0 DK GRN

RH PARK AND
TURN LAMP ,• S121

593-.S DK BLU/WHT

14-.5 LT BLU

I1 2 -.8 TAN

■ 9-.8 BRN

LH PARK AND I 11-1.0 LTG RN

TURN LAMP
S122

11-1.0 LT GRN |

12-.8 TAN
LH
HIGH-LOW
HEADLAMP NOTE: THIS HARNESS IS
593-.8 DK BLU/WHT 151-3.0 BLK
SHIPPED ALONG WITH THE
VEHICLE AND IS INSTALLED
BY THE BODY BUILDER.
14 L
LH G105
SHEET G104

0
SIDE MARKER
METAL FRAME
LAMP
GROUND Q ) GROUND

C141
12077765

C-20 FORWARD LAMP HARNESS

W/DRL
 SIDE MARKER LAMP(S) DO NOT OPERATE
CIRCUIT OPERATION
TEST RESULT ACTION
PARK AND MARKER LAMPS 1. Place light switch in PARK Test lamp lights. ISOLATE problem in body builder’s
Voltage is applied through the TAIL LPS Fuse to the Turn Lamps and both Turn Indicators flash on and off. position. Connect a test lamp from installed wiring.
Light Switch at all times. With the Light Switch in PARK BRN (9) wire at connector C101 to
or HEAD, voltage is applied to the Park, Tail, Marker, and The Front Marker Lamps flash in HAZARD FLASH just ground. (See page 15 for wiring of Test lamp does not light. LOCATE and REPAIR open in BRN
License Lamps. The Front Marker Lamps are grounded as they did in TURN RIGHT and TURN LEFT, if the Lamp marker lamp circuit.) (9) wire from connector C101 to
through the LH and RH Park and Turn Lamps. switch is in OFF, they flash on when the Hazard Lamps light switch connector C202.
are on. If the Lamp Switch is in either PARK or HEAD,
HAZARD LAMPS they flash on when the Hazard Lamps are off, and off
Voltage is applied at all times through the STOP-HAZ when the Hazard Lamps are on. HAZARD SIGNAL LAMPS DO NOT OPERATE
Fuse and the Hazard Flasher to the normally open
In HAZARD, the circuit is always open, and the TEST RESULT ACTION
contact of the Hazard Switch in the Turn Signal Switch.
With the Hazard Switch in HAZARD FLASH, voltage is Hazard Flasher Controls the Lamps. 1. Place ignition switch in RUN and Turn signal lights operate. GO to step 2.
applied to both Front and Rear Turn Lamps. All of the position turn signal lamps as if
making a turn. Turn signal lights do not operate. REFER to "Turn Signals Do Not
Work On One Side" symptom.
DIAGNOSIS - PARK, MARKER AND HAZARD LAMPS
2. Turn off turn signal lamps and put Test lamp lights. REPLACE turn signal switch.
hazard warning lamps ON.
Connect a test lamp from BRN Test lamp does not light. CHECK condition of STOP/HAZ
PRELIMINARY CHECKS: (27) wire at turn signal switch fuse and for an open in ORN (140)
If only one lamp is inoperative, inspect wire(s) to connector C211 to ground. wire and BRN (27) wire. If fuse and
affected lamp socket, check bulb-to-socket fit or replace wiring are good, REPLACE hazard
bulb. flasher.

PARK LAMPS DO NOT OPERATE

TEST RESULT ACTION

1. Place light switch in PARK Test lamp lights. GO to step 3.

position. Connect a test lamp from
ORN (40) wire at light switch Test lamp does not light. GO to step 2.
connector C202 to ground. (See
page 15 for wiring of park lamp
circuit)

2. Connect a test lamp from RED (2) Test lamp lights. CHECK condition of TAIL LPS fuse.
wire at fuse block to ground. If fuse is good, LOCATE and
REPAIR open in ORN (40) wire.

Test lamp does not light. LOCATE and REPAIR open in RED
(2) wire from fuse block to battery
junction block.

3. Connect a test lamp from BRN (9) Test lamp lights. GO to step 4.
wire at light switch connector
C202 to ground. Test lamp does not light. REPLACE light switch.

4. Connect a test lamp at BRN (9) Test lamp lights. ISOLATE problem in body builder’s
wire at connector C101 to ground. installed wiring.

Test lamp does not light. LOCATE and REPAIR open in BRN
(9) wire from connector C101 to
light switch connector C202.

PARK, MARKER AND HAZARD SIGNAL LAMPS C-21

 STOPLAMP
SWITCH
(CLOSES WHEN
(CLOSES WHEN
BRAKE PEDAL
BRAKE PEDAL
IS DEPRESSED)
IS DEPRESSED)

,
140
< HOT A T A L L TIMES C liP CLUSTER
m vw w w w s CONNECTOR
(SEE PAGE 55)
STOP-HAZ C218
12040744
15 AMP
C216 (STEERING COL SWITCHES)

I
17-1.0WHT
2984235

z
a: --~~~;F=n
~~rl
- - ---
0 ~ 18-1.0YEL
C!

~ ,.. 16-.8 PPL _ _ _ _~~~Iy~

P
N
M
17
19
17-1.0WHT
19-1.0 DK G RN
18-1.0YEL
.rr-I t;:
S2
a:
§
I-

~
27-1.0 BRN _ _ _~ 18
~

I•
L 16 16-.8 PPL
K 27 27-1.0 BRN
I
_ _ _ _ _ _ _ 140-.100RN _ _ _ _ _ _ _ _ 1 J 15 15-.5 DK BLU
I
I
S210

I
HORN ~,
14-.5 LT BLU ---~W:!rLJ H 14-.5 DK BLU
I
t-~c>:L
I
-
-
HAZARD G 28-.5 BLK

. ._ _ 17-1.0 WHT _ _- '

FLASHER 14-.5 LT BLU
F .8 LT GR N -
'KEvT
-s. -= ~fi!;'S
~~
C212 E
0 NORMALLY
2973385
z OPEN
a:
0
__• ___ 27-1.0 BRN
112~. SWITCHES ~
C! 12004147 12004148
6 W~--..- - . 140-1.0 OR N
;:: _ _ _ _ _ _.15-.5 DK BLU _ _ _ _ I TURN SIGNAL
. ._ _ _ _ _.14-.5 LT BLU _ _ _ _ _ _ .1 SWITCH

--- --
PRNDL LAMP
(SEE PAGE 58) .......
- - - 8-.5 GRA
p _____________________ 15-.5DKB
LU

~~~~~~~~~~~~~~-
A
B 3
1 240 111
11 350
C 140 15 120
0
439 7

5
2

11
H
1~.J.:;4""'2::J0'T'4"'4"&'~59::"'2,..l J
K
liP
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 14-.5 LTB

. ._ _ _ _ _ _ _ _ 15-.5 D( B
LU

-
---- -
-- -
D 9 508 33 ~+6:;842;11+4",1..:;9LL::..!-481 WIGASOLINE LU
E 35 8 397 I 110 5 ~ MI . ._ _ _ _ _ _ 14-.5 LT B
F 300 30 I 50 I
G 39 12341 311 59 I 50 I I
I 901 9 75 NTlO WIDIESEL
..________.1_ _ _____ 16-.8 PPL LU •

-
824 14 46 P 12015964
1 2 3 4 5 10 9 8 7
_ _ _ _ _ _.19-1.0 DK
GRN
Cl00 F
_ . _ _ _ _ _ _ _ 18-1.0 YEL

1 2
DIESEL ONLY
GASOLINE ONLy'l GAS~LlNE ONLY
3 \. 4 l5
G 39 1234 311159 50
F 300 30 50
10 '\9
I r T\
8 7
824 14
6
4
901 9:l1 75
P ENG
N 481
-- - _ _ _ _ _ _ _ 140-1.0 OR

~ 17-1.0WHT
N
E

--
E 35 8 397 -] 10 50 MIIU)W/GASOLINE
0
D 9 508 331
C 140 15 12~-
B ~5QL:::t-1
'r ---=::;Z68 25.19
5931111
420 440 IS
L
K
J
~10WIDIESEL
•
A

12015113 r

H
A r1W,ollll]1 I 439 17 2Il H 12015113
REAR LAMP
---II-

-
19-1.0 DK GRN

~ ~\ HARNESS
12020926 12020786

C400
~ w ,~ _ _ _ __ 12065158

g C . ._ _ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _ _ _ _ _ _ _ _ _. .
«
(!l 17-1.0 WHT _

. ._ _ _ _ _ 15-.5 DK BLU _ _ _ _ _•
A B
. .- - - - - - - - - - - - 15-.5 DK BLU ---------:~~iiC~D~
_ _ _ _ _ _ _ _ _ 140-1.00RN _ _ _ _ _ _ _ _ __
1- FORWARD LAMP Cl0l
• _ _ _ _ _ _ _ _ 16-.8 PPL _ _ _ _ _ _ _ _ _ _• 12059472
GT100 HARNESS
12085003 (UPPER)
12085003 (UPPER)
12085002 (LOWER)
12085002 (LOWER)

C-22 HAZARD SIGNAL LAMPS

CIRCUIT OPERATION TURN SIGNALS DO NOT OPERATE
TEST RESULT ACTION
TURN SIGNAL LAMPS 1. Place hazard warning lamps to Hazard lamps operate. GO to step 2 .
With the Ignition Switch in RUN or START, voltage is Lamp will find a path to ground through Splice S123 and ON position.
applied through the TURN/BU Fuse and Turn Flasher to the Park and Turn Lamp to ground. This Lamp provides Hazard lamps do not operate. REFER to "Hazard Lamps Do No
the normally closed contact of the Hazard Flasher Switch low resistance paths to ground. The Marker Lamps will Operate" symptom.
in the Turn Signal Switch. flash with the Turn Lamps.
2 . Connect a test lamp from PPL (16) Test lamp lights. REPLACE turn signal switch.
wire at turn signal switch
With the Turn Signal Switch in LH Turn position, When the Light Switch is in either PARK or HEAD, connector C211 to ground. Test lamp does not light. CHECK condition of TURN/BU fuse
voltage is applied to both the LH Turn Indicator and the voltage is applied through the TAIL LPS Fuse, Lamp and for an open in PPL (16) wire
LH Front Park and Turn Lamp LT BLU (14) wires. Switch, and Splice S122 to the Marker and Park Lamps. or DK BLU (38) wire. If fuse and
Voltage is applied to the LH Tail, Stop and Turn Lamp If the Turn Signal Switch is in TURN LEFT, the LH Side wiring are good, REPLACE turn
YEL (18) wire.' Marker Lamp will have voltage at both connections and signal flasher.
will go out. When the Flasher removes voltage to the
The Lamps go on immediately. They begin to flash Turn Lamp, the Marker Lamp will be grounded through
when the current flow heats up the Timing Element in the the Turn Lamp and will go on. In this way, the LH Side TURN SIGNAL LAMPS FLASH RAPIDLY
Flasher and it repeatedly opens and closes the circuit. Marker Lamp will flash on when the LH Park and Turn
TEST RESULT ACTION
Lamp goes off, and off when the Turn Lamp goes on.
The voltage applied to the LH Park and Turn Lamp 1 . Turn hazard lamp switch to ON One side of turn signal lamps REPLACE inoperative turn signal
will also be applied to the LH Side Marker Lamp. If the With the Turn Signal Switch in TURN RIGHT, voltage position. Check from turn signal flash rapidly. bulb.
Lamp Switch is in the OFF position, the LH Side Marker will be applied to the RH Lamps in the same way. lamps and rear taillamps.
Only one side of turn signals REFER to “Turn Signals Do Not
light but do not flash rapidly. Work On One Side" symptom.
DIAGNOSIS - TURN LAMPS
TURN SIGNALS DO NOT WORK ON ONE SIDE
TEST RESULT ACTION
1. Turn hazard warning system on. Lights flash. CHECK for improper bulb.
Observe lights on side of turn REPLACE if necessary.
signals that did not work.
Lights do not come on. GO to step 2.

2. Turn hazard warning system off. Test lamps lights. GO to step 4.

Place ignition switch to RUN and
turn signal to side that does not Test lamp does not light. GO to step 3.
work. Connect a test lamp from LT
BLU (14) or DK BLU (15) wire
(depending upon which side does
not work) at turn signal switch
connector C211 to ground.

3. Connect a test lamp from PPL (16) Test lamp lights. REPLACE turn signal switch.
wire at turn signal switch
connector C211 to ground. Test lamp does not light REPLACE turn signal flasher.

4. Connect a test lamp from LT BLU Test lamp lights. ISOLATE problem in body builder’s
(14) or DK BLU (15) wire installed wiring.
(depending on which side did not
work) at connector C101 to Test lamp does not light. LOCATE and REPAIR open in
ground. either LT BLU (14) or DK BLU (15)
wire(s) between turn signal switch
connector C211 and connector
C101.

TURN SIGNAL LAMPS C-23

 ~BA~ ~ I1l ~ [0 [ffi 0
L
lID lID ~ ill ~ [0 [ffi 0 liP CLUSTER
[ID[ID~D[oOD
o CONNECTOR
(SEE PAGE 55)
ACC IGN HTR PWR
C218

~DD~EJ GAUGES PWR

12040744 TURN
SIGNAL
[}DOO[}D~
HORN/OM INSTR-LPS
TRANS ECM-BAT
SWITCH
(STEERING COLUMN SWITCHES)

OODDOO~
TAIL LPS INJ HTR ACC-RADIO

1 I 00
[}§J [}§J
STOP-HAZ ECM-CRNK
30A
AUX WIPER

0000 0 ALT CRNK

T~ ~spQ
P 17-1.0WHT
19-1.0DKGRN -----~If19]iB N
M 18-1.0 YEL ------t--+---t.....
L 16-.8 PPL +-_....J
. - - -_ _

_ ....-:;:-1....., K 27-1.0 BRN

r-~-+-16 J

...J
W H
>- JIIlII'I"":::"+rr" G

L-...._+-38
p----_____________
16-.8 PPL

•
15-.5 DK BLU _ __

_ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _. .
~
F
E
D

TURN C211
FLASHER . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ 15-.5 DK BLU _ _ _ _ _ 1_ 12004147 12004148

OPEN
• _ _ _ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _ _ 1_ - SWITCHES

t-....1...f'=Cr'JlI:o'-r""2'='! H
592 J
3 11 K
0419 L
5 MI
liP

481 W/GASOLINE
15-.5 DK BLU

14-.5 LT BLU
---- PRNDLLAMP
(SEE PAGE 58) . . - 8-.5 GRA

-
75 N 10 W/DIESEL
4 P 12015964 16-.8 PPL
1 2 6

19-1.0DKGRN F
Cl00
~ 18-1.0YEL E

C
~

B
7 6
ENG

~
4 4 P .18-1.0 Y E L r
3 75 N 481 W/GASOUNE A
50 5 Mild) Cl02
~Vl0 W/DIESEL
25 0419
59 3 11 C400
12020786
42 4 o 592 12065158

r~
J "" 19-1.0 DK GRN_
439 7 2 H
L"'l
12015113
DIESEL ONLY I~ c:::s::::

L
14-.5 LT BLU _ _ _ _ _ _ _ _ _ _ _ _ _- .

J[
14-.5 LT BLU 1- - 15-.5 DK BLU _ _ _ _ _ _ _ _ _ _ _ _ _. .

GT100
• _ _ _ 15-.5 DK 12085003 (UPPER)
BLU
12085002 (LOWER)
FORWARD LAMP Cl0l
12059472
HARNESS
. ._ _ _ _ _ _ _ _ _ 16-.8 PPL

C-24 TURN SIGNAL LAMPS

CIRCUIT OPERATION
When the Horn Switch is depressed, one side of the
Horn Relay coil is grounded. The relay is energized. Its
contacts close and battery voltage is applied to the
Horns.

DIAGNOSIS - HORNS

PRELIMINARY CHECKS:
Check to see that the HORN/DM fuse is not blown.
REPLACE if blown.

HORN W ILL NOT OPERATE

TEST RESULT ACTION
1. Connect a test lamp from DK GRN Test lamp lights. ISOLATE problem in body builder’s
(29) wire at connector C101 to installed wiring.
ground. Press horn switch.
Test lamp does not light. GO to step 2 .
2. Remove horn relay. Connect a test Test lamp lights. GO to step 3.
lamp from ORN (240) wire at horn
relay connector C207 to ground. Test lamp does not light. LOCATE and REPAIR open in ORN
(240) wire between horn relay
connector C207 and fuse block or
REPLACE HORN/DM fuse
3. Reinsert horn relay. Disconnect Horn does not sound. GO to step 4.
turn signal switch connector C211.
Connect a jumper wire to BLK (28) Horn sounds. REPLACE horn switch.
wire at turn signal switch
connector C211 to ground.

4. Disconnect horn relay. Install a Horn sounds. REPLACE horn relay.

jumper wire from ORN (240)
terminal to DK GRN (29) terminal Horn does not sound. LOCATE and REPAIR open in DK
at horn relay connector C207. GRN (29) wire from horn relay
connector C207 to horn. If no
open is found, ISOLATE problem
in body builder’s installed wiring.

HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSIN G HORN SWITCH

TEST RESULT ACTION

1 . Disconnect turn signal switch Horn stops. REPLACE horn switch.

connector C211.
Horn continues to sound. GO to step 2.

2. Disconnect horn relay connector No shorts found. REPLACE relay.

C207. Check for a short to ground
in BLK (28) wire. Short(s) found. REPAIR or REPLACE as required.

HORN C-25
 y v w /w w v w
> HOT AT ALL TIMES C
> V W W V V \V \A T A

HORN/DM }
HORN
15 AMP * C 207
RELAY 12065169

2
G
C
o
17 17-1.0 WHT
I 240-1.0 ORN I PROVISIONS FOR [
DOME LAMP 19 ■ 19-1.0 D K GRN
(SEE PAGE 59) 18 „ 18-1.0 YEL
16 - 16-.8 PPL

27 ^ 27-1,0 BRN
15 15-.5 DK BLU

X - 14-.5 LT BLU
14
- 28-. 5 BLK

HAZARD
I
I
8
I
3 | 16 13 5 0 1 | | |420[ 4 4 0 ! 592 C211
140 15 120 — 593 11 12004147 12004148
L _
9 508 33 68 250 419 .481 W /G ASO LINE
— n O r—
35 8 397 ^ w 10 505
TURN
1300 30 | 50 | | |901| 93 75 10 W /D IESEL
39 11234 3 1 1 59 |
2 3
50 ] | | (8 2 4 |1 4 4 SIGNAL
5 10
■v SWITCH
12015964

prndl 8-.5 g r a
LAMP
C100
(SEE PAGE 58)

12015113

DIESEL ONLY

o
'
n==r- L 29-1.0 DK GRN
A B C D

2
G
C
O lr
FORWARD
DRL RELAY ^ ■ ■ I ^ H I 240-1.0 ORN
LAMP
(SEE PAGE 18) GT100
12085003
HARNESS
(UPPER)
240-1.0 ORN 12085002
(LOWER)
S214

C-26 HORN
CIRCUIT OPERATION WIPERS DO NOT OPERATE IN LO
TEST RESULT ACTION
WIPER Place ignition in RUN and wipers Wiper motor does not run. LOCATE and REPAIR open in GRN
The W iper Motor is supplied battery voltage with the circuit is through the PPL (92) wire, the Wiper/Washer to LO. Connect a fused jumper (91) wire between wiper motor
Ignition Switch in START or RUN, with ground supplied Switch and the BLK (150) wire to ground. from GRA (91) wire at wiper switch connector C150 and wiper switch
by the Wiper/Washer Switch. connector C207 to ground. connector C207. If no open is
WASHER found, REPLACE wiper motor.
When the Wiper Motor is in LO, battery voltage is Battery voltage is applied to the washer pump
supplied to the motor through the WHT (93) wire and the Wiper motor runs. REPLACE wiper washer switch.
through the WHT (93) wire, to the switch and to ground
ground circuit is through the GRA (91) wire. through the BLK (150) wire. The washers are operational
as long as the paddle switch on the Wiper Switch arm is
When the wiper is in HI, battery voltage is supplied to on.
the motor through the WHT (93) wire and the ground

DIAGNOSIS - WIPER/WASHER

PRELIMINARY CHECKS:
Check condition of WIPER and INST LPS fuses. If
fuses are in good condition, use the following diagnostic
procedures.

WIPERS DO NOT OPERATE IN ANY MODE

TEST RESULT ACTION

1. Place ignition in RUN and turn Test lamp does not light. LOCATE and REPAIR open in
wipers to HI. Connect a test lamp WHT (93) wire between wiper
from WHT (93) wire at wiper motor motor connector C150 and fuse
connector C150 to ground. block.

Test lamp lights. GO to step 2.

2. Connect a fused jumper from BLK Wiper motor runs. LOCATE and REPAIR open in BLK
(150) wire at wiper switch (150) wire between wiper switch
connector C207 to ground. and ground G102 (Gasoline) or
G101 (Diesel).

Wiper motor does not run. REPLACE wiper motor.

WIPERS DO NOT OPERATE IN HI

TEST RESULT ACTION

1. Place ignition in RUN and wipers Wiper motor does not run. LOCATE and REPAIR open in PPL
to HI. Connect a fused jumper (92) wire between wiper motor
from PPL (92) wire at wiper switch connector C150 and wiper switch
connector C207 to ground. connector C207. If no open is
found, REPLACE wiper motor.

Wiper motor runs. REPLACE wiper washer switch.

WINDSHIELD WIPERS/WASHERS C-27

 HOT IN A C C Y O R RUN

WIPER
25 AMP

L 93-3.0 WHT I

A 2 150 124011111 | 11 17 i 2 H l/P

B 3 i 16 1350} | | I' BOI 440 592 J
C 140 15 120 \ 1593 11 K
— ^ L _
D 9 508 33 r n ^ % 250 419 L .481 W/GASOUNE
E 35 8 397 ^ ^ n 1»505 M
F 1300 30 | 50 | | |9 0 ir 9 3 75 Nl •10 W/DIESEL
G 39 1234 31 ! 59 | 50 | | | |824f 14 4 P
1 2 3 4 5 10 9 8 7 6

12015964

C100

194*1.0 PNK I
12015113
192-1.0 PPL* WIPER MOTOR DIESEL ONLY
■97-1.0 LT BLU I (BODY BUILDER GASOUNE ONLY I GASOLINE ONLY
H \
■ 91-1.0 GRAh INSTALLED) 1 10 8 ENGINE
3911234 31 |« iT 5 0 l .. 1824114
„ 481 W/GASOLINE
35 8 397J
9 508 33
140 15 120
o
I
— —
I
I 1flW 505

Jr
419
1593 11
m> 10 W/DIESEL
A»n i
2 [150 I 240|111|/ # 3 9 1 17 I 2
GASOUNE ONLY D IE9fl ONLY

■93-3.0 WHT l
DIESEL
ONLY

|^H150-.8 BLK* ■ 15Q-.8 B LK *

• M 150-1.0 BLK 150-1.0. BLK ■

PULSE WIPER,
S112 PULSE WIPER WASHER SWITCH

I
S204
(SEE PAGE 12) CONTROL MODULE
(SEE PAGE 11) (COLUMN MOUNTED)

GT100 97
12085003
(UPPER) 1150-.8 BLKI
12085002
(LOWER)

94 T
ENGINE
GROUND B= i . J
C207
G102 (GAS) 12020492 C204
G101 (DIESEL)

C-28 WINDSHIELD WIPERS/WASHERS

CIRCUIT OPERATION ENGINE DOES NOT CRANK AND STARTER SOLENOID DOES NOT CLICK
TEST RESULT ACTION
START 1. Place transmission in PARK. Battery voltage. GO to step 2.
When the Ignition Switch is moved to the START contacts to open simultaneously. As soon as the Connect a voltmeter from PPL (6)
position, battery voltage is applied to the Starter contacts open, the starter circuit is turned off. wire at starter solenoid to ground. No voltage. GO to step 3.
Solenoid. Both solenoid windings are energized. The Turn ignition switch to START
circuit through the Pull-In Winding is completed to CHARGE position.
ground through the Starter Motor. The windings work The Generator provides voltage to operate the
2. Connect a voltmeter from PPL (6) Battery voltage. REPLACE starter solenoid.
together magnetically to pull in and hold in the Plunger. vehicle’s electrical system and to charge its Battery. A
wire to starter mounting bolts.
The Plunger moves the Shift Lever. This action causes magnetic field is created when current flows through the Less than battery voltage. CLEAN starter motor mounting
the Starter Drive Assembly to rotate as it engages the Rotor. This field rotates as the Rotor is driven by the bolts, starter motor, and mounting
Flywheel ring gear on the engine. At the same time, the engine, creating an AC voltage in the Stator windings. surface.
Plunger also closes the solenoid switch contacts in the The AC voltage is converted to DC by the rectifier bridge
Starter Solenoid. Full battery voltage is applied directly and is supplied to the electrical system at the Battery 3. With ignition switch in OFF Battery voltage. REPLACE ignition switch.
terminal. position, connect a voltmeter from
to the Starter Motor and it cranks the engine.
RED (2) wire at ignition switch No voltage. LOCATE and REPAIR open in RED
connector C200 to ground. (2) wires and fusible link between
As soon as the Solenoid Switch contacts close, ignition switch connector C200
voltage is no longer applied through the Pull-In Winding, This Generator’s regulator uses digital techniques to and battery junction block.
since battery voltage is applied to both ends of the supply to Rotor current and thereby control the output
windings. The Hold-ln Winding remains energized, and voltage. The Rotor current is proportional to t h e width of
its magnetic field is strong enough to hold the Plunger, the electrical pulses supplied to it by the Regulator. STARTER SOLENOID CL CKS, ENGINE DOES NOT CRANK OR CRANKS SLOWLY
Shift Lever, and Drive Assembly Solenoid Switch When the Ignition Switch is placed in RUN, narrow width TEST RESULT ACTION
contacts in place to continue cranking the engine. pulses are supplied to the Rotor, creating a weak
magnetic field. When the engine is started, the 1. Connect a voltmeter to positive Voltage reading greater than 9.5 GO to step 2.
When the Ignition Switch is released from the START Regulator senses Generator rotation by detecting AC and negative battery terminals. volts after 15 seconds cranking.
voltage at the Stator through an internal wire. Once the Turn ignition switch to START.
position, battery voltage is removed from the PPL (6) wire
engine is running the Regulator varies the field current Voltage less than 9.5 volts after PERFORM a Battery Load Test.
and the junction of the two windings. Voltage is applied
15 seconds cranking. Refer to Section 6D in 1991 R/V, P
from the Motor contacts through both windings to by controlling the pulse width. This regulates the
Light Truck Service Manual.
ground at the end of the Hold-ln Winding. However, the Generator output voltage for proper battery charging and
voltage applied to the Pull-In Winding is now opposing electrical system operation. 2. Connect a voltmeter from negative Less than .5 volts. GO to step 3.
the voltage applied when the winding was first energized. battery terminal to engine block.
The magnetic fields of the Pull-In and Hold-ln Windings The digital regulator controls the VOLTS Indicator light More than .5 volts. REPLACE negative battery cable.
now oppose one another. This action of the windings, with a solid-state light driver. The light driver turns on
3. Connect a voltmeter from positive Less than .5 volts. REPAIR starter motor.
with the help of the Return Spring, causes the Starter the light whenever undervoltage, overvoltage or a battery terminal to starter solenoid
Drive Assembly to disengage and Solenoid Switch stopped Generator is detected. terminal to BLK (2) wire. More than .5 volts. REPLACE positive battery cable.

DIAGNOSIS - START AND CHARGE

BATTERY IS UNDERCHARGED OR OVERCHARGED
TEST RESULT ACTION
1. Connect a voltmeter from RED (2) Battery voltage. GO to step 2.
wire at generator to ground.
No voltage. LOCATE and REPAIR open in RED
(2) wire and fusible link from
generator to battery junction block.
2. Connect generator connector Reading of 13-16 volts. PERFORM Generator Bench Test.
C105 and terminal. Have all Refer to Section 6D in 1991 R/V, P
accessories turned off and engine Light Truck Service Manual.
running at fast idle. Connect
voltmeter from battery terminal on Reading of less than or greater REPAIR generator.
generator to ground. than 13-16 volts.

STARTING/CHARGING C-29
 idd o‘Q-9
I
I
i qbu
o'9-z

ECM-BAT
1 0 AMP

------*4—X -----k-ai—■. -a
ki ■■■»■■ p*
yC I h .....L
m k. i- -a
«
i / 1„| ■
'-----J t — -a •

g s a - l

CRUISE
CONTROL
MODULE
(SEE PAGE 52)

G110
C-30 STARTING/CHARGING
GASOLINE ENGINE
 4 4 0 -.8 O R N I
„TCM
(SEE PAGE 40)

l/P CLUSTER
(SEE PAGE 56)

FUSE BLO C K
ENGINE ENGINE (SEE PAGE 4)
GROUND GROUND
LH CYLINDER RH CYLINDER
HEAD HEAD
G113 G112
STARTING/CHARGING C-31
DIESEL ENGINE
 ECM-CRNK
10 AMP I 1439-1.0 PNK/BLK

I 439-1.0 PNK/BLK

I423-.8 WHT,

I430-.8 PPiyW HT

1424-.8 TAN/W HT H --------------

■453-.S BLK/RED '
C125

12015791 12010996

P424-.8 T A N /W H T I

! L i. ^!4 2 4 -.8 TAN/W HT

-.8 W H T i I
Lr — 4 4 5 3 -.8 BLK/RED

C121
12040705 J430-.8 PPL/WHT I ^ *

1 3-5.0 PNK |

GT100
12085003
(UPPER)
wmmmm S205 I i i -
\ f (SEE PAGE 4)
DISTRIBUTOR I1 2 1 -.8 W H T |
12085002
(LOWER)

f a r jm m r ^ i 4 3 9 - . s p n k / b lk m h t

IGNITION
• i I 3-5.0 P N K i - SWITCH

SPLICE S202
(SEE PAGE 4)
(SEE PAGE 19)

■439-1.0 PNK/BLK I

-1 r-
GE] ro <o
o o
o
oo
C122 Ul
fO cn »
2977253 o
Ul (0 o
Ul
o «
£ Ul to
- (0
ti <D fo
TACHOMETER fe\r * e- I

10 W /D IE SEL 481 W /G ASOLINE

10 W /D IESEL
481 W /G ASOLINE

-32 IGNITION
CIRCUIT WIRE COLOR CAVITY . DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
465 .8 DK G RN/W HT A1 FUEL PUMP RELAY DRIVE 439 .8 PNK/BLK C1 12V IGNITION FUSED
1223 .8 YEL/BLK A2 SOLENOID B DRIVER 450 .8 BLK/WHT C2 SYSTEM GROUND
1222 .8 LTG R N A3 SOLENOID A DRIVER 551 .8 TAN/W HT C3 SYSTEM GROUND
422 .8 TAN/BLK A4 TCC DRIVER 416 .8 GRA C4 5V SENSOR REFERENCE
A5 NOT USED 417 .8 DK BLU C5 TPS
A6 NOT USED 441 .8 LT BLU/WHT C6 STEPPER COIL A HIGH
419 .8 BRN/WHT A7 SYSTEM C H EC K LAMP 442 .8 LT BLU/BLK C7 STEPPER CO IL A LOW
A8 NO T USED 444 .8 LT GRN/BLK C8 STEPPER CO IL B LOW
A9 NO T USED 443 .8 LT G RN/W HT C9 STEPPER CO IL B HIGH
A10 NOT USED 432 .8 LTG RN C10 MAP
435 .8 GRA A11 EVRV SOLENOID 1061 .8 ORN/BLK C11 SERIAL DATA
420 .8 PPL A12 BRAKE SIGNAL C12 NO T USED
NO T USED 413 .8 TAN C13 OXYGEN SENSOR GROUND
B1
1226 .8 RED B2 PRESSURE SW ITCH MANIFOLD C 412 .8 PPL C14 OXYGEN SENSOR
B3 PRESSURE SW ITCH MANIFOLD B 468 .8 DK GRN C15 INJECTOR B (2) DRIVER
1225 .8 DK BLU
B4 PRESSURE SW ITCH MANIFOLD A 467 .8 DK BLU C16 INJECTOR A (1) DRIVER
1224 .8 PNK
B5 NOT USED 440 .8 ORN D1 12V BATTERY FUSED
B6 NOT USED 455 .8 PPL D2 SENSOR GROUND
1229 .8 LT BLU/WHT B7 FORCE MOTOR LOW 452 .8 BLK D3 SENSOR GROUND
1228 .8 BLK/RED B8 FORCE M OTOR HIGH 474 .8 GRA D4 5V SENSOR REFERENCE
1230 .8 DK BLU/WHT B9 INPUT SPEED HIGH 496 .8 DK BLU D5 KNOCK SIGNAL
1231 .8 GRA/RED B10 INPUT SPEED LOW 451 .8 W HT/BLK D6 ALDL
437 .8 BRN B11 DRAC MODULE 120 .8 TAN/W HT D7 ELECTRIC FUEL PUMP FEED
59 .8 DK GRN B12 AIR CO NDITIO NING FUSED
D8 NOT USED
POWERTRAIN CONTROL MODULE CONNECTOR D9 NOT USED
D10 NO T USED
423 .8 W HT D11 HEI SPARK TIM ING
424 .8 TAN/BLK D12 HEI BYPASS
453 .8 BLK/RED D13 DISTRIBUTOR REFERENCE LOW
430 .8 PPL/WHT D14 DISTRIBUTOR REFERENCE HIGH
1227 .8 BLK/YEL D15 TRANSMISSION TEMPERATURE
410 .8 YEL D16 COOLANT TEMPERATURE

POW ERTRAIN CONTROL MODULE CO NNECTOR

POWERTRAIN CONTROL MODULE (PCM) C-33

GASOLINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
 ECM-BAT ~
ECM-CRNK'
10AMP J...
10 AMP ~.'_ _ _ _ _ _ _ _ _ _ _
439-.8 PNKlBlK

44O-.80RN
~ ~ ~ ~

I S111
(SEE
• _ PAGE
_4)
44O-.80RN

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 450-.8 BIK
.r.•.
417-.8DKBLU _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
417-.8 DK BLU
•
TP 416_-'6GRA
416-.8GRA
••
Jl
432-.8 LTGRN
SENSOR . . . . . - - - - - - - - 432-.8lTGRN - - - - - - - - - - - - - - - - - - - - - - - - - - - -
474-.8GRA - - - - - - - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
474-.8 GRA
•
[§ 452
417 C
416
I-~t__-..

Cll0
. .- - - - - - 496-.8 DK BlU - 496-.8 DK BLU
•
12078090

________ 455-.8 PPl _ _ _ _ _ _ _ _ _ _ _ _• _ _ __ S107

--:1 1
____ • _

S106
452-.8 BlK _ _ _ _ _ _ _ _ _ _ _..._ __

410-.8VEl _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
- - - - - - - 410-.8 VEL -
-------------- •

_____ r-=
- -_ _ _ _ 455-.8 BLK - - - -....

- - -_ _ _ _ 452-.8 BLK - - - -. . .~

~ ~ ..... 1227-.8 BLK/YEL ..

_ _ _ _ _ _ _ 410-.8 VEL _ _ _ _
~~

-I.~

MAP ----t- • _
_ _ _ _ _ _ _ 412-.8 PPL _ _ _ _. . . . .

1226-.8 RED •
SENSOR

ESC KNOCK
r .......... ~ ~ ~ ...-., ~ -' ~ """'" 1230-.8DKBlU/WHT . . . . . .
_ _ _ _ _ _ _ 1225-.8 DK BlU _ _ _ _....

COOLANT
TEMPERATURE
SENSOR
1tI~- 452-.8 BLK - - - - .
SENSOR
,, ,.--" - - - - --- 1231-.8 GRA/AED _
_ _ _ _ _ _ _ 1224-.8 PNK
~

•
Cl0e
12078084
496

,, . ._ _ _ 455-.8 PPl

Cl17
12015375
,,
OXYGEN
~------------412-.8 PPl _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
,,
SENSOR
,,
,,
I,
,, q

,,
!
--=
~
123o
J , -
1230
INPUT I
~
"""",,,'W_. - _ - - - - - - - - -
SPEED
SENSOR
si
~
?--------- 123
1231
B
~ _1231-.8GRA/RED _ _ _ _ _ _ _ _ _ _ _ _ ...-..
-
ENGINE ENGINE TRANSMISSION ALTERNATOR BRACKET
C173
GROUND CONNECTOR GROUND
12078084 G100 G103
C-34 POWERTRAIN CONTROL MODULE (PCM)
INPUTS - GASOLINE ENGINE
 439-.S PNK/BLK ~
. - . . . - 439-.&
• 440-.& ORN _ ,

- l- - - - - - -
,-,-
45Q-.& BLKlWHT

,-
450-.8 BLKlWHT,. - - - - - - - - - - - - 45O-.BBLKlWHT· _ _ ...,-.
... - _ _ _ _ _ _ _ _ _ _ ..-454-.&BLKlWHT _ _ ...~ 'II1II
454-.& BLKlWHT

...
454-.& BLKlWHT'" ..

417-.&DKBLU -l- GT100

120&5003
(UPPER)
417-.& OK BLU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 &DKBLU

,-,-, ...
.. _ 416-.&GRA _ . _ 120B5002 416-.& GRA 416-.&GRA
(LOWER) ,- "1-
.. ,~ 432-.&LTGRN _~_ 432-.& LTGRN 432-.& LTGRN

-l. 474-.8 GRA -

L
. . . , - 474-.8GRA

... , _ 496-.&DKBLU _ , _ 496-.& OK BLU

440
0
c ~r>J~
~ ,. .. ,. .
1
j

-- -
.455 2450,..

- -- -
452 3~"'~

, l I • 474 4~ 1-

r
496 5 417
. - 451-.&WHT/BLK _ _ _ _
. ._ _ _ _ _ 440-.& ORN _ _ _ _ _•

.........- F 451 6 00

... ,
44O-.&ORN @Q] 7 rngJ

",'_455-.BPPL _,_ 455-.8 PPL

-_ I
OB~
o
010~
9 [ffi]

-- ............................
~

~
. . , _ 452-.&BLK _ , _

----_
452-.& BLK ~1100

. . ~ _ _ 1227-.& BLK/YEL - , - . ....,. .......

1227-.& BLK/YEL ~, ..,.-~ ....... -=
~I..
.i= ~120
@§ID 13 413
@Q] 14 f.illl
~15[@

4~~~::::L ............... 1
~._41o-.&YEL_

-_... ,
-

,,'_412-.&PPL -l. 'lllll1IGIQJ 16 [§1J

~, 2:J
...

~,.
_1226-.8RED_,_ 1226-.8 RED

.............. _----- , I C250

12052177
412-.& PPL •

- ,. ~
_ 1230-.8DKBLU/WHT _ 1230-.& OK BLU/wHT .......... ~

, ,,
. ., _ '22'5-.8 OK BlU _ , . 1.225-.8 OK BLU

~ _ . - 1231-.& GRNRED . . . _
---~-- - - - - - - - ..., PCM

,
1231-.& GRNRED • - - ,

,,'_1224-.&PNK _~_ 1224-.& PNK

CONNECTORS

i r
m
413-.8 PPL E
439-.B PNK/BLK -
I_ _ _ _ _ _ 413-.& PPL

. ._ _ _ _ 440-.& ORN _ _- .

w
413-.& PPL

,.-- - '. -- _ _ _ _ _ 439-.&PNKlBLK ... ~

413-.BPPL _

44O-.BORN Z
::;

l
,
w o

I
Z

~
::;

..
0 .J
U> W
U>

~"
W
CD c::::J 1
~ '" It)
1226 2
g; ..
~
<XI
e ~
~
0
1225 3

I
,
1 24
@Q] 5
0 6

~7

---....,.--•
~ ~e
Z
o 1230
w
Z
'" ~~
~~+...:::.=--,
.Je"
w
U> A
w C251
i5 12052175
w
z
::;
o
U>
~
ALDL AIR CONDITIONING
C204 . .- - 59-.& OK GRN - - - -... -c
... (SEE PAGE 50)
12020043

POWERTRAIN CONTROL MODULE (PCM) C-35

INPUTS - GASOLINE ENGINE
 ·I-::::::::::::::::::::::::::::::::::::::::::::::::~~:~::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::---""":
~ r" ,...., ~ ,....,
~ ..." ..." ,....,,....,
439-1.0PNK/BLK ~,....,,...., ,...., ,...., , . . . . , , . . . . , . . . " , . . . . , , . . . . , . . . . . , ~ ..." -

L ----. rir..." ...". .",....,,....,

- ,...., ...,. . ,
, . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 44O-1.00RN _

,. . , ,. . , ,. . , .-., . ." 1
~

250-1.0BRN
a.
~
~
~ ~ ~
450-.8BLK/WHT ___ ,....,

A
~
~ ~
~ ~
,...., ~ ~ ...., ..."
~
_ Slll

~ -","
.... ~ 450-.8 BLK/WHTF ......
~ ,....,,...., ~ ,...., ~ .... . , IDLE AIR 442 ~ - - 442-.8DKGRN/BLK - ~ ,...." ,'~ ~ ~ ~ ..

'I. ,
• CONTROL .... ~ ... 441-.8 DK GRN/WHT ... - ~

· , , .. ..
IIiIo
. .- - - - - - - - - - - - - - 44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _. . . B ...... • ~ _ . . 439-.8 PNK/BLK . . . . . .
III ACTUATOR ,...., ... 443-.8DKBLU/WHT ~ . . " , ... ,. ...--..... •

:J =- - 44O-.80RN C

0
--- 12047951
. .- - - - - - - - - - - - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

~~
444-.8 DK BLU/BLK

~-
- - - ---

~
,
- - -
120-.8 GRA

. - 423-.8WHT
C
C

_ --,. -I ..... -
450

c
_ ,...., .....,,...., ~ -
,...., -
,...., .---
-
..... ...-.....
..."
,. ...--t . .
. . . " ,...., - - - " ' I F - - . . . . ." 424-.8TAN/WHT --C

...... ,rr ~-
.......... ,....,' ....
EVRV 435
0
- ___ ....,,....,,....,- - - -~
- ........., ....
~ ~
-I ... ,. . _ . .
~ ~
I-,~·
F , - - - 453-.8BLK/AED· ........

,-,, ' ,-, ___________________

B
43O-.8PPL/WHT ..-..c
;- - - -t:.:~:.:,.:,:..::~:,:. : ='::~~""--:
439

C120
12078082

r ·..." - .-., - . . . . - .... - 1-

'I - .... - . -..-- - .-1,....,· ...... - ~ ",F .-~ ... ~ ,...., • • •,. .... _465-.8DKGRN/WHT ..........

~
ELECTRONIC
SPARK
EST SIGNAL
423

430
~-,,..,-,-,
_
, "--1-I - - . - ......-,:,--
430-.8 PPL/WHT_ ...
.
...... ~ - • ..." ---...... .... ....1,. - ..."
·-1-1-. .-1-
~, :c
1228-.8BLK/AED

,422-.8TAN/BLK

r.'=-:'::t':!r _:1- __ ""G"_,_

EST REFERENCE PULSE HI

_,_- :-,',.
TIMING . _ 424-.8 TAN/WHT_
_467-.8DKBLU-l . .
424
EST BYPASS B
453
EST REFERENCE PULSE LO
_ 453-.8 BLK/RED... ....

.,-.-.-.-~
0112
12020549
GROMMET
101
12084618
r--
I ---------.-
• ,•
••
I -44O-.80RN-
, ..
L.... .....
111.. ....., - -
•
... 443-.8DKBLU/WHT . . . . . . .

I I, ,. ......,--- ....
F .-- , ..., _ . - . , .... 444-.8 DK BLU/BLK . . . ......
..._ _ _ _ 468-.8 DK GRN _ _ _ _I

INJ-2@:~~~
ffi ,
,III- - -.-- -,...., .
"'442-.8DKGAN/BLKF . . ......
INJ-2

'F.- I
to , 441-.8DKGRN/WHT_k .....
..._ _ _ _ 462 8 WHT ~ • • • •

- -
-. --, • _ _• • 1222-.8LTGAN_ ......

:'~tr T - - - - -, - - ~ :':""-'=:
INJ-1 @~:
INJ-1
t-____ 467-.8DKBLU-::-1
-----1 -.,_"'' £0_' ~_ ,"'_.,,.,, ,_1=
.
t-____ 461-.8AED S109 1- , - -

~~ I 0
~
~.
~
120-.8GRA $

i~
..J
c
~ I i ~ ~:o!~
r.~:r71rn~~~------120-'8 12~90 ~
120

A GRA - - _ . _••••••••••••••••••••
: , ;

itIII---44O-·80RN------ l'" • ':J

L..-_ _ _- - '
440
Cl18
. .12065401
0
_ _ _ _ _ _ _ _ _ _ _ 440-.80RN _ _ _ _ _. .
I ~
8153
_ -250-.8 BRN.' _ _ _ _ _ 250-.8 BRN _ , _ _ _ _ _ _ _ 250-.8 BRN _.~
•

~ ~ i
. ._ _ _ _ _ _ _ _ 490-.8 RED _ _ _ _ _ _ _ __

- -1- '
~ , , I

~
..J I &\ A
FUEL

e
. . . , . . . , ... 465-.8 OK GRN/WHT .... ,...., . . - , • .... ... ,....-- SHEET ALTERNATOR
PUMP
RELAY 120-.8 GRA
F . . . " .......... 450-.8BLK/WHT.-- ,...., ~ . . . . . . . . .
- ~ ~ G~;r~~D (Q) ~~~~~
BRACKET
GROUND
...... _ _ ,...., ...... _ ..." ,....,,....,,....,...... ......
G100
-
G103
_

; ~ ~=~
Cl03
12052287

C-36 POWERTRAIN CONTROL MODULE (PCM)

OUTPUTS ■ GASOLINE
OUTPUTS· GASOUNE ENGI·NE
ENGINE
 ,,
-"481-1.0 RED

~250-1.00RN

'-439-1.0 PNK/B LKr~""'~~ r~

~440-1.0 ORN

-- -- -- ,..- - -
- . . 450-.8 BLKJWHT_

~ 450-.8 BLKIWHT r

~ 439-.8 PNK/BLK_
- - .-
-..-- .-
.- -,-
.- --,--
1-
1..-
1..-
-
___

---
~
-
~
- 450-.8 BLKJWHT ,...,. -
... 450-.8 BLKJWHT ~ _

. - 439-.8 PNK/BLK _
-
~440-.80RN

-,- I- 44O-.80RN

I-

--
-"120-.8GRA,

.- -,- -
120-.8GRA

"-423-.8WHT

. . 424-.8 TAN/WHT...

"-453-.8 BLK/RED.,.
~

-- --..--.- -,-
,...,- .-
-.-... -......, 1-
i~
c-

~ -----
_ _ _ _ 453-.8BLKlRED _ _ •
423-.8 WHT

_424-.8TAN/WHT _

-
"-430-.8 PPL/WHT_

"'1229-.8LTBLU/WHT _ ,..., ~

-,-,- --,......,-
~
" ......,
~,-...
1"-
1- ~ c:s::::
II
~
7n .,.
-- -

-~
- _430-.8PPL/WHT _ _ ...

... 1229-.8 LT BLU/WHT"

-.
- --- j[5Jf
"-435-.8GRA I- 435-.8GRA

. . 485-.8DKG RN/WHT

~1228-.8 BLK!RED_ .-...

HT _ _ _ _ ..-
-_ .. - - - .. ," ......,
1-

-
~
~ ~
-- _
_ 465-.8 OK GRN/WHT,..

~1228-.8BLK/RED __
.-- ...
...

-
~,..-- _454-.8 BLKJWHT _ _ •
1- ~--
. . . 454-.8 BLKJW

--
-,- r..- ..-
BLK ___
~--
-~--..-
-
. . . 422-.8 TANI ~ 422-.8 TAN/BLK ___

-- -
"'487-.8DKBLU 467-.8 OK BLU

"488-.8DKG RN 468-.8 OK GRN

-I-
-- . .. - -,-
I-
~443-.8DKB LU/WHT .- ,.. ... r
-- ..- ,..
I-
..-
GT100
12085003 (UPPER)
12085002 (LOWER)
~- - 120-.8GRA

_443-.8 OK BLU/WHTr .... .

-"444-.8DKB LU/BLK'

-"442-.8LTB LU/BLK'

""441-.8LTBLU/BLK.
---..-- - -..... r_- --
.- "
~

,,~
...
r -r'"
--
-,-
..- ,.......,
..-
"
i-
I-
....
~-
- -
......-
-
_ ..- 444-.8 OK BLU/BLK r

_442-.8 LT BLU/BLK,..

_441-.8 LT BLU/WHT"
-.- ...
.. r

-...
...

...,....- I-
-
~1222-.8LT GRN 1222-.8 LT GRN _

- . - ,. ,......-
--
_ 1223-.8 YELlBLK _
. . . 1223-.8 YEllBLK.,. ~ r .... i- ~~
~

--
- - - -i:- I-
--
"'490-.8 RED

.481-.8 RED

- I-
.... .......
-
.,.
,, ,"'-1 0-
-"440-1.0 OR N
_440-1.00RN_ : , -~
j 12015964

~_,,,J
.120-.8GRA
TCC
SWITCH
A 2 150 240 111
B 3 16 350
I 439 1. 2
420 440 592
H
J

, ,, ,,
C 140 15 120 593 11 K 0

[g:
W
I H
:~I
o 9 250 419 a:
c:::J (OPENS WHEN E 35 8 7 10 505 481 <Xl

-,
A 250 BRAKE PEDAL IS F 300 O[ 50 I I 901 93 75 N
DEPRESSED) G 39 . 1 59 J 1824114 4 P i 490 422

r---- .
S207 1 2 4 5 10 9 8 7 6

;h: -
1061 Ir
--
250-1.0 BRN • 1250-1.0 BRNI
BRN/wHT~

,,
"-419-.8
12015113 436 C

SERVICE
t ~ G "
1 2 3
311~
4 5
10 9 8 7 6
824 14 4 P
451
450 ,.
0 ~
300 30 50 901 93 75 N
ENGINE FUEL 35 8 397 ~ L,J.l0 505481 '\
SOON CYCLE D 9 33 ~ ( 250419 ... ..::'

~ 1~0
15 120,. 593 11 K
LAMP MODULE 16 350 420 440 1-
(SEEPAGE)
(SEEPAGE)

POWERTRAIN CONTROL MODULE (PCM) C-37

OUTPUTS - GASOLINE ENGINE
 FUEL CYCLE MODULE W Cl

GROUND ~O

--
o 1-..- - - 150-.8 BLK

-
___ .e 5206
(SEE PAGE 11)

.... -
, r: ,. ." -
()

IGNITION _ 2:!0
...

ISO

120
30
ELEC. FUEL PUMP ..2!0
< F
C '"c N
C

~
ECM-CRNK GAUGES

1
INJ '-

r,
E
10AMP 7.5 AMP 20AMP C219
12047886
<t ,..."
481-1.0 RED

PNKlWHT~'
D

J
L 439-1.0 PNK/BLK - - - ~
350-.8

I
_ _ _ _ _•
350-.8 PNKlWHT - , . . . " ..

120-.8 GRA . _. . . . . .. .
... C

r ,..." =.._.• AI
• 8218
3.5.0.-.8.P.N.KIW_.HT
___.....
II1II

e...._..I.... . ._ _ _ _ _ _ 481-1.0 RED _ _ _ _ _ _ _ _ _ _ _ _ _ ..

IIIIIIIII
~
A

Cl02
12020786 12020829
A
B 3
2 150 240 111
16 50
C 140 15 120
I/P
. . . . . , . . . " ...... _ ,..." 120-.8TAN/WHT _ _ ,..." ...- ..III J C400
12020827

,
0950833 r--t-;'~~r-::.L.,::;+-481 W/GASOLINE
~ , . . . " . . . . 439-.8 PNK/BLK r _ _ _ _ ..... _ , . . . " _ _ _ ,..." . . . - _
E358397

--- <B
F 300 30 50 10 W/OIESEL
G 39 1234 31 59 50 824 14
1 2 3 4 5 10 9 8 7 6

-.
12015964

... '~ ~ ,...,,"--i!.1---.

Cl00
_ ... 450-.8 BLKlWHT _ , . . . " , . . . " , . . . " ~
12015113

11-________ 417-.8 DK BLU ~ ,..." ,..."

481 W/GASOUNE u.L..--'rl,I----~---- 488-.8 DK GRN

I
~
~ ___ ~ _ _ _ _ 467-.8 DK B
LU
~ .
g:~~~===~
~

1-___ ~---_412-.8 PPL

GASOLINE ONLY
~ _
DIESEL
... , . .
NlY
_
12015113

120-.8TAN/WHT...-....
"
•
,
1-__ ..-i~ ____ 452-.8 BLK t..... ...-...- .... ... ~ .... ...
1-___~----416-.8 GRA
lIIi _ A.~439-.8 PNK/BLK _ _ _ .J PCM
CONNECTOR

-
..- ....... ...
GT101
c~

-----e•
12084615 0
~ 1 rID ... I- ...
. .

~
5109 ~2~ ~ ~ ~

~ 3 @!l _
~ ~ 416
~
:t:: ~ 5 417

INJ-2
1 ~
~.=~
7 ~
[Ig[J

©~
482-.8 WHT _ _ _ _ _ _. .

467-.8 DK BLU _ _ _ _ _ _ _ _. ._ _. .
- DB~
D
D
9
10
[ID]
[ill]

--
~11~
E
t::: [!W 12 D 1=1
~13~1........1
~14 412
INJ-l . ._ _. ._ ._ _ _ _ _ _ _ _ 412-.8 PPL _ _ _ __
~15 46B

e_
~ 5111
,..." ...- .-a TP
SENSOR i4'1'2l
-('

-
[!jQJ 16 467
loy,
.InnI

~ (SEE PAGE 11) C250

12052177
452
t"'-- 450-2.0 BLKlWHT r---r- . ._ _ _ _ _ _ _ _ 150-1.0 BLK _ _ _ _ _. .

L.---r-
416 FRAME
12010996 C136 liP
l/P , %
12015791 GROUND
GROUND (Q )

C ..38
G200 ~ -- G400

C-38 THROTTLE BODY INJECTION

GASOLINE ENGINE
CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
A1 NOT USED 450 .8 BLK/WHT C1 SYSTEM GROUND
A2 NOT USED 551 .8 TAN/W HT C2 SYSTEM GROUND
1224 .8 PNK A3 PRESSURE SW ITCH MANIFOLD A 452 .8 BLK C3 SENSOR GROUND
1225 .8 DK BLU A4 PRESSURE SW ITCH MANIFOLD B 416 .8 GRA C4 5V SENSOR REFERENCE
1226 .8 RED A5 PRESSURE SW ITCH MANIFOLD C C5 NOT USED
1223 .8 YEL/BLK A6 SOLENOID B DRIVER C6 NOT USED
1222 .8 L TG R N A7 SOLENOID A DRIVER C7 NOT USED
451 .8 WHT/BLK A8 ALDL C8 NOT USED
A9 NOT USED C9 NOT USED
A10 NOT USED C10 NOT USED
A11 NOT USED C11 NOT USED
440 .8 ORN A12 12V BATTERY FUSED C12 NOT USED
C13 NOT USED
B1 NOT USED
C14 NOT USED
B2 NOT USED
1228 .8 RED/BLK C15 FORCE M OTOR LOW
B3 NOT USED
PPL/BLK 439 .8 PNK/BLK C16 12V IGNITION FUSED
420 .8 B4 BRAKE SIGNAL
422 .8 TAN/BLK B5 TCC D1 NOT USED
B6 NOT USED 437 .8 BRN D2 DRAC MODULE
B7 NOT USED 1231 .8 DK BLU/WHT D3 INPUT SPEED LOW
B8 NOT USED 1230 .8 GRA/RED D4 INPUT SPEED HIGH
1234 .8 GRA/RED B9 SYSTEM CHECK LAMP D5 NOT USED
1061 .8 ORN/BLK B10 SERIAL DATA 121 .8 W HT D6 ENGINE SPEED
1233 .8 DK GRN/YEL B11 OUTPUT SPEED SENSOR LOW 476 .8 BLK/PNK D7 SENSOR GROUND
1232 .8 LT BLU B12 OUTPUT SPEED SENSOR HIGH 417 .8 DK BLU D8 TPS
D9 NOT USED
TRANSMISSION CONTROL MODULE CO NNECTO R D10 NO T USED
D11 NOT USED
D12 NOT USED
1227 .8 BLK/YEL D13 TRANSMISSION TEMPERATURE
433 .8 GRA/BLK D14 MAP
D15 NO T USED
1229 .8 LT BLU/W HT D16 FORCE M OTOR HIGH

TRANSM ISSION CONTROL MODULE CO NNECTOR

TRANSMISSION CONTROL MODULE (TCM) PINOUTS C-39

DIESEL ENGINE
 «l V A M V M /W W \M H
S HOT AT A L L TIMES ^ j ) K HOT IN START OR RUN ! ? ^

’WvVVWVWVV^T » nvMwwvvwA | 1250-1.0 ORN I

TRANS ECM-CRNK ^ 439-.S PNK/BLK -4 H T |

ECM B ^ 10 AMP ^
10 AMP 10 AMP 1440-1.0 ORN I
1250-1.0 ORN I 439-.8 PNK/BLK fl

L 1 440-1.0 ORN I 11226- 8 RED I c

P SENSOR
11225-.8 DK BLU I

-4 5 2 C 11224-.8 P N K M
I 476-.8 PNK/BLK I

-417 B 121-.8 W H T l
1417-.8 DK BLU I

1416-.8 GRA I
-4 1 6
1420-.8 PPUBLK m

422-.8 TAN/BLK r

■ 417- 8 DK BLU ■

1229-.8 LT BLU/WHT I

( 455 )

r« D

I4 5 5 -.8 PPL I

I 433-.S G R A /B LK I I4 3 3 -.8 G R A/BLK I

■416-.8 G R A * I 1222-.8 LT GRN I

C135 \ 416 )
12020403

450-1.0 BLK/WHT ^

1227-.8 BLK/YEL

C173 1230-.8 DK BLU/WHT < A 1231-.8 DK BLU/WHT ■

INPUT 12078084
1231-.8 G R A / R E D ^ 11230-.8 GRA/RED W T
SPEED
SENSOR
452 )
1228-.8 RED/BLK

I4 5 2 -.8 BLK I

(§ « •» 1121-.8 W H T l 1150-1.0 BLK |

FT
C175 ■450-1.0 B L K /W H Ti
12015792 CUD
ENGINE
SPEED
SENSOR

1 2 3 4 5 10 9 7 6
391 31 I 59 I 50 | | ® 4 | 14 4
I 300 30 I 50 I n> 4 93 75
C172
12084690
35
9
8 397
33
— i ~ L _ V 250pH i
— , o
140 15 120 1 593] 11
TRANSMISSION 3 I 16 |350{ i 14201 440 tm m

to
CONNECTOR

4k
2 150 I 4 3 9 1 17 I 2

O
______ i ENGINE
GROUND
C-40 TRANSMISSION CONTROL MODULE (TCM) I 250-.8 BRN I I 250-.8 BRN I
G109
DIESEL ENGINE
~ _ _ _ 439-1.0PNK/BlK _ _ _ _ L ,..,. ....
--- ---1 "L", -
439-1.0PNK/BlK _ _ _ . . -
r- - 1234-.8 GRA/RED
1234-.8GRNRED - - - ~
lIP
l/P CLUSTER
(SEE
(SEE PAGE 56)
56)
..

~ _
250-1.0 OR N

...-1223-.BYEL/BlK_
- - - ..
-- --
1223-.BYEL/BlK ......

1
- - - - - - - ...,., -,-...,.,
---------~ ~~
_1223-.BYEL/BlK_...,., ~

,,
-
~ _ """439-.B PNK/BlKr

.. 1226-.B RED 1226-.BRED_. •

1225-.BDKBLU_. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ,
.. 1225-.BDK BlU

1,
1224-.8 P N K _ I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _• -I

",. . WH._' ', -,,

.. 1224-.B PNK

..

~
121-.BWHT

...,., "-476-.B PNK/BlK_~_~'"

-- _ ....
476-.8PNK/BlK~ ........ ...,., -

~
- ~
- -...,., -~-...,.,~=...,., - . .,.,. - 1
... -
~~ -, ....
B

c:J
qCJ 2 CJ
1
A

c::J
::>

,--,

1
-- - ...
~ _ ...-42O-.B PPL/B l K _
':::r-'till3Jill..-
1225

.
_~ 4
T
_~
~ ~
5 1226
. . . . _ _ 422-.B TAN/BlK ... ..- 422-.BTAN/BlK -., .- - -..... ••
CJ6 ~ . " ~ ...,., C216
12059125
CJ 7 1222
L.... ......
-- CJ B TsfI. ~
".~----_417-.B DK BLU' 417-.BOKBLU _. " ,

. . . . . ...,., ..-1229-.BlT BlU/WHT ~ '".."'OCUlWH'_ , __ ,_ -, , , ~~9CJ

11061110 @Bl1
CJ
~ ~ . .t. . ..I1061-.B ORN/BLK - 1

,~ - ,-r
. 112331 11

'" -, .- - ~ ~,,. I, (12321 12 440

~

-- _::J
....._ _ _ _ _ 440-1.0 OR 44O-1.00RN
N
...- 451-,B WHT/BLK _
~ _ ..-433-.B GRA/BlKr ~ ...,., ...,., . . -
.... 433-.B GRA/BlK ~ . . . ~., ... " . . . ...,., - .. , r . . ~ TRANSMISSION
-t
::: :=r. ='--,=....c,. :t:=: :,----. . .
........._ _ _ _.1222-.B IT GRN
1222-.BLTGRN - - -,-,- - - - CONTROL
MODULE
~.~-----41B-.B GRA
GT100 CONNECTORS

. . - _.......... -, ........,...,.............1
-,......................, I
....._ _ _ _ _.452-.B BlK 120B5003 (UPPER)

r __
."".,.,"""'"'--,- _.,--.- -,-~
120B5002 (lOWER)

551-1.0TAN/WHT _ _ . . . . . . . . . . . . _551-1.0TAN/WHT _ _ _

-,-~--,---
-- .
.... ~ "450-1.0BlKIWHT--~ ~'"

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GROUND • ~ ...,., ...,., _ . . . , . , ,422-.BTAN/BlK _ ~ _ ~ _ ~ _ ~ ~ ~ _ .......
G108
G10a

TRANSMISSION CONTROL MODULE (TCM) C-41

ENGINE
DIESEL ENGINE
 "39-.8 PNK/BLKI

ECM-CRNK l/P CLUSTER

10 AMP 39-1.0 PNK/BLK
4 CONNECTOR
S209
(SEE. PAGE 56)

DRAC MODULE
V
39-.8 PNK/BLK 4

(Z D i f 4~6fil
12261 2 (1223)
824-.S LT BLU/BLK -
5225] 3 3JSS21 SPEEDOMETER
11224 4 f 4221 (SEE PAGE 57)

□ 5
CZD 6 c m ]
ff22§t 7 DPI
fi228l 8 HZ]
9 a
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r s n 12 rwi z

-r
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B 3 [ 16 13501 1 T 14201440 592 J
C 140 15 120
D 9 508 33
— /-\ V -
I
593
68 250
11
419
K
L .481 W/GASOLINE
E 35 8 397
—, O X
j w r * 10 505 M
F [300 30 .1 50 1 1 19*1 93 75 -10 W/DIESEL
G 39 11234 31 1 591 j50 | | [824(14 4 P 12015964
1 2 3 4 5 10 9 8 7 6

12015964

12015113
DIESEL ONLY
S213 (GASOLINE) GASOLINE ONLY I GASOLINE ONLY
(SEE PAGE 30) 1 2
3\ * t 5 10 \ 9 8 7 6
39-.S PNK/BLK V G 39|1234 3 1 |^ 5 9 |5 0 | I I \ | 8 2 4 | 14 4 P
ENGINE
„ 481 W/GASOLINE
L, m\
F I 300 30 P 50 1
E 35 8 397-J*-----!---------1
D 9 508 33
M
f y -- l 10i
93 75 N
505
=T2T68 250 419
m
q 10 W/DIESEL
C 140 15 12°!- \\ 593 11
K
CRUISE 3 I 16 14201 4401 592 j
|B
CONTROL 2 1150 ^ 0 1 1 1 1 1 / 1439 j 17 I 2 12015113
MODULE SOLINE ONLY DIESEL ONLY
(SEE PAGE 52)

139-.8 PNK/BLK
824-.8 LT BLU/BLK 4

S152
(DIESEL)
(SEE PAGE 47)

150-.8 BLKI S112

(SEE PAGES 11, 12)

3Q-.8 PNK/BLK
GT100
12085003

vss 12085002

1233-.8 DK GRN/YEL I

■1232-.8 LT BLUI
ENGINE
(Q ) GROUND

G102

C-42 DIGITAL RATIO ADAPTER CONTROLLER (DRAC)

CIRCUIT OPERATION WAIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME WHEN
ENGINE IS BELOW NORMAL OPERATING TEMPERATURE
The heating of the Glow Plugs is controlled by the After the initial time period the relay will be de-energized TEST RESULT ACTION
Glow Plug Relay in the Glow Plug Controller. Battery for five seconds then will cycle ON/OFF for approximately
1. Place ignition switch in RUN Test lamp lights. GO to step 2.
voltage is applied to the relay contacts through the RED 10 seconds.
position. Connect test lamp from
(2) wire from Junction Block. The relay is operated by a RED (2) wire at glow plug Test lamp does not light. LOCATE and REPAIR open in RED
Solid-State Controller. The Controller responds to engine When the Glow Plug Controller receives the Start controller connector C190 to (2) wire and fusible link from glow
temperature and also to an Ignition Switch Start Input. Input, the Glow Plugs and WAIT Indicator will cycle ground. plug controller connector C190 to
ON/OFF after the Ignition Switch is returned to RUN, battery junction block.
When the Ignition Switch is turned to RUN, battery
voltage is applied to the Enable Input of the Controller. After approximately 25 seconds the Controller will 2. Connect a test lamp from PNK (3) Test lamp lights. GO to step 3.
The Glow Plug Relay within the Controller will be open the Glow Plug Relay and the heating of the plugs wire at glow plug controller
connector C113 to ground. Test lamp does not light. LOCATE and REPAIR open in PNK
energized for approximately five seconds during which it stops.
(3) wire from glow plug controller
applies voltage to the Glow Plugs and WAIT Indicator.
connector C113 to fuel shutoff
valve connector C129.
DIAGNOSIS - GLOW PLUGS 3. Connect a test lamp from PNK (3) Test lamp lights. GO to step 4.
wire to BLK (150) wire at glow
PRELIMINARY CHECKS: plug controller connector C113. Test lamp does not light. LOCATE and REPAIR open in BLK
A check of the glow plug system should be Turn ignition switch to OFF and then momentarily to (150) wire from glow plug
performed before doing diagnostic procedures. START and return to RUN position. The WAIT Indicator controller connector C113 to
should flash for approximately 25 seconds and then go ground G101.
With engine below normal operating temperature, turn out.
4. Connect a test lamp from PPL Test lamp lights. GO to step 5.
ignition switch to RUN. The WAIT Indicator should light.
(906) wire at glow plug controller
After approximately 10 seconds, the WAIT Indicator must With engine at normal operating temperature, turn connector C113 to ground. Place Test lamp does not light. LOCATE and REPAIR open in PPL
begin to flash for an additional 10 seconds and then go ignition switch to RUN. The WAIT Indicator should flash ignition switch in START position. or RST (906) wire from glow plug
out. for a 6.2L engine. controller connector C113 to
starter motor.
5. Place ignition in OFF position. Test lamp lights. REPLACE glow plug controller.
Connect a test lamp from ORN
(503) and ORN/BLK (509) wires at Test lamp does not light. GO to step 6.
glow plug controller connector
C191 to ground.

6. Disconnect glow plug controller Reading of 2 ohms or less. GO to step 7.

connector C113. Using a positive
polarity ohmmeter. Check Reading greater than 2 ohms. LOCATE and REPAIR open in ORN
continuity between ORN (503) and (503) wire from glow plug
BLK (150) wires. controller connector C113 to glow
plug harness splice S154.
7. Connect glow plug controller Test lamp cycles on and off for GO to step 8.
connector. Connect a test lamp approximately 25 seconds then
from ORN (503) and ORN/BLK goes off.
(509) wires at glow plug controller
connector C191 to ground. Turn Test lamp does not light or cycles REPLACE glow plug controller.
ignition switch momentarily to for the incorrect time.
START and then release to RUN
position.

8. Remove all connectors from glow Test lamp lights for all glow plugs. LOCATE and REPAIR open in ORN
plugs. Connect one lead of test (503) and ORN/BLK (509) wires
lamp to battery voltage and other and fusible links from glow plug to
lead to each glow plug. glow plug controller connector
C190.

Test lamp does not light for one or REPLACE glow plug(s) where test
more glow plugs. lamp did not light.

GLOW PLUGS C-43

 1906-1.0 PPL |

■ 2-8.0 R E D M

1 f
m _____ n
RIGHT BANK GLOW PLUGS
+ +
RH LH
BATTERY BATTERY
11-32.0 BLKI

1906-1.0 PPL I
a
m
509-5.0 ORN/BLK I

503-5.0 ORN I

503-1.0 ORN I

■906-.5 R S T B M B ■•
(FUSIBLE LINK) S150
— E ^O |
■6-5.0 PPL I

503-1.0 ORN I

STARTER MOTOR

■2-3.0 R S T » ■ 6-5.0 PPL I

(FUSIBLE LINK) S158

V o

S101
■2-2.0 R S T I
(FUSIBLE LINK)
LH LEFT BANK GLOW PLUGS
SHEET CYLINDER
RH CYLINDER / \ /A METAL HEAD
HEAD GROUND O O GROUND GROUND 2-5.0 RED I

G112 G110 G113

C-44 GLOW PLUGS

 C190

3-5.0 PNK I

FUEL
SHUTOFF
VALVE
S 1C
GLOW PLUG C298
1 2-5.0 RED 4 G H [m L
6294641
CONTROLLER
D

C113
12015982

16-5.0 PPL

1509-5.0 ORN/BLK I

■503-5.0 o r n m a m

■ 503-1.0 ORN ■

13-5.0 PNK ■ ■ 13-5.0 PNK I S200 12-5.0 RED

S105
(SEE PAGE 5)
13-5.0 PNK I

13-5.0 PNK I • S112

A 2 1150 I 2 4 0 11111 I I 4 3 9 1 17 I 2 H l/P (SEE PAGE 1.2)
B 3 16 3 5 0 1 | 14 2 0 1440 592 J
1503-1.0 ORN I ■503-1.0 o r n m m m m m 9 S 250 C 140 15 120
—J ^ -\ L_ 593 11 K
D 9 508 33 68 250 419 L .481 W /G ASO LINE
E 35 8 397 ^ w 10 505 M
F 1 300 30 i son r i9 01| 9 | 75 n ' ■10 W/D1ESEL

12-5.0 RED I 12-5.0 RED I

G 39 (1234 31 | 59 | 50 | | [ 824}
4 4 P
12015964

12015964 IGNITION
0100 L r m m r y e l/b lk w j b t
SWITCH
5-5.0 PPL I ■6-5.0 PPL I
12015113 DIESEL ONLY
I 33
G ASO LINE O NLY

i
GASOLINE ONLY

GT100 ENGINE I 111

12085003 481 W /G ASOLINE
12085002 3
CO 300
10 W /D IESEL
START
12015113
O RUN

\
l/P CLUSTER
° “T
O OFF

LOCK

(SEE PAGE 56) __/. ACC

J B T ^ H 5 0 5 -.8 YEL/BLK

IQ)
1 2-5.0 RED I = - ENGINE
G101 GROUND
1 6-5.0 PPL I

GLOW PLUGS C-45

CIRCUIT OPERATION FUEL HEATER DOES NOT OPERATE
TEST RESULT ACTION
The Diesel Fuel Filter System combines six functions thermostatic switch. The switch opens or closes, to turn
1. Disconnect fuel heater connector Battery voltage. GO to step 2.
into a single package: the heater off or on, depending on the temperature of C128. Place ignition switch to RUN
1. It heats diesel fuel to prevent wax-plugging of the the fuel. position. Connect a voltmeter from No voltage. CHECK condition of ALT fuse. If
filter; PNK/BLK (39) wire at fuel heater fuse is good, LOCATE and REPAIR
2. It combines very small droplets of water in the fuel The fuel then passes through the Primary and connector C128 to ground. open in PNK/BLK (39) wire from
into larger drops and separates the water from the Secondary filters. Next the fuel flows through the water fuel heater connector C128 to fuse
fuel; coalescer. Here the droplets of water in the fuel are block.
3. It filters the diesel fuel; combined into larger drops, the drops fall to the water
2. Connect a voltmeter from Battery voltage. REPLACE fuel heater.
4. It detects an excessive pressure drop indicating filter reservoir in the filter. When fuel flows from the Fuel Filter
PNK/BLK (39) wire to BLK (150)
plugging; (Vacuum Switch) Assembly to the injection pump, it is clean and free of wire at fuel heater connector N o voltage. LOCATE and REPAIR open in BLK
5. It detects the presence of excess water in the fuel; water. C128. (150) wire from fuel heater
and connector C128 to ground G 102 .
6. It provides a means to drain the water it has The Solid-State Water In Fuel Sensor applies voltage
separated. to a Probe. When the Probe touches water, the Module
closes a switch. This completes a circuit to ground to WATER IN FUEL INDICATOR LIGHTS WITH NO WATER IN FUEL
The Fuel Filter Assembly consists of the following light the SERVICE FUEL FILTER Indicator. TEST RESULT ACTION
main parts: Fuel Heater, the Water In Fuel Sensor, the
Fuel Pressure Switch, and a Filter. The Filter contains A time delay circuit in the Water In Fuel Module 1. Place ignition switch in RUN Water in fuel indicator stays on. LOCATE and REPAIR short to
the coalescer (the device that combines small droplets position. Disconnect water in fuel ground in YEL/BLK (508) wire.
grounds the Indicator bulb briefly to test the bulb each
sensor connector C127.
of water into larger ones) and the filter/separator. time the system is turned on.
Water in fuel indicator goes out. REPLACE water in fuel sensor.
An electric fuel pump delivers diesel fuel from the tank The Fuel Heater is operated by a built-in thermostatic
to the fuel filter. As fuel enters the filter, it passes first switch. When the switch is closed, battery voltage is
through the Fuel Heater. The heater contains a applied to the heater from the GAGES Fuse.

DIAGNOSIS - DIESEL ENGINE FUEL CONTROLS

SERVICE FUEL FILTER INDICATOR DOES NOT LIGHT BRIEFLY WITH
IGNITION SWITCH TURNED TO RUN
TEST RESULT ACTION

1. Disconnect water in fuel sensor Battery voltage. GO to step 2.

connector C127 and place ignition
switch in RUN position. Connect a No voltage reading. CHECK condition of ALT fuse. If
voltmeter from PNK/BLK (39) wire fuse is good, LOCATE and REPAIR
at water in fuel sensor connector open in PNK/BLK (39) wire from
C127 to ground. water in fuel sensor connector
C127 to fuse block.

2. Connect a voltmeter from Battery voltage. GO to step 2.

PNK/BLK (39) to BLK (150) wire at
water in fuel sensor connector No voltage. LOCATE and REPAIR open in BLK
C127. (150) wire from water in fuel
sensor connector C 127 to ground
G102.

3. Connect a voltmeter from YEL/BLK Battery voltage. REPLACE water in fuel sensor.
(508) wire at water in fuel sensor
connector C127 to ground. No voltage. CHECK water in fuel lamp. If lamp
is good, LOCATE and REPAIR
open in YEL/BLK (508) wire.

C-46 FUEL CONTROLS

DIESEL ENGINE
■ W V W /W W W V V / •
< HOT IN STAR T OR RUN ^ /
S209
>WWVVWVWV'vrA Vm v (SEE PAGE 42)

ALT
20 AMP

FAST IDLE COLD

SOLENOID c ADVANCE C
CONTROL *_l
s S m
£
531 531

C129
12004267

I 508-.8 YEL I WATER IN FUEL LAMP

(SEE PAGE 56)

r\— I -M
.— ----------------------— ---------------------A
A h s q | 2 4 0 I111j I 439| 17 | 2 H l/P
B 3
J r 6J
P50|
C 140 » 5 | 20 _ J
|
^ L_
14201440 I 592 J
593 11 K
D 9 S08f33 250 419 L
— , O
E
F
311 8 [397 ^
300 30 I 50 |
w
|
10
19011 93 75 N
Ml

G 39 I 31 I 59 | |[ 824114 4 P
1 2 3 4 5 10 9 8 7 6

C100

1 2 3 4 5 10 9 8 7 6
391 31 I 5911111 | 18 2 4 114 4 P
F I 300 30 I 50 I 1 |901| 93 75 N
E 35 8 397 _ J _ L _ 10 M
D 9 508 33 250 419 L
— . O _
Cj 140 120 593 11 K
3 \ % |350i. | |4 2 0 | 4401 592 J
A 2 1150 I 2 4 0 1 I |4 3 9 i 17 | 2 H
■ .................................... ~ V I

I
3
UJ
> -

_____J

ENGINE
GROUND
G102 FUEL SOLENOID
FUEL CONTROLS C-47
DIESEL ENGINE
CIRCUIT OPERATION AUXILIARY COOLING FAN DOES NOT RUN
TEST RESULT ACTION
Battery voltage is applied to the Auxiliary Cooling Fan DK GRN (935) wire is grounded and the Auxiliary Cooling 1. Disconnect auxiliary cooling fan Auxiliary cooling fan does not run. GO to step 2.
Relay at all times by the RED (2) wire and by the Fan Relay energizes. Battery voltage is applied across temperature switch connector
PNk A/VHT (350) wire through the GAUGES fuse, when the Auxiliary Cooling Fan Motor and the Cooling Fan C106. Connect a fused jumper Auxiliary cooling fan runs. REPLACE auxiliary cooling fan
the Ignition Switch is in RUN or START. When the runs. from DK GRN (935) wire at temperature switch.
Auxiliary Cooling Fan Switch closes at 107°C (225°F), the auxiliary cooling fan temperature
switch connector C106 to ground.
DIAGNOSIS ~ AUXILIARY COOLING FAN 2. Disconnect auxiliary cooling fan Test lamp lights. GO to step 3.
AUXILIARY COOLING FAN RUNS CONTINUOUSLY relay connector C138. Connect a
test lamp from PNK/WHT (350) Test lamp does not light. CHECK condition of GAUGES fuse
TEST RESULT ACTION wire at auxiliary cooling fan relay and/or LOCATE and REPAIR open
connector C138 to ground. in PNK/WHT (350) wire from
1. Place ignition switch in RUN Auxiliary cooling fan runs. GO to step 2.
auxiliary cooling fan relay to fuse
position and with engine coolant
block.
temperature below 107°C (225°F), Auxiliary cooling fan does not run. REPLACE auxiliary cooling fan
disconnect auxiliary cooling fan temperature switch. 3. Connect fused jumper from DK Test lamp lights. GO to step 4.
temperature switch connector GRN (935) wire at auxiliary cooling
C106. fan temperature switch connector Test lamp does not light. LOCATE and REPAIR open in DK
C106 to ground. Connect a test GRN (935) wire between auxiliary
2. Disconnect auxiliary fan relay Test lamp lights. CHECK for short in DK GRN (935)
lamp from PNK/WHT (350) wire to cooling fan temperature switch
connector C190. Connect a test wire from auxiliary cooling fan relay
DK GRN (935) at auxiliary cooling connector C106 and auxiliary
lamp from PNK/WHT (350) to DK connector C138 to auxiliary cooling
fan relay connector C138. cooling fan relay connector C138.
GRN (935) wires at auxiliary fan temperature switch connector
cooling fan relay connector C138. C106. 4. Connect a test lamp from RED (2) Test lamp lights. GO to step 5.
wire at auxiliary cooling fan relay
Test lamp does not light. REPLACE auxiliary cooling fan connector C138 to ground. Test lamp does not light. LOCATE and REPAIR open in RED
relay. (2) wire and fusible link between
auxiliary cooling fan relay
connector C138 and battery
junction block.

5. Connect 30 amp fused jumper Auxiliary cooling fan does not run. GO to step 6.
from RED (2) wire to BLK/RED
(702) wire at the auxiliary cooling Auxiliary cooling fan runs. REPLACE auxiliary cooling fan
fan relay connector C138. relay.

6. Leave 30 amp fused jumper Test lamp lights. GO to step 7.

connected. Disconnect auxiliary
cooling fan connector C152. Test lamp does not light. LOCATE and REPAIR open in
Connect a test lamp from BLK/RED (702) wires from auxiliary
BLK/RED (702) at auxiliary cooling cooling fan connector C152 to
fan connector C 152 to ground. auxiliary cooling fan relay
connector C138.

7. Connect a test lamp from Test lamp lights. REPLACE auxiliary cooling fan.
BLK/RED (702) to BLK (150) wires
at auxiliary cooling fan connector Test lamp does not light. LOCATE and REPAIR open in BLK
C152. (150) wire from auxiliary cooling
fan to ground G102.

C-48 AUXILIARY COOLING FAN

GASOLINE ENGINE
 GAGES
20 AMP a I 350-.8 PNK/WHT I
S218
(GASOLINE ONLY)
(SEE PAGE 38)

BATTERY JUNCTION
BLOCK

o o o o ? y

I 2-.8 RST ■ ■ ■ S104

p « r\
(FUSIBLE LINK)
A 2 |1 5 0 » 4 0 | 1 1 l | I 4 3 9 1 17 I 2 H l/P

CM

3
B 3 I 16 13 5 0 1

o'
*■
| 592 J
C 140 15 120 _ J ^ L _ 593 11 K
D 9 508 33 68 250 419 L .481 W /G ASOLINE
— n O r—
E 35 8 397 ^ w n 10 505 M
F !3 0 0 I 30 I 50 I 1901] 93 75 N ■10 W /DIESEL
G 39 11234! 31 | 59 | 50 | | 824| 14 4 P 12015964
1 2 3 4 5 10 9 8 7 6
150
-r — U — k-

150-.8 BLK I 2-2.0 RED i I 2-2.0 RED

C100
702-2.0 BLK/RED

DIESEL ONLY
702
G ASO LINE ONLY | ^GASOLINE ONLY

I 9 3 5 ,8 DK GRN ENGINE
AUXILIARY 481 W /G ASOLINE
COOLING
FAN
r 10 W /D IESEL

12015113

150 ~)
GT 100
12085003
’/> (UPPER)
150-.8 BLK 12085002
(LOWER)
9 3 5 ,8 DK GRN I • S 114

C153
AUXILIARY 12015792

COOLING
FAN
PRESSURE
SWITCH
I 150-.8 BLK I

I 935-.8 DK GRN

935-.8 DK GRN I I 150-.8 BLK ; • S112

| (SEE PAGE 11)
I v ' 702-2.0 BLK/RED

I 2-2.0 RED

AUXILIARY
COOLING FAN COOLING
TEMPERATURE SWITCH FAN
(CLOSED WHEN ENGINE RELAY
COOLANT EXCEEDS GROUND
225°F)

AUXILIARY COOLING FAN C-49

GASOLINE ENGINE
 PROVISIONS
FOR AIR — — — o m jo kg rn ,

CONDITIONING

B A r-
1*40 I 1 I.463J
f ia o l z C3 c
l« * l 3 CO E
C Z 3 4 I435I
rVsTl a POWERTRAIN
C Z I 6 I439] CONTROL
A 2 1150 I 24C S3 C 14391 17 I 2 H l/P D bb ] 7 t ia a l
B 3 I 16 |350| “T t 142014 4 0 1592 J I'ss '] B L.4B1] MODULE
C 140 15 120 593 11 K
D 9 508 33
J /~ \ L_
68 250 419 L .481 W/GASOUNE C Z ] 9 UsTI
O r -
10 505 I 434 I 10 GUI
E 35 8 397 1 ^ n M
F 1300 30 50 \ i !901| 93 75 N' -10 W/DIESEL r~ ]u m i
G 39 11234 31 I f j |824| 14 4 P \ 4B0I L
1 2 3 X
•I » l
5 10 9 8 7 6

12015964 C251
12052175

S124 C100

12015113
DIESEL ONLY
IN-UNE GASOUNE ONLY I GASOUNE ONLY
DIODE

481 W/GASOUNE

S123
10 W/DIESEL
sO zC
C
0
Q
m

59-.8DKGRN|

150-.8 BLK I • S112

(SEE PAGE 11)

COMPRESSOR

sue
159- 8 DK GRN

59-.8 DK GRN

GT100
ENGINE 12085003
(UPPER)
GROUND 12085002
G102 (LOWER)

C-50 PROVISIONS FOR AIR CONDITIONING

GASOLINE ENGINE
CIRCUIT OPERATION TEST RESULT ACTION

from the VSS. The driver gives his input to the Cruise 5. Connect a test lamp from GRA Test lamp lights. GO to step 6.
The Cruise Control regulates the speed of the vehicle
(397) wire at brake switch
in response to driver commands. Control Module through the components listed above.
connector C245 to ground. Test lamp does not light. LOCATE and REPAIR open in GRA
The Cruise Control Module circuitry receives the driver’s (397) wire from brake switch
The Cruise Control Module contains electronic input and generates electrical pulses. These pulses connector C245 to splice S215.
circuitry and a stepper motor. The other system cause the stepper motor and its output reel to rotate.
components are: The throttle is controlled by a cable wound on the output 6. Connect a test lamp from TAN Test lamp lights. GO to step 7.
reel. The Cruise Control Module also contains a clutch (901) wire at brake switch
• Cruise Control Switch which releases the cable when the Cruise Control connector C246 to ground. Test lamp does not light. LOCATE and REPAIR open in TAN
System must be shut off. This clutch will operate when (901) wire from brake switch
• Brake Switch
connector C246 to cruise control
• Vehicle Speed Sensor (VSS) the Brake Pedal is depressed, the Cruise Control System
module connector C248.
is turned off, or the Cruise Control System detects a
The Cruise Control Module receives voltage from the failure. 7. Connect a test lamp from BRN Test lamp lights. GO to step 8.
IGN Fuse in RUN or START. A speed signal is received (86) wire at brake switch
connector C246 to ground. Test lamp does not light. CHECK adjustment of brake
switch. If properly adjusted,
DIAGNOSIS - CRUISE CONTROL REPLACE brake switch.

CRUISE CONTROL DOES NOT DISENGAGE WHEN BRAKE PEDAL IS DEPRESSED 8. Connect a test lamp from BRN Test lamp lights. GO to step 9.
(86) wire at brake switch
TEST RESULT ACTION connector C245 to ground. Test lamp does not light. CHECK adjustment of brake
REPLACE control module. switch. If properly adjusted,
1. Place ignition switch in RUN Test lamp does not light.
REPLACE brake switch.
position and cruise control switch
to ON. Depress brake pedal. Test lamp lights. CHECK adjustment of brake 9. Connect a test lamp from DK BLU Test lamp lights. REPLACE cruise control switch.
Connect test lamp from BRN (86) switch. If adjustment cannot be (84) wire at cruise control switch
wire at brake switch connectors corrected, REPLACE brake switch. connector C244 to ground. Test lamp does not light. GO to step 10.
C245 and C246 to ground.
10 . Depress SET switch. Connect a Test lamp lights. GO to step 11.
test lamp from DK BLU (84) wire at
CRU ISE CONTROL DOES NOT OPERATE cruise control switch connector Test lamp does not light. REPLACE cruise control switch.
TEST RESULT ACTION C244 to ground.

1. Place ignition switch in RUN and Test lamp lights. GO to step 2. 1 1 . Connect a test lamp from DK BLU Test lamp lights. GO to step 12.
cruise control switch to ON. (84) wire at cruise control module
Connect a test lamp from Test lamp does not light. CHECK condition of IGN fuse. If connector C248 to ground. Test lamp does not light. LOCATE and REPAIR open in DK
PNK/BLK (39) wire at cruise fuse is good, LOCATE and REPAIR BLU (84) wire from cruise control
control switch connector C244 to open in PNK/BLK (39) wire from module connector C248 to cruise
ground and then cruise control cruise control switch connector control switch connector C244.
module connector C248 to C244 and cruise module connector 12. Depress and hold RESUME/ Test lamp lights. GO to step 13.
ground. C248 to fuse block. ACCEL switch. Connect test
2. Connect a test lamp from GRA Test lamp light. GO to step 3. lamp from DK GRN (83) wire at Test lamp does not light. REPLACE cruise control switch.
(397) wire at cruise control switch cruise control switch connector
connector C244 to ground. Test lamp does not light. REPLACE cruise control switch. C248 to ground.

3. Connect a test lamp from GRA Test lamp lights. GO to step 4. 13. Connect a test lamp from DK GRN Test lamp lights. GO to step 14.
(397) at cruise control module (83) wire at cruise control module
connector C248 to ground. Test lamp does not light. LOCATE and REPAIR open in GRA connector C248 to ground. Test lamp does not light. LOCATE and REPAIR open in DK
(397) wire from cruise control GRN (83) wire from cruise control
module connector C248 to cruise module connector C248 to cruise
control switch connector C244. control switch connector C244.

4. Connect a test lamp from GRA Test lamp lights. GO to step 5. 14. Raise vehicle so drive wheels can Pulses between 0 and battery REPLACE cruise control module.
(397) to BLK (150) wires at cruise be turned by hand. Connect voltage as wheels are turned.
control module connector C248. Test lamp does not light. LOCATE and REPAIR open in BLK voltmeter from PNK/WHT (39) wire
to DK GRN (389) wire at cruise Does not pulse or no voltage CHECK speed sensor circuit. Refer
(150) wire from cruise control
module connector C248 to ground control module connector C248. reading. to Fuel, Driveability and Emission
G202. Slowly turn drive wheels. Manual (Gasoline).

CRUISE CONTROL C-51

 yW W vW W vW V /
s HOT IN START OR RUN Z
>VVV\M/VVVWW''* IGNITION - 39
ACCEL/RESERVE SW - 83
CRUISE ENGLARGER SWITCH - 84 CRUISE
GROUND - 150 CONTROL
ALT
20 AMP VEHICLE SPEED INPUT - 389 MODULE
* ELECTRONIC CRUISE - 397
BRAKE SWITCH _ 901

8209 09
(SEE PAGE 42) $

l/P
A 4011111 >l 17 I 2'
>01440 { 592
l/P
B 161
C
D 68 250 419 .481 W/GASOLINE
E 397 O 10505
F 1300 1901J 9 3 10 W/DIESEL
g 551 31159 ( 50 | 1 | l824jT4
10 9 8

C100
12015113
DIESEL ONLY ENGINE
GASOLINE ONLY GASOUNE ONLY
I 150-.8 BLK I S112
(SEE PAGES 11, 12)
481 W/GASOLINE

10 W/DIESEL

GASOLINE ONLY DIESEL ONLY

GT 100
12085003
(UPPER)
12085002
(LOWER)
BRAKE
SWITCHES
(OPEN WHEN
BRAKE PEDAL I 3S9-.8 DK GRN I DRAC
IS DEPRESSED)
§ m 0 Z
(SEE PAGE 42)
* *
d>
co
o
co i $
CRUISE
C245 CONTROL
12010649 ACTIVATOR

139-.8 PNK/BLK ' 39-.8 PNK/BLK I

S213 (SEE PAGE 30)
■397-.8 G R A ^ H I 397-.8 G R A B *
S215
1 901 -.5 TAN ■ ■
A ENGINE
(Q ) GROUND
G102

C-52 CRUISE CONTROL

CIRCUIT OPERATION DIAGNOSIS - INSTRUMENT PANEL: GAGES AND INDICATORS

The operation of an individual Indicator is described TEMPERATURE GAGE PRELIMINARY CHECKS:

along with its circuit. Refer to the schematic and text for The Temperature Gage is also operated by two coils. Check the condition of GAGES and INST LPS fuses.
the circuit that is indicated below each of the Indicators. Battery voltage is applied to both coils. One is grounded If fuses are in good condition, use the following
directly and the other is grounded through the diagnostic procedures.
PARK BRAKE WARNING LAMP Temperature Sender. This has 55 ohms resistance at
Battery voltage is applied to the Brake Indicator when 127°C (260°F) (hot coolant) and its resistance becomes FUEL GAGE INDICATES FULL OR BEYOND AT ALL TIMES
the Ignition Switch is in RUN, or START. Three Switches greater at lower temperatures. It is approximately 1400 TEST RESULT ACTION
are connected to the Brake Indicator. When any one of ohms at 38°C (100°F). This causes the current through
these switches closes, a ground is provided and the the Sender and one coil to increase as the coolant 1. Disconnect fuel pump connector Fuel gage indicates full. LOCATE and REPAIR a short in
indicator lights. temperature increases. This moves the pointer. C401 and place ignition switch to PNK (30) wire. If not short is found,
RUN. Connect a fused jumper REPLACE fuel gage.
from PNK (30) wire at fuel pump
The Park Brake Switch provides a ground when the LOW COOLANT INDICATOR (DIESEL) connector C401 to ground. Fuel gage indicates empty. GO to step 2.
Park Brake is applied. The Brake Indicator lights to alert The Low Coolant Indicator comes on to warn the
the driver. driver when a low level of coolant exists in the radiator. 2. Connect a fused jumper from PNK Fuel gage indicates full. LOCATE and REPAIR open in BLK
Battery voltage is applied to the Low Coolant Module. (30) wire to BLK (150) wire at fuel (150) wire.
The Brake Pressure Switch closes to light the Brake When a low coolant condition exists, a signal is sent to pump connector C401.
Indicator when there is low brake fluid pressure in one of the Low Coolant Module from the Low Coolant Sensor. Fuel gage indicates empty. REPAIR/REPLACE fuel pump.
the two hydraulic brake systems. This could be caused The Low Coolant Module will provide a ground to the
by a leak in one of the brake lines. Low Coolant Indicator. FUEL GAGE INDICATES EMPTY WHEN THERE IS FUEL IN THE TANK
TEST RESULT ACTION
The Ignition Switch grounds the Brake Indicator when The Low Coolant Sensor is not a switch that opens
the Ignition Switch is turned to START to provide a quick and closes. It has a very high resistance to ground, 1. Disconnect fuel pump connector Fuel gage indicates full. REPAIR/REPLACE fuel pump.
check of the Brake Indicator Bulb and circuitry. more than 50,000 ohms, when the engine coolant level C401 and place ignition switch to
is low. This causes the Low Coolant Module to light the RUN. Fuel gage indicates empty. LOCATE and REPAIR a short in
FUEL GAGE Low Coolant Indicator. With more of the Sensor covered PNK (30) wire. If no short is found,
The pointer of the Fuel Gage is moved by the by coolant, its resistance decreases. When the fluid level , REPLACE fuel gage.
magnetic fields of two coils. The coils are at right angles is good, the resistance between 10,000 and 50,000
to each other. Battery voltage is applied to the E-coil ohms, the Sensor is partly covered and the fluid is not FUEL GAGE IS INACCURATE
and the circuit divides at the opposite end of the coil. low enough to cause the warning to be displayed. TEST RESULT ACTION
One path continues to ground through the F-coil.
Another goes to ground through the variable resistor of CHECK ENGINE (GASOLINE) INDICATOR 1. Disconnect fuel pump connector Gage responds correctly. CHECK BLK (150) wire for high
the Fuel Gage Sender. Refer to Light Duty Truck Fuel, Driveability and C401. Connect one RED lead of J resistance. If wire is good,
Emissions Service Manual, Section 3. 34029-A Multimeter to PNK (30) REPAIR/REPLACE fuel pump.
When the tank is low, the resistance of the Sender is wire and other to ground. Set
resistance dials to 0 ohms and Gage does not respond correctly. CHECK for high resistance in PNK
low. A large flow of current passes through the E-coil WATER IN FUEL WARNING INDICATOR then to 90 ohms. Fuel gage (30) wire. If wire is good, REPLACE
and the Fuel Gage Sender resistor. This moves the Refer to Fuel Controls (Diesel), Page B-38. should indicate empty and then fuel gage.
pointer toward E on the scale. When the tank is full, the full. (Allow time for gage to reach
Sender resistance is high. More current now flows full due to anti-slosh device.)
GLOW PLUG INDICATOR
through the F-coil, moving the pointer toward F on the
Refer to Glow Plugs (Diesel), Page B-11.
scale.
OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN OIL PRESSURE IS GOOD
With two coils operating the pointer, the Gage is not
RH/LH TURN SIGNAL INDICATORS
TEST RESULT ACTION
affected by changes in the system’s battery voltage. Refer to Front Exterior Lamps, Page B-24.
1. Disconnect oil pressure sender Oil pressure gage indicates high REPLACE oil pressure sender.
OIL PRESSURE GAGE HIGH BEAM INDICATOR connector C118 (Gasoline) or pressure or indicator light goes
Refer to Headlamps, Page C119 (Diesel) and place ignition out.
The engine oil pressure is displayed by the Oil
switch to RUN.
Pressure Gage. The pointer of the Gage is moved by Oil pressure gage indicates no or LOCATE and REPAIR short in TAN
two coils, and its operation is similar to that of the Fuel DRL INDICATOR low pressure or indicator light (31) wire. If wire is good, REPLACE
Gage. Refer to Headlamps with Canadian Daytime Running stays on. oil pressure gage.
Lamps, Page
The Oil Pressure Sender is connected to the junction
of the two coils. It has low resistance when the oil
pressure is low, and 90 ohms resistance when the oil
pressure is high. This changing resistance changes the
current flow through the coils. The magnetic field of the
coils move the pointer from low to high.

INSTRUMENT PANEL C-53

 OIL PRESSURE GAGE INDICATES HIGH PRESSURE AT ALL TIMES LoWCO oLANT INDICTOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLy)
TEST RESULT ACTION TEST RESULT ACTION

1. Disconnect oil pressure sender Oil pressure gage indicates low REPLACE oil pressure sender. 1. Disconnect low coolant warning Low coolant indicator lights. REPLACE low coolant warning
connector C118 (Gasoline) or pressure or indicator lights. switch connector C 126 and place switch.
C119 (Diesel) and place ignition ignition switch to RUN. Observe
switch to RUN. Connect a fused Oil pressure indicates high LOCATE and REPAIR open in TAN low coolant indicator light. Low coolant indicator does not GO to step 2.
jumper from TAN (31) wire at oil pressure or indicator does not (31) wire. If wire bulb is good, light.
pressure sender connector C118 light. REPLACE oil pressure gage. 2. Disconnect low coolant warning Battery voltage. GO to step 3.
(Gasoline) or C119 (Diesel) to module connector C223. Connect
ground. voltmeter from BLKlORN (550) No voltage. LOCATE and REPAIR open in
wire at low coolant warning BLU/ORN (550) wire. If wire is
module connector C223 to good, REPLACE GAUGES fuse.
TEMPERATURE GAGE INDICATES HOT WITH ENGINE COOLANT ground.
BELOW OPERATING TEMPERATURE AND IGNITION SWITCH IN RUN
TEST RESULT ACTION 3. Con nect a voltmeter from Battery voltage. GO to step 4.
PNKlBLK (39) wire to BLK (150)
1. Disconnect temperature sender Temperature gage indicates cold. REPLACE temperature sender. wire at low coolant warning No voltage. LOCATE and REPAIR open in BLK
connector C104 (Gasoline) or module connector C223. (150) wire.
C108 (Diesel) and place ignition Temperature gage does not LOCATE and REPAIR a short in
switch to RUN. indicate cold. DK GRN (35) wire. If no short is 4. Connect a voltmeter from GRA Battery voltage. GO to step 5.
found, PERFORM diagnostic (69) wire at low coolant warning
procedures under symptom module connector C223 to No voltage. LOCATE and REPAIR short to
MTemperature Gage Is Not ground. ground in GRA (69) wire from low
Accurate.- coolant warning module connector
C223 to low coolant warning lamp.
5. Connect a voltmeter from Battery voltage. LOCATE and REPAIR short to
TEMPERATURE GAGE INDICATES COLD ALL THE TIME
PNKlBLK (39) wire to YEl/BLK ground in YEl/BLK (68) wire from
TEST RESULT ACTION (68) at low coolant warning low coolant warning module
module connector C223. connector C223 to low coolant
1. Disconnect temperature sender Temperature gage indicates hot. REPAIR/REPLACE temperature warning switch connector C126.
connector C104 (Gasoline) or sender.
C108 (Diesel). Ground the DK No voltage. REPLACE low coolant module.
GRN (35) wire at temperature Temperature gage does not LOCATE and REPAIR open in DK
sender connector C1 04 (Gasoline) indicate hot. GRN (35) wire. If wire is good,
or C108 (Diesel). REPLACE temperature gage.

TEMPERATURE GAGE IS NOT ACCURATE

TEST RESULT ACTION

1. Disconnect temperature sender Gage indicates correctly. REPLACE temperature sender.

connector C104 (Gasoline) or
C108 (Diesel). Connect RED lead Gage is not correct. LOCATE and REPAIR open in DK
from J 34029-A Multimeter to DK GRN (35) wire. If wire is good,
GRN (35) wire and other lead to REPLACE temperature gage.
ground. Adjust resistance dials to
1400 ohms and then to 55 ohms.
Temperature gage should indicate
cold then hot.

LOW COOLANT INDICATOR IS LIT WHEN COOLANT LEVEL IS GOOD

TEST RESULT ACTION
1. Connect a fused jumper from low Low coolant indicator goes out. REPLACE low coolant probe.
coolant warning switch connector
C150 to ground. Place ignition Low coolant indicator stays lit. LOCATE and REPAIR open in
switch to RUN and observe low YEl/BLK (68) wire. If wire is good,
coolant indicator light. follow diagnostic procedures listed
under symptom -Low Coolant
Indicator Does Not Light With
Coolant Level Low.·

C-S4 INSTRUMENT PANEL

 --
ILLUM ILLUM ILLUM ILLUM ILLUM ILLUM

r------r---,
I ORL

: I

Q
~5~Q)
v
'-
150
: (C~~~~,AQ N
~ bi
I 150
HIGH
BEAM
LEFT

TURN
_

_1~
RIGHT
TURN
-
15
I
I
r---
593:
I

-,- : '- I
L ________ ...J
11
(629W/DRL)

39
r--

WATER
IN
LOW
COOLANT
....
SERVICE
ENGINE
-
419

SERVICE
BRAKE
PARKING
BRAKE
GLOW
PLUG - -
FUEL SOON (DIESEL SPEEDO- OIL
FUEL

-
(DIESEL ONLy) METER
ONLy)

VOLT TEMP

r ~ 1
~. ~ ...~ C218
,---.""'-~
eM "'e
,,.. =
= e~ -e F
-------

I
~
~
12040746

L-~~------------~~----------------~----------------~----------~--+-+-t--39----~==~&.~ M ~----
--~----~
• =
..~te~
eg..
~
68----.....
507-----+--~~

- ~
.= e~ "'0
824 ---4III-III-;ffioe'" ... ~tF~HI--l50 _____+--J
_-+----~- 39 ~ ., AetlF=tfI-419 ---~~-----+~~+-'
---------------t----------------""""I~-------------+----_I~_+--1_-150 - I
--- 8
· == e~
e~ '"
~
C1i -
111 :==:a:==~=+:t'
33
593----~~-----+~
..
O~ ~e :::== •
' - - - - - 3 5 -~"-=HI"~ ~. !== •
r - - 31 t:i :!e F= •
_~~---150 0 ~etlF=HI'-l50 -----+-----..
1""'"1234 - A~ ~~f.p;;;~1-P-15----_+----""
--------------""""I~--------------~------_I--_+--~--+_11~29--~t:~~~~~~~~~::J1~14----~~
----" ~

........... I '"
l\.T}JI.
/

INSTRUMENT PANEL C-55

 RPO
RPO CODES
CODES

C7P
C7P -- 16,000
16,000 lBS
LBS GWI
GVW RATING
RATING

GAUGES
ALT
20 AMP '-- - -"..,,,"'"'- -- - -------- ---- ---~ 15
Z
Cl
2l
0
-< 02l
0
r
."

;:
~ ~ 550-.8 BLK/ORN _ ~ ~ .-r _ _ .-r ~ ,..,. ..-r ::::j c: » UI LOW COOLANT
20 AMP 0 Z
0
;: ::E
z ." ::::j
WARNING MODULE
(')
:r (DIESEL ONLy)
150 69 68
LOW COOLANT 550·
AUTO APPLY PARK

cru
WARNING A C223
SENSOR 12004706 PARK BRAKE BRAKE
(DIESEL ONLy)
(DIESEL ONLY) SWITCH SWITCH
C126
. - 550-.8 BlK/ORN _ _ (GASOLINE W/C7P)
CLOSED WHEN (CLOSED
(CLOSED WHEN
WHEN

.,
...l AUTO PARK BRAKE PARKING
PARKING BRAKE
BRAKE
...... . - r _ ~ .-r _ _ _ 68-.8YELJBLK . . . . . - r ~ ...
IS APPLIED) 33 450 IS
IS APPLIED)
APPLIED)

---
,
~
,
~ _

_111
~ _ ~

-.8 BLK _ _ _ _ _•
~ ..-r _ ~ 508-.8YELJBlK"'..-r _ _

--- C189

L, ---
C220

" u
12010651

"A ~ I IGNITION
SWITCH
...,.. _ 33-.8 TAN/WHT _

, ~_ ~
(SEE PAGE 4)
2 "50 240 111 439 17 2 H I/P
J
._..-r _ , ,
B 3 16 350 4:!11 440 592 J _33-.5TAN/WHT..,. . . . .
C 140 • 120 593 11 K

0
,,
o 9 508133l 68 250 419 l 481 W/GASOlINE . . . . . -1..-450-.8BlKIWHT . . - .....,
E 35 8 397 10 505 MI
F 300 30 50 r 901 93 75 N 10 W/DIESEl ~
~

,, ,
...J
G 391 12341311591501 1 824'14 4 P III (!) S209
12015964 <Xl <Xl
1 2 3 4 5 10 9 8 7 6

-- lIP
6
~
a;
co
(SEE PAGE 42)

\ ,-"'''''"'
, ,
C10D

rr4~--~~--~~

GlOWPLUGS ~
(SEE PAGE 44)
_505-1.0YEL _ ..-r
L-
- -- , ,
,
~ lIP
l/P CLUSTER
~CONNECTOR
CONNECTOR
(SEE
(SEE PAGE
PAGE 55)
55)

-- -
(DIESEL ONLy)

PCM
(SEE PAGE 35)
.. _ 419-.B BRN/WHT_
(GASOLINE ONLy)
• 39-.8 PNK/BLK -1 III.
- - - - -...-@I1(j~-jItI-
• Slll

_-,
_111-.BBLK 150-.8 BLK - - . ~ (SEE PAGE 11)

, _ 111-.8BLK

...
~ 508-.8 YELJBLK ..,.

.. - -::::::tt::~~ L=...._
-
-
RH TURN SIGNAL 150-.B BlK ..
(SEE PAGE 24) ,._ _ _ _ _ _ __ _ 15-.5 DK BLU I PCMITCM
(SEE PAGE 41)
-1~.5DKGRN_~~~~~~~~~~~~"r-""
, - 68-.8 YELJBLK -
~ .-r 68-.8 YELJBll< IF . . - r _ _ ,
12085003 (UPPER)
12085002 (LOWER)
~
~
~
~
LH TURN SIGNAL , , - - - - - - - -
(SEE PAGE 24)
-
,,
BRAKE
PRESSURE
C218
WARNING 12040744
SWITCH 150-.8 BLK

WATER
J 150-.8 BLK

_ 450 2.0
2.0 BLK/WHT
BLKlWHT '•
-
~-
450
IN FUEL C154
12004635 ~
SENSOR
SENSOR G200 G 100
G100 1H.OLTGRN ~ DIMMER SWITCH
DIMMERSWITCH
I 11-1.0 LT GRN I
(DIESEL
(DIESEL ONLY)
ONLy)
lIP SHEET
SHEET (SEE PAGE
(SEE PAGE 14)
14)
C127
~l
12015793 (CLOSES WHEN
UNEQUAL PRESSURE
-- GROUND METAL
GROUND
EXISTS BETWEEN
FRONT AND REAR
. ._ _ _ _ 111-.8 BlK _ _ _ _ _ _ _ _. . BRAKES) ---
C-56 INDICATOR LAMPS
 I 39-.8 PNK/BLK

ALT
20 AMP

ENGINE COOLANT OIL PRESSURE FUEL PUMP

TEMPERATURE TEMPERATURE SWITCH OIL PRESSURE
SWITCH SENDER (DIESEL)
SENSOR AND SWITCH
DRAC
(SEE PAGE 42)
(CLOSES AT
APPROXIMATELY
107°C (225°F)

31-.5 TAN

Z
cc z
<3
IS

GT100
12085003 (UPPER)
12085002 (LOWER)

FRAME l/P
GROUND (O ) GROUND
GASOUNE ONLY DIESEL ONLY
G400 ■=■ G200
c io o

GAGES C-57
 C203
12020030

PANEL
DIMMER
SWITCH

-1 5 6

I 44-1.0 DK GRN
INSTR-LPS
5 AMP LIGHT
19*1.0 BRN I SWITCH
(SEE PAGE 14)

PROVISIONS
I 156-. 8 WHT I FOR DOME LAMPS
(SEE PAGE 59)
HEAD

18-.5 GRA I
S208

I 150-3.0 BLK I

A 2 l | 5 0 I 240 11111 [ 17 | 2
I 439 H l/P
B 3 I Me 13501 | 14201440! 592 J
C 140 120 —J / - \ L_ 68 593 11 K
D 9 33 250 419 L .481 W/GASOLINE
E 35 8 397 ^ ^ 10 505 M
F 1300 30 ! 50 I l« 0 1 l 93 75 N* ■10 W/DIESEL
G 39 11234 31 I 59 | SO | | 1 18241 14 4 P
5 10 9 8

12015964

12015113
DIESEL ONLY
GASOLINE ONLY I GASOLINE ONLY

10 8 7 6
ENGINE
31 ly59 | 50 | I \|8 2 4 | 14 4 p
. 30 P 50 „ 481 W/GASOUNE
I 19011 93 75 N
397? I 1 10 505 -is
—— 2t>0 419 L -
T l 593 11 K
'1 0 W/DIESEL P
6 |350j* 14201440)592 J 19 I
50 I 24011111/ I 439 j 17 I 2 H 18 M
SOLINE ONLY DIESEL ONLY 16 L
27 K
15 J

he
14 H
28 G

f F
E
I
D
I S-.5 GRA I [
12004147 12004148
PRNDLLAMP C211

Q
- 8-.5 GRA -

l/P
TURN GROUND
SIGNAL SWITCH G200

C-58 INSTRUMENT PANEL LAMPS

 A 2 150 240 111 439 17 2 H liP
B 3 16 350 420 440 592 J
~_ _ _ _ _ _ _ _ _ _ _ 240-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
HORN/OM
15 AMP '1 C 140 15 120
0950833
E358397
F 300 30 50
o 593 11
68 250419
10 505
901 93 75
K
L
M(
N
481 W/GASOLINE

10 W/OIESEL
G 39 1234 31 59 50 824 14 : P 12015964
1 2 3 4 5 10 9 8 7

44

C100

PANEL DIMMER
SWITCH C202 150 156
DOME
12020029 2
C203
12020030 CIRCUIT "PARK
BREAKER
25 AMP I I
10
HEAD
S214
LIGHT ,
OFF

SWITCH 40
'PARK
9 ............................. (SEE PAGE 18)

HEAD

LIGHT SWITCH
1"__ 24O-1.00RN _ _ _~ PROVISIONS
FOR

~
DOME LAMPS
S206
.-_150-3.0 BLK _ _ _"

~ 2~5981
15B-.8WHT

. . . .- - - - - - - -. .- - -. .- - - - - - - - - - - -. .- - - - - - - - - - - - - - - - - -. .

HORN RELAY
(SEE PAGE 26)

liP
l/P A
GROUND ~
G200 -

PROVISIONS FOR DOME LAMPS C-59

CIRCUIT OPERATION BACKUP LAMPS DO NOT OPERATE
TEST RESULT ACTION
BACKUP LAMPS PARK, TAIL, MARKER, AND LICENSE LAMPS 1. Place transmission in reverse. Test lamp lights. ISOLATE problem in body builder’s
With the Ignition Switch in RUN or START, voltage is Voltage is applied through the TAIL LPS Fuse to the Connect test lamp from LT GRN installed wiring.
applied through the TURN/BU Fuse to the Transmission Light Switch at all times. With the Light Switch in PARK (24) wire at rear lamp harness
Position Switch or the Backup Lamp Switch. Whenever or HEAD, voltage is applied to the Park, Tail, Marker, and connector C400 to ground. Test lamp does not light. GO to step 2 .
the gear selector lever is shifted to REVERSE, the License Lamps.
Transmission Position Switch or the Backup Lamp Switch 2. Connect a test lamp from DK BLU Test lamp lights. GO to step 3.
closes and voltage is applied to the Backup Lamps and (75) wire at backup lamp switch
connector C214 to ground. Test lamp does not light. CHECK condition of TURN/BU
the lamps turn on.
fuse. If fuse is good, LOCATE and
REPAIR open in DK BLU (75) wire
DIAGNOSIS - REAR EXTERIOR LAMPS from backup lamp switch
connector C214 to fuse block and
PRELIMINARY CHECKS: DK BLU (38) wire.
The rear lamp systems (taillamps, backup lamps, and socket(s). If only one system is not working, LOCATE 3. Connect a test lamp from LT GRN Test lamp lights. LOCATE and REPAIR open in LT
license plate lamps) all receive voltage from the same and REPAIR an open in the wiring and/or bulbs that (24) wire at backup lamp switch GRN (24) wire from backup lamp
wire circuit (BRN 9) and are grounded at the bulb pertain to that system. connector C214 to ground. switch connector C214 to rear
lamp harness connector C400.
NONE OF THE REAR LAMP SYSTEMS OPERATE
Test lamp does not light. Adjust backup lamp switch. If
TEST RESULT ACTION backup lamp switch will not adjust
properly, REPLACE backup lamp
1. Connect a test lamp from ORN Test lamp lights. GO to step 2. switch.
(40) wire at light switch connector
C202 to ground. Test lamp does not light. CHECK condition of TAIL LPS fuse.
If fuse is good, LOCATE and
REPAIR open in RED (2) wire from
light switch connector C202 to
battery junction block and/or ORN
(40) wire from light switch
connector C202 to fuse block.

2. Place light switch to PARK Test lamp lights. GO to step 3.

position. Connect test lamp from
BRN (9) wire at light switch Test lamp does not light. REPLACE light switch.
connector C202 to ground.
3. Connect a test lamp from BRN (9) Test lamp lights. LOCATE and REPAIR open in BLK
wire at rear lamp harness (150) wire.
connector C400 to ground.
Test lamp does not light. LOCATE and REPAIR open in BRN
(9) wire from rear lamp harness
connector C400 to light switch
connector C202.

C-60 REAR LAMPS

 24-.8 LT GRN ■

RH
PROVISIONS FOR BACKUP
RH SIDE MARKER LAMP

[CUD] (CHDh-8BLK
C406
2977107

RH TAIL STOP AND

TURN LAMP

RH LICENSE
LAMP NOTE: THIS HARNESS IS
07 I
SHIPPED ALONG WITH THE
VEHICLE AND INSTALLED
BY THE BODY BUILDER.

LH LICENSE
LAMP

LH
BACKUP
LAMP
LH TAIL, STOP AND
TURN LAMP ^ 2 4 ^ - 6BLK^

C405
2977107

PROVISIONS FOR
LH SIDE
MARKER
24-,8 LT GRN

REAR LAMPS HARNESS C-61

 C247
12020030

PANEL DIMMER 156

SWITCH

C202
12020029

HEAD

LIGHT
SWITCH

I 9-1.0 BRN

p i i -■ r\

9-.8 BRN
A 1150 | 2 4 0 11111 | [ 439 17 | 2 H l/P C400
B I 16 1350J | | 14201440 592 J 12065150
C
D
1
9
15 120
33
_J LZ 593 11 K
250 419
^ o *
L .481 W/GASOLINE
E 35 8 397 ^ ^ r~ 10 M
F !300 30 I 50 I | 19011 93 75 N* •10 W/DIESEL
G 39 I I 59! I I
CO
CM

31 14 4 P
1 2 3 12015964
4 5 10 9 8 7 6
-------------- ------

DIESEL ONLY C100

GT100
12085003
(UPPER)
12085002
S115
(LOWER)
(SEE PAGE 15)
C-62 TAILLAMPS
 TRANSMISSION
I ID 0] I BACKUP LAMP
I 1 !I J] [][][ SWITCH

I □ II □ 11 I
VAM M M /W VW V*
< HOT IN START OR RUN ? ■H I B/f I II □ I H
m w /w w v w ^
IkS Ekfi 4-0 (pi
0yfl Ik® Skf I [ kS
A —S [«k1 I [ k S
fri I o)

REAR LAMP
HARNESS

I 24-1.0 LTGRN1

-r
A 2 150 | 240 J1111 | I 4391 17 1 , 2 H l/P 12020926
B 3 I 16 13501 | i I420l44tf L592 J
C 140 15 120
— I ^ -\ I— 59: I 11 K
D 9 508 33 68 250 B19 L -481 W/GASOLINE
E 35 8 397 ^
— « o
^
^
n 10 5 0 5 1 ,3 M
F |300 30 i 50 | I 1901] 93 75 [-10 W/DIESEL
G 39 11234 311 59 | 50 | | J824I 14 4 P I 7S-.BOKBLU
1 2 3 4 5 10 9 8 7 6
-j— v -r—

C100

BACKUP LAMPS C-63

CIRCUIT OPERATION

VACUUM SYSTEMS EGR VALVE VACUUM SYSTEM

A vacuum-operated component uses the force of The EGR valve is operated by an integral vacuum A leak in the EGR (exhaust gas recirculation) vacuum
normal air pressure working against the lower air actuator that controls a pintle within the valve. The pintle system can upset the ECM’s programmed control of
pressure of a partial vacuum to operate the component. remains closed to prevent exhaust gas recirculation until exhaust gas recirculation and adversely affected engine
The vacuum created within the inlet manifold when the vacuum is applied to the actuator. The vacuum causes operation. Too much exhaust gas recirculation at idle or
engine is running is stored in a vacuum tank in the the pintle to open, allowing a measured flow of exhaust cruise can result in the engine stalling after closed
engine compartment. A check valve in the line feeding gas to enter the inlet manifold. throttle deceleration, surging during steady throttle
vacuum to the tank keeps the stored vacuum from cruising, or a rough idle. Too little exhaust gas flow
weakening when inlet manifold vacuum drops during The EGR system remains closed during periods of allows combustion temperatures to become too high and
high speed or high power operation. engine idle and deceleration to prevent rough idle from bring about detonation ("spark knock") or an overheated
excessive dilution of the fuel-air mixture. It also remains engine. In addition, nitrous oxide emissions may be high
Vacuum is routed through hoses (and in some cases, closed at wide-open throttle to prevent power loss. At enough to cause the vehicle to fail an emissions test.
tubing) to a mechanical or electric valve that provides a other times, it rapidly cycles open and closed to
means of controlling the vacuum-operated component. modulate the flow of exhaust gas as required. Under Because the source of a EGR system symptom might
When the valve is open, it allows vacuum to go to an certain circumstances, it may remain fully open to be traced to a mechanical or electrical condition as well
actuator that actually operates the component. When provide the maximum EGR. as a faulty vacuum system, an effective systematic
the component is to be returned to its original position, diagnosis procedure should examine all three categories
the valve cuts off the vacuum to the actuator hose and A manifold absolute pressure (MAP) sensor measures of components - not just the vacuum system alone.
vents the hose to normal air pressure. the strength of the vacuum in the EGR vacuum circuit Therefore, no exclusive vacuum system diagnosis
and sends a signal back to the electronic control module procedures are provided here. For more information on
A typical actuator is a metal shell with a movable shaft (ECM). If actual vacuum differs from the preferred the EGR system, refer to the 1991 “Fuel and Emissions
that retracts and extends to mechanically operate the vacuum as calculated by the ECM, the ECM will adjust Service Manual."
component. A flexible diaphragm separates the interior the on-off intervals of the EGR valve to correct the flow
of the shell into two chambers - a sealed chamber to of exhaust gas into the cylinders. This provides the DIAGNOSIS
which vacuum can be admitted, and an open chamber required control of oxides of nitrogen emissions while
exposed to normal air pressure. The movable shaft is retaining engine performance under all operating Conditions most likely to cause vacuum system
attached to the center of the diaphragm and extends conditions. The ECM also uses the signal from the MAP problems include hoses that leak or become
from the open chamber. sensor to control fuel delivery and ignition timing. disconnected. With the engine running, either condition
is easily detected from the hiss of air at the opening.
When the vacuum is directed to the sealed chamber, Vacuum for the EGR system is taken from the throttle Other common vacuum problems are kinked or
normal air pressure presses on the other side of the body and routed through a hose to the electronic obstructed hoses, hoses connected incorrectly or
diaphragm and causes it to retract the shaft. When the vacuum regulator valve (EVRV) solenoid. The solenoid binding components.
vacuum is cut off, the sealed chamber is vented to is controlled by the 435 circuit from the ECM. When the
outside air to balance the air pressure on both sides of solenoid opens the electronic vacuum regulator valve A vacuum pump can be used as a vacuum source to
the diaphragm and eliminate the force that retracted the vacuum reaches the EGR actuator through another operate components and test the system. The built-in
shaft. A coiled spring within the sealed chamber vacuum hose and opens the EGR pintle valve to allow vacuum gage of the pump provides a means of checking
expands to push the diaphragm back to its original exhaust gas to flow into the inlet manifold. When the for a vacuum leak as well. Once vacuum is applied to
positions. This extends the shaft. EVRV solenoid is released, the valve vents the EGR operate the component, the gage should hold steady
actuator to outside air to close the EGR pintle valve. until the vacuum is purposely released.
EXHAUST GAS RECIRCULATION
VACUUM SYSTEM On vacuum systems that are controlled by electrical
All 1991 P-Motorhome gasoline engines are equipped or electronic switches, check for a blown fuse, wiring that
is cracked, frayed or burned, and high resistance in
with an exhaust gas recirculation (EGR) system. The
connectors of the control circuits) before checking for a
EGR system allows a small amount of exhaust gas to
suspected vacuum system problem.
flow from the exhaust manifold into the inlet manifold
when the throttle is opened beyond idle and inlet
manifold vacuum is normal. This reduces combustion
temperatures in the engine to control oxides of nitrogen
emissions.

C-64 VACUUM SYSTEM

 S111
(SEE PAGE 11)

I 450-.6 BLK/WHT W T JL • I

ENGINE
GROUND
G100

EXHAUST GAS RECIRCULATION (EGR) VACUUM SYSTEMS C-65

V8 GASOLINE ENGINE
 S113 S116

C108

C196

C197
C105

C199
4

1. Cold Advance Control

2. Fast Idle Solenoid
3. Fuel Shut-Off Valve
4. Generator
5. Glow Plug (RH)
6. Cold Advance and Fast Idle 1. Glow Plug (LH)
Temperature Switch 2. Coolant Temperature Sender

Figure 1 • Engine W iring Harenss -- RH Side (6.2L V 8 HD Diesel Engine) Figure 2 - Engine Wiring Harness -- LH Side (6.2L V8 HD Diesel Engine)

C-66 COMPONENT LOCATOR VIEWS

 1. Low Coolant Warning Switch
2. Map Sensor
3. Battery Junction Block

Figure 3 - Batteries and Cables (6.2L V8 HD Diesel Engine) Figure 5 - Engine Wiring Harness to Cowl/Radiator (6.2L V8 HD Diesel Engine)

C121
C113 8
C128

1. Glow Plug Controller

2. Water in Fuel Sensor
3. Fuel Heater C120
4. Output Speed Sensor
5. Transmission
6. Input Speed Sensor
7. Oil Pressure Sender
8. Engine Speed Sensor
C104
C190 C191 1. Coil
2. Distributor 7
3. Electronic Spark
Module
4. Input Speed Sensor
5. Output Speed Sensor
FRONT
6. Transmission
OF 7. Engine Temperature
VEHICLE Sensor
C172 C172
VIEW C174 12H31

Figure 4 - Engine Wiring Harness -- Rear (6.2L V8 HD Diesel Engine) Figure 6 - Engine Wiring Harness - LH Side (7.4L V8 Gasoline Engine)

COMPONENT LOCATOR VIEWS C-67

 S106

C115 ?I [ I—] C110 C111 C112

S108

12H11
S109

C175-

C106-

1. Fuel Pump Relay

2. Brake Pressure Warning Switch

C117 Figure 8 - Engine W iring Harness to Cowl (7.4L V8 Gasoline Engine)

1. Idle Air Controller
2. TP Sensor
3. Injectors
4. EVRV
5. Cooling Fan Switch S103
6. Starter Motor
7. Knock Sensor
8. Map Sensor
9. Generator
10 . Coolant Temperature
Sensor

12H32

C116 8 • C109 GJ03 C105

10

FRONT
OF
VEHICLE FRONT
OF
VEHICLE
VIEW A VIEW B

Figure 7 - Engine Wiring Harness, RH Side (7.4L V8 Gas Engine) Figure 9 - Steering Column Switches

C-68 COMPONENT LOCATOR VIEWS

1. Horn Relay 6. PCM
S126 C100 C208
2. Cooling Fan Relay 7. Dimmer Switch
3. DRL Relay 8. Ignition Switch
4. Hazard Flasher 9. Backup Lamp Switch C210 IT]
5. DRAC Module

1. Fuel Sender Assembly

[I]
C206
C207
C251
C205
C250
GT100

S214

VIEW 0 12H10
VIEW 0 12H47 12H42

Figure 10 - Engine Wiring Harness to Cowl (7.4L va Gasoline Engine) Figure 12 - Fuel Sender and Rear Lamp Wiring

S1 C209~
,.....,........-----7'~"'-~ / C208
~~=---I~J
o
C200

1. Battery
2. Starter Motor

1. Horn Relay
2. DRL Relay
3. DRAC Module
4. Hazard Flasher
5. rCM
S200
6. ALDL G109
7. Ignition Switch
8.
9.
Dimmer Switch
Backup Lamp Switch
FRONT~
OF VEHICLE
VIEW0
C214 12H42

Figure 11 - Engine Wiring Harness to Cowl (6.2L va HD Diesel Engine) Figure 13 - Battery and Leads (7.4L va Gasoline Engine)

COMPONENT LOCATOR VIEWS C-69

C O M P O N E N T L O C A T IO N Page -- Figur COMPONENT LOCATION Page - Figure
Auxiliary Cooling Fan Relay ................ Top LH side of shipping p a n e l..................... .............. 69 10 Injector # 2 ............................................... Top of e n g in e ................................................................. 68 7
Auxiliary Cooling Fan Switch .............. RH side of e n g in e .......................................... .............. 68 7
Backup Lamp S w itc h ............................ On steering c o lu m n ........................................ .............. 69 10 Input Speed S e n s o r........................ LH side of transm ission.......................................... . . . 67 4
69 11 67 6
Battery, F ro n t.......................................... RH frame rail behind engine ....................... .............. 67 3 Knock Sensor ................................. RH side of e n g in e ................................................... . . . 68 7
Battery, Rear .......................................... RH frame rail behind engine ........................ .............. 67 3 Low Coolant Warning Switch . . . . . . . RH side of radiator ................................................. . . . 67 5
69 13 MAP Sensor (Diesel) ..................... LH side of shipping panel ..................................... . . . 67 5
Battery Junction B lo c k .......................... LH side of shipping panel ............................ .............. 67 5 MAP Sensor (Gasoline) ................ RH rear of e n g in e ................................................... . . . 68 7
Brake Pressure Warning Switch ......... Near master c y lin d e r...................................... .............. 68 8 Oil Pressure S e n d e r....................... LH rear of engine ................................................... . . . 67 4
Cold Advance Control .......................... Top front of e n g in e ........................................ .............. 66 1 Output Speed Sensor ................... LH side of transm ission.......................................... . . . 67 4
Cold Advance Fast Idle Temperature 67 6
Switch ................................................. RH rear of engine .......................................... .............. 66 1 PCM ................................................. LH side behind shipping panel ............................ . . . 69 10
Coolant Temperature Sender Starter M o t o r ................................... RH side of e n g in e ................................................... . .. 67 3
(D ie s e l)................................................. LH front of e n g in e .......................................... .............. 66 2 68 7
Coolant Temperature Sensor 69 13
(G asoline)............................................. Top RH front of engine ................................. .............. 68 7 TCM ................................................. LH side behind shipping panel ............................ . . . 69 11
Cruise Control S w itc h ............................ LH side of steering column .......................... .............. 68 9 Top of e n g in e .......................................................... . . . 68 7
Distributor ............................................... Top rear of e n g in e .......................................... .............. 67 6 Turn Signal S w itc h .......................... LH side of steering column ................................... . . . 68 9
DRAC Module ........................................ Inside LH side of shipping p a n e l................ .............. 69 10 Water in Fuel S e n s o r ..................... RH rear of e n g in e ................................................... . . . 67 4
69 11 Connectors:
DRL R e la y ............................................... Top LH side of shipping p a n e l..................... .............. 69 10 C100 ............................................. . . . Top of LH cowl ........................................................ . . . 69 10
69 11 69 11
Engine Speed Sensor .......................... Rear of engine ............................................... .............. 67 4 C101 ................................. . . . Front of LH cowl ..................................................... . . . 69 10
Engine Temperature S e n s o r................ LH side of engine .......................................... .............. 67 6 69 11
ESC Module .......................................... Top of engine near d is trib u to r..................... .............. 67 6 C102 ............................................. LH frame rail near f r o n t .......................................... . . . 68 8
E V R V ........................................................ RH front of e n g in e .......................................... .............. 68 7 C103 ............................................. . . . At fuel pump re la y ................................................... . . . 68 8
Fast Idle Solenoid ................................. Top front of e n g in e ........................................ .............. 66 1 C104 ............................................. At engine temperature s e n s o r.............................. . . . 67 6
Fuel Heater ............................................. Top rear of e n g in e ......... ? .............................. .............. 67 4 C105 ............................................. At generator ............................................................ . . . 66 1
Fuel Pump Relay ................................... LH frame rail behind shipping panel ......... .............. 68 8 68 7
Fuel S e n d e r............................................. Inside fuel tank ............................................... .............. 69 12 C106 ............................................. At cooling fan s w itc h ............................................... . .. 68 7
Fuel Shutoff Valve ................................. Top front of e n g in e ........................................ .............. 66 1 C108 ............................................. At coolant temperature s w itc h .............................. ... 66 2
Generator (Diesel) ................................. Front of e n g in e ................................................. .............. 66 1 C109 ............................................. At coolant temperature s e n d e r.............................. ... 68 7
Generator (Gasoline) ............................ Front of e n g in e ................................................. .............. 68 7 C 110 ............................................. At TP s e n s o r............................................................ . .. 68 7
Glow Plug #1 ........................................ LH side of engine .......................................... .............. 66 2 cm ... ....... . . . At RH in je c to r .......................................................... ... 68 7
Glow Plug # 2 ........................................ RH side of e n g in e .......................................... .............. 66 1 C112 ............................................. At LH injector .......................................................... ... 68 7
Glow Plug # 3 ........................................ LH side of engine .......................................... .............. 66 2 C113 ............................................. At glow plug controller............................................ ... 67 4
Glow Plug # 4 ........................................ RH side of e n g in e .......................................... .............. 66 1 C114 ............................................. . . . At cold advance/fast idle temperature switch . . . ... 66 1
Glow Plug # 5 ........................................ LH side of engine .......................................... .............. 66 2 C115 ............................................. . . . At idle air c o n tro lle r................................................. ... 68 7
Glow Plug #6 ........................................ RH side of e n g in e .......................................... .............. 66 1 C116 . ........................................... At MAP sensor ........................................................ ... 67 5
Glow Plug # 7 ........................................ LH side of engine .......................................... .............. 66 2 68 7
Glow Plug #8 ........................................ RH side of e n g in e .......................................... .............. 66 1 C117 ............................................. At knock sensor ..................................................... ... 68 7
Glow Plug Controller ............................ Top LH rear of e n g in e ................................... .............. 67 4 C119 ............................................. At oil pressure s e n d e r............................................ ... 67 4
Hazard Flasher ...................................... Top LH side of shipping p a n e l..................... .............. 69 10 C120 ............................................. . . . At electronic spark c o n tro l..................................... ... 67 6
69 11 C121 ................................. . . . At ignition c o i l .......................................................... ... 67 fi
Headlamp Dimmer Switch ................... LH side of steering column .......................... .............. 69 11 C123 ............................................. At engine speed sensor ........................................ ... 67 4
Horn R e la y ............................................... Top LH side of shipping p a n e l..................... .............. 69 10 C125 ............................................. Left of d is trib u to r..................................................... ... 67 6
69 11 C126 ............................................. At low coolant warning switch .............................. ... 67 5
Idle Air Control A c tu a to r....................... Top LH side of e n g in e ................................... .............. 68 7 C127 ............................................. At water in fuel s e n s o r............................................ ... 67 4
Ignition C o i l ............................................. Top rear of e n g in e .......................................... .............. 67 6 C128 ............................................. At fuel heater .......................................................... ... 67 4
Ignition S w itc h ........................................ On steering c o lu m n ........................................ .............. 69 10 C129 ............................................. At fast idle s o le n o id ................................................. ... 66 1
69 11 C130 ............................................. At cold advance co n tro l.......................................... ... 66 1
Injector # 1 ............................................... Top of e n g in e ................................................. .............. 68 7 C131 ............................................. At fuel shutoff v a lv e ................................................. ... 66 1

C-70 COMPONENT LOCATOR INDEX

COMPONENT LOCATION Page - Figure COMPONENT LOCATION Page -- Figure
C150 ................... ....................... LH side of front cro s s m e m b e r..................... .............. 69 10 C252 ........................................ LH front frame r a i l ........................................................... 69 11
69 11 C253 ........................................ LH front frame r a i l ........................................................... 69 11
C151 .... ....................... LH side of front cro s s m e m b e r..................... .............. 68 8 C401 ........................................ At fuel level s e n d e r ......................................................... 69 12
C153 .......................... ....................... RH side of front cro ssm e m b er..................... .............. 68 8 C402 ........................................ LH side of rear crossm em ber........................................ 69 12
C154 .......................... ....................... At brake pressure warning switch .............. .............. 68 8 Grommets:
C155 .......................... ....................... Center of front cro ssm e m b er........................ .............. 68 8 GT100 ...................................... LH side of c o w l................................................................ 69 10
C172 .......................... ....................... At transmission electronic control .............. .............. 67 4 69 11
67 6 GT101 ...................................... Injector b o d y .................................................................... 68 7
C173 .................................................. ....................... At output speed s e n s o r................................. .............. 67 4 Grounds:
67 6 G100 ........................................ Lower LH side of c o w l.................................................... 69 10
C174 .......................... ....................... At input speed s e n s o r................................... .............. 67 4 G101 ........................................ Top front of e n g in e ......................................................... 66 1
67 6 G103 ........................................ At alternator bracket ...................................................... 68 7
C175 .......................... ............................................. At EVRV .................................................................................................................. ........................... 68 7 G109 ........................................ Lower LH side of c o w l.................................................... 69 11
C190 .......................... ............................................. At glow plug co ntro lle r .................................................................... ........................... 67 4 G110 ........................................ RH frame rail below rear battery ................................. 67 3
C191 . . ....................... At glow plug co n tro lle r................................... .............. 67 4 69 13
C192 .......................... ........................... 66 1 G4Q0 ........................................ LH crossmember in front of fuel t a n k .......................... 69 12
C193 .......................... .............. 66 1 Splices:
C194 .......................... .............. 66 1 510 0 Battery junction block .................................................... 67 5
C195 .......................... ....................... At #8 glow plug ............................................. ............................ 66 1 510 1 Battery junction block .................................................... 67 5
C196 .................................................. ............................................. At # 7 glow plug ...................................................................................... ........................... 66 2 510 2 Battery junction block .................................................... 67 5
C197 .................................................. ........................... 66 2 510 3 RH lower side of engine ............................................... 68 7
C198 .................................................. ............................................ At # 3 glow plug ...................................................................................... ........................... 66 2 510 4 Battery junction block .................................................... 67 5
C199 .................................................. ............................................. At #1 glow plug ............................................. ........................... 66 2 S 1 0 6 .......................................... LH frame rail behind cowl ............................................. 68 8
C200 .......................... ....................... At ignition s w itc h ...................................................................................... ........................... 69 11 510 8 LH frame rail behind cowl ............................................. 68 8
C201 .................. ....................... At ignition s w itc h ...................................................................................... ............................ 69 11 510 9 Front center of e n g in e .................................................... 68 7
C204 .................................................. ............................................ At ALDL ................................................................................................................. ............................ 69 11 511 0 LH side of transmission (d ie s e l)................................... 67 6
C205 .................................................. ............................................ At DRAC m o d u le ...................................................................................... ........................... 69 10 LH side of cowl (g a s o lin e )............................................. 68 8
69 11 511 1 Front RH side of engine ............................................... 68 7
C206 .......................... ....................... Base of steering column ........................................................... ........................... 68 9 511 2 Rear center top of engine ............................................. 67 4
69 10 68 7
C207 .................................................. ............................................ LH frame rail behind cowl ....................................................... ............................ 69 10 511 3 LH top of e n g in e ............................................................. 66 2
69 11 511 4 LH side of c o w l............................................................... 68 8
C208 .................................................. ............................................ At DRL relay .................................................................................................... ........................... 69 10 69 10
69 11 511 5 RH side of c o w l............................................................... 68 8
C209 .................................................. ....................... At horn re la y .................................................................................................... ........................... 69 10 69 11
69 11 511 6 LH top rear of engine .................................................... 66 2
C210 .................................................. ............................................ At cooling fan r e la y ............................................................................. ........................... 69 10 S 1 2 6 ........................................ LH side of c o w l............................................................... 69 10
C211 .................. ....................... Lower left of steering c o lu m n .............................................. ........................... 69 10 515 0 RH lower side of engine ............................................... 66 1
69 11 515 1 Rear center of engine .................................................... 67 4
C212 .................................................. ............................................ At hazard fla s h e r ...................................................................................... ........................... 69 10 515 2 Rear center of engine .................................................... 67 4
69 11 515 3 LH side of tra n sm issio n ................................................. 67 4
C213 .................................................. ............................................ Lower left of steering c o lu m n .............................................. ........................... 69 10 515 4 LH top rear of engine .................................................... 67 4
C214 ....................... At backup lamp switch ................................................................ ........................... 69 10 515 6 RH top side of c o w l........................................................ 69 11
69 11 515 7 LH top side of c o w l........................................................ 69 11
C215 .................................................. ............................................ At headlamp dimmer s w itc h .................................................. ............................ 69 10 S200 ........................................ Cowl near steering column .......................................... 69 10
69 11 69 11
C220 ....................... ....................... LH frame rail near cowl ................................................................ ........................... 68 8 5204 Lower RH corner behind cowl ...................................... 69 10
C222 .................................................. ............................................ LH cowl top center ............................................................................. ........................... 68 8 5205 Lower RH corner behind cowl ...................................... 69 10
C244 .................................................. ............................................ Base of steering column ........................................................... ........................... 68 8 521 3 Lower RH corner behind cowl ...................................... 69 10
C250 .................................................. ............................................ LH front frame r a i l .......................................... ........................... 69 10 521 4 Lower RH corner behind cowl ...................................... 69 10
C251 .................................................. ............................................ LH front frame r a i l .................................................................................. ........................... 69 10 69 11
521 5 Lower RH corner behind cowl ...................................... 69 10

COMPONENT LOCATER INDEX C-71

COMPONENT LOCATION Page -- Figure
8216
521 .......................
6 . LH top of cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69 11
8217
521 .......................
7 . Top LH corner
comer of cowl.
cowl . . . . . . . . . . . . . . . . . . . . .. 69 10
S250 .......................
8250 .......................................... . Top LH ·corner
corner of cowl.
cowl . . . . . . . . . . . . . . . . . . . . .. 69 11

C-72 COMPONENT LOCATER INDEX

Abbreviation List ................................................... 10 Charge/Start and, Gasoline, P Motorhome . . . C-30 Control Module, Outputs, Diesel, Diesel, Transmission Control Module,
Air Conditioning, Front Manual, R/V ................ A-94 Circuit Diagrams .................................................... 3 Electronic, R / V ................................................. A-64 P M o to rh o m e ....................................................C-40
Air Conditioning, Provisions For, Circuit M a lfu n c tio n s ............................................... 4 Control Module, Outputs, Gasoline, Diesel, Transmission Control Module,
P Motorhome ................................................... C-50 Circuit Operation .................................................... 3 Electronic, R/V ................................................. A-60 Pinouts, R / V ...................................................... A-67
Air Conditioning, Rear, R /V ................................ A-95 Circuit Wiring Repair Procedures ....................... 6 Control Module, Outputs, Gasoline, Diesel, Transmission Control Module,
Alarm, Audio, R /V .................................................A-111 Cluster, Instrument Panel, R/V ..........................A-103 Electronic, P Commercial ...............................A-46 Pinouts, P Commercial ................................... B-55
AM Radio, R / V ......................................................A-144 Cluster, Instrument Panel, P Commercial . . . . B-69 Control Module, Outputs, Gasoline, Diesel, Transmission Control Module,
Antilock Brakes, Rear Wheel, R / V .....................A-116 Cluster, Instrument Panel, P M o torho m e ......... C-55 Powertrain, R /V ................................................. A-70 Pinouts, P M otorhom e......................................C-39
Audio Alarm, R / V .................................................A-111 Component Locations .......................................... 3 Control Module, Outputs, Gasoline, Digital Ratio Adapter Controller (DRAC)
Auxiliary Battery, R/V ..........................................A-22 Component Locater Index, R /V ..........................A-194 Powertrain, P C o m m e rcial............................... B-52 Module, R / V ...................................................... A-75
Auxiliary Cooling Fan, R/V ................................ A-89 Component Locater Index, P Commercial . . . . B-87 Control Module, Outputs, Gasoline, Digital Ratio Adapter Controller (DRAC) Module,
Auxiliary Cooling Fan, P M o torho m e ................ C-49 Component Locater Index, P Motorhome . . . . C-70 Powertrain, P Motorhome ...............................C-36 Gasoline W/Man Trans or Auto Trans and Diesel
Auxiliary Fuel Tank and Fuel Tank Component Locator Views, R/V ....................... A-166 Control Module, Outputs, Diesel W/Auto Trans, P Commercial ........................ B-64
Selector Switch, Diesel, R/V ......................... A-81 Component Locator Views, P Commercial . . . B-81 Transmission, R /V .............................................A-72 Digital Ratio Adapter Controller (DRAC) Module,
Auxiliary Fuel Tank and Fuel Tank Component Locator Views, P Motorhome . . . . C -66 Control Module, Outputs, Diesel Transmission, Diesel W/Man Trans, P Com m ercial.............. B-65
Selector Switch, Gasoline, R/V .....................A-80 Conditioning, Air, R /V .......................................... A-94 P C o m m e rcial.................................................... B-56 Digital Ratio Adapter Controller (DRAC)
Auxiliary Heater, R/V ..........................................A-99 Conditioning, Air, Provisions For, Control Module, Outputs, Diesel Transmission, Module, P M otorhom e......................................C-42
Backup Lamps (Fleetside and Wideside), P M o to rh o m e ....................................................C-50 P M o to rh o m e ....................................................C-40 Distribution, Power, Diesel, R /V ..........................A-12
R /V ...................................................................... A-154 Connectors, Metri-Pack ........................................ 8 Controller (DRAC) Module, Digital Distribution, Power, Diesel W/Man Trans,
Backup Lamps (Stepside), R /V ......................... A-155 Connectors, W eather-P ack................................... 8 Ratio Adapter, R/V .......................................... A-75 P C o m m e rcial.................................................... B-6
Backup Lamps (Suburban and Utility), Contents, Table o f ................................................. 1 Controller (DRAC) Module, Digital Ratio Distribution, Power, Diesel W/Auto Trans,
R /V ...................................................................... A-155 Control, Cruise, R / V .............................................A-124 Adapter, W/Man or Auto Trans and Trans P M o to rh o m e ...................................................... B-7
Backup Lamps, P Commercial ......................... B-77 Control, Cruise, P Motorhome ..........................C-52 and Diesel W/Auto Trans, P Commercial . . . B-64 Distribution, Power, Diesel W/Auto Trans,
Backup Lamps, P M otorhom e............................ C-63 Control Module, Electronic, Pinouts, Controller (DRAC) Module, Digital Ratio P Motorhome .................................................... C-5
Basic Electricity ..................................................... 4 Diesel, R / V ........................................................ A-62 Adapter, Diesel W/Man Trans, Distribution, Power, Diesel Driveaway
Battery, Auxiliary, R /V ..........................................A-22 Control Module, Electronic, Pinouts, P C o m m e rcial.................................................... B-65 P C om m ercial.................................................... B-8
Block, Fuse, R/V .................................................A-14 Gasoline, R / V ....................................................A-57 Controller (DRAC) Module, Digital Ratio Distribution, Power, Diesel Driveaway,
Block, Fuse, Gasoline W/Man Trans, Control Module, Electronic, Pinouts, Adapter, P Motorhome ................................... C-42 P M o to rh o m e .................................................... C-7
P C o m m e rcial................................................... B-10 Gasoline, P Commercial ................................. B-43 Convenience Center, R / V ................................... A-21 Distribution, Power, Gasoline, R /V ..................... A-10
Block, Fuse, Gasoline W/Auto Trans, Control Module, Powertrain, Pinouts, Cooling Fan, Auxiliary, R / V ................................. A-89 Distribution, Power, Gasoline W/Man Trans,
P C o m m e rcial................................................... B-11 Gasoline, R / V ....................................................A -66 Cooling Fan, Auxiliary, P Motorhome .............. C-49 P C o m m e rcial.................................................... B-4
Block, Fuse, Gasoline, P Motorhome .............. C -8 Control Module, Powertrain, Pinouts, Cruise Control, R/V .............................................A-124 Distribution, Power, Gasoline W/Auto
Block, Fuse, Diesel W/Man Trans, Gasoline, P Commercial ................................. B-49 Cruise Control, P M o to rh o m e ............................ C-52 Trans, P Commercial ........................................ B-5
P C o m m e rcial................................................... B-12 Control Module, Transmission, Pinouts, Data, Bulb, R/V ....................................................A-15 Distribution, Power, Gasoline W/Auto
Block, Fuse, Diesel W/Auto Trans, Gasoline, P M otorhom e................................... C-33 Data, Bulb, P C om m ercial................................... B-14 Trans, P M o to rh o m e ........................................ C-4
P C o m m e rcial................................................... B-13 Control Module, Transmission, Pinouts, Data, Bulb, P M o to rh o m e ................................... C-10 Distribution, Power, Gasoline Driveaway
Block, Fuse, Diesel, P Motorhome ................... C-9 Diesel, R / V ........................................................ A-67 Daytime Running Lamps (Canada Only), P C om m ercial.................................................... B-9
Brake Booster Vacuum System, Power, R/V . . A-164 Control Module, Transmission, Pinouts, R /V .......................................................................A-22 Distribution, Power, Diesel Driveaway,
Brake Warning System, School Bus, Diesel, P Commercial ..................................... B-55 Daytime Running Lamps (Canada Only), P M o to rh o m e .................................................... C-6
P C o m m e rcial................................................... B-74 Control Module, Powertrain, Pinouts, P C o m m e rcial.................................................... B-28 Dome Lamps, Instrument Panel Compartment
Brake Warning System, R / V .............................. A-114 Diesel, P M otorhom e........................................C-39 Daytime Running Lamps (Canada Only), Lamp and Lighted Vanity Mirror, R /V ............A-119
Brake Warning System Without Rear Control Module, Inputs, Diesel, P Motorhome ....................................................C-18 Dome Lamps, Provisions For, P Motorhome . . C-59
Wheel Antilock Brakes, R /V ............................A-115 Electronic, R / V ................................................. A-63 Defogger, Rear, R / V .............................................A-146 Door Locks, 2-Door, (With Power Outside
Bulb Data, R / V ..................................................... A-15 Control Module, Inputs, Gasoline, Diagnosis C h a r ts .................................................... 4 Rearview Mirrors), Power, R / V ....................... A-131
Bulb Data, P C o m m e rcia l................................... B-14 Electronic, R/V ................................................. A-58 Diagrams, C ir c u it.................................................... 3 Door Locks, 2-Door, (Without Power Outside
Bulb Data, P Motorhome i ................................ C-10 Control Module, Inputs, Gasoline, Diesel, Electronic Control Module, R / V ............A-63 Rearview Mirrors), Power, R / V ....................... A-130
Camper and Trailer Wiring, R/V ....................... A-160 Electronic, P Commercial .............................. B-44 Diesel Engine Fuel Controls, P Commercial . . B-63 Door Locks, 4-Door, (With Power Outside
Cargo Lamp, R / V .................................................A-120 Control Module, Inputs, Gasoline, Diesel Engine Fuel Controls, P Motorhome . . . C-47 Rearview Mirrors), Power, R / V ....................... A-132
Center, Convenience, R/V ................................ A-21 Powertrain, R /V ................................................. A -68 Diesel Engine Fuel Controls, 6.2L, R / V ............A-87 Door Locks, 4-Door, (Without Power Outside
Charge, Start and, Diesel, R/V ......................... A-56 Control Module, Inputs, Gasoline, Diesel Engine Fuel Controls, 6.2L HD, Rearview Mirrors), Power, R / V ....................... A-133
Charge, Start and, Diesel, P Commercial . . . . B-41 Powertrain, P C o m m e rcial.............................. B-50 R /V .......................................................................A -88 Drive, Four-Wheel, R / V ........................................ A-126
Charge, Start and, Diesel, P M otorhom e......... C-31 Control Module, Inputs, Gasoline, Diesel, Transmission Control Module, R/V . . . . A-72 Electrical Test E qu ip m e n t...................................... 4
Charge, Start and, Gasoline, R/V .....................A-55 Powertrain, P Motorhome ...............................C-34 Diesel, Transmission Control Module, Electricity, B a s ic ...................................................... 4
Charge, Start and, Gasoline, P Commercial . . B-40 P C o m m e rcial.................................................... B-56

GENERAL INDEX 1
Electronic Control Module Pinouts, Diesel, Fuse Block, Gasoline W/Auto Trans, Horns, R /V ............................................................. A-49 Lamps (Fleetside and Wideside), Backup,
R /V .......................................................................A-62 P M o to rh o m e .................................................... C -8 Horns, P C o m m e rcia l.......................................... B-36 R /V ...................................................................... A-154
Electronic Control Module Pinouts, Gasoline, Fuse Block ID and Bulb Data, R/V ...................A-15 Horns, P Motorhome .......................................... C-26 Lamps, Backup, P C om m ercial.......................... B-77
R / V .......................................................................A-57 Gages (Fleetside), Instrument Panel, R/V . . . . A-109 Hot Fuel Handling, R /V ........................................ A-79 Lamps, Backup, P M o to rh o m e ..........................C-63
Electronic Control Module Pinouts, Gasoline, Gages (Suburban and Utility), Instrument How To Use This M a n u a l..................................... 3 Lamps (Fleetside and Wideside), Park and
P C o m m e rcial.................................................... B-43 Panel, R/V .........................................................A-108 Idle Air Control, Fuel Control and, R/V ............A-78 Marker, R/V ...................................................... A-35
Electronic Control Module - Inputs, Diesel, Gages, Instrument Panel, P C o m m e rcial......... B-72 Idle Air Control, Fuel Control and, Lamps, Front Park, Marker, Roof and
R / V .......................................................................A-63 Gages, Instrument Panel, P M o to rh o m e ......... B-57 P C o m m e rcial.................................................... B-54 Hazard, R/V ...................................................... A-34
Electronic Control Module - Inputs, Gasoline, Glow Plugs, R /V ....................................................A-84 Ignition, Gasoline, R/V ........................................ A-76 Lamps, Park and Marker Signal,
R / V .......................................................................A-58 Glow Plugs, P C o m m e rcia l................................. B-60 Ignition, Gasoline, P Commercial ..................... B-42 P C om m ercial.................................................... B-31
Electronic Control Module - Inputs, Gasoline, Glow Plugs, P Motorhome ................................. C-44 Ignition, Gasoline, P M o torho m e ....................... C-32 Lamps, Park and Marker Signal,
P C o m m e rcial.................................................... B-44 Ground Distribution, Diesel, R / V ........................A-18 Index, Component Locater, R/V ....................... A-94 P M o to rh o m e ....................................................C-22
Electronic Control Module - Outputs, Diesel, Ground Distribution, Diesel W/Man Trans, Index, Component Locater, P Commercial . . . B-87 Lamps, Rear Exterior, R/V ................................. A-149
R / V .......................................................................A-64 P C o m m e rcial.................................................... B-19 Index, Component Locater, P Motorhome . . . . C-70 Lamps, Roof Marker, R / V ................................... A-34
Electronic Control Module - Outputs, Gasoline, Ground Distribution, Gasoline W/Auto Trans, Index, Symptoms, R/V .......................................... A -8 Lamps (Stepside), Backup, R/V ....................... A-154
R /V .......................................................................A-60 P C o m m e rcial.................................................... B-20 Index, Symptoms, P Commercial ....................... B-3 Lamps (Suburban and Utility), Backup,
Electronic Control Module - Outputs, Gasoline, Ground Distribution, Diesel, P Motorhome . . . C-12 Index, Symptoms, P M o torho m e....................... C-3 R N ...................................................................... A-157
P C o m m e rcial.................................................... B-46 Ground Distribution, Forward Lamps, Indicator Lamps (Fleetside), R /V ....................... A-106 Lamps (Suburban and Utility), Indicator,
Four-Wheel Drive, R/V ........................................ A-126 P C o m m e rcial.................................................... B-15 Indicator Lamps (Suburban and Utility), R /V ...................................................................... A-104
Forward Lamp Harness, P C om m ercial............B-24 Ground Distribution, Gasoline, R / V ...................A-16 R /V ...................................................................... A-104 Lamps (Suburban and Utility), Park and
Forward Lamp Harness, P M o to rh o m e ............C-14 Ground Distribution, Gasoline W/Man Trans, Indicator Lamps, P Commercial ....................... B-70 Marker, R/V ...................................................... A-159
Forward Lamp Harness, W/DRL, P C om m e rcial.................................................... B-16 Indicator Lamps, P M o torho m e ..........................C-56 Lamps (With Quad Halogen), Hazard, R/V . . . A-38
P C o m m e rcial.................................................... C-27 Ground Distribution, Gasoline W/Auto Trans, Injection, Throttle Body, R / V .............................. A-77 License Lamp (Fleetside and Wideside),
Forward Lamp Harness, W/DRL, P C om m e rcial.................................................... B-17 Injection, Throttle Body, P C o m m e rc ia l............ B-48 R /V ...................................................................... A-159
P Motorhome .................................................... C-20 Ground Distribution, Gasoline, P Motorhome . C-11 Injection, Throttle Body, P Motorhome ............C-38 License Lamp (Suburban and Utility),
Front Manual Air Conditioning, R /V ...................A-94 Ground Distribution, Rear, P Commercial . . . . B-21 Instrument Panel Cluster, R /V ............................ A-103 R /V ...................................................................... A-158
Front Park, Marker, Roof and Hazard Harness, Forward Lamps, P Commercial . . . . B-24 Instrument Panel Cluster, P C o m m e rcial......... B-69 Locations, C o m p o n e n t.......................................... 3
Lamps, R /V ........................................................ A-33 Harness, Forward Lamps, P M o to rh o m e ......... C-14 Instrument Panel Cluster, P Motorhome ......... C-55 Malfunctions, C irc u it............................................... 4
Fuel Control and Idle Air Control, Harness, Forward Lamps W/DRL, Instrument Panel Indicators, R /V ....................... A-104 Manual, How To Use This ................................... 3
Gasoline, R / V ....................................................A-78 P C om m e rcial.................................................... B-27 Instrument Panel Indicators, P Commercial . . . B-70 Marker Lamps (Fleetside and Wideside),
Fuel Control and Idle Air Control, Gasoline, Harness, Forward Lamps W/DRL, Instrument Panel Indicators, P Motorhome . . . C-56 Park and, R /V ....................................................A-35
P C om m ercial.................................................... B-54 P Motorhome ....................................................C-20 Instrument Panel Gages (Fleetside, Marker Lamps (Suburban and Utility),
Fuel Controls, Diesel Engine, P Commercial . . B-63 Harness, Rear Lamps, P C o m m e rc ia l.............. B-76 Wideside, Crew Cab), R /V .............................. A-106 Park and, R /V ....................................................A-34
Fuel Controls, Diesel Engine, P Motorhome . . C-47 Harness, Rear Lamps, P Motorhome .............. C-61 Instrument Panel Gages (Suburban and Marker Signal Lamps, Park and,
Fuel Controls, (6.2L), Diesel Engine, Harnesses, Vacuum, R/V ................................... A-164 Utility), R / V ........................................................ A-108 P C om m ercial.................................................... B-31
R /V .......................................................................A-87 Hazard Lamps, (All Models), Rear, R / V ............A-35 Instrument Panel Gages, P Commercial ......... B-71 Marker Signal Lamps, Park and,
Fuel Controls, (6.2L HD), Diesel Engine, Hazard Signal Lamps, P Commercial .............. B-32 Instrument Panel Gages, P M otorhom e............C-57 P M o to rh o m e ....................................................C-22
R /V .......................................................................A -88 Hazard Signal Lamps, P M otorhom e ................ C-22 Instrument Panel Lamps (Fleetside), Marker, Roof and Hazard Lamps, Front
Fuel Handling, Gasoline, Hot, R /V ..................... A-79 Hazard Lamps with Quad Halogen R /V ...................................................................... A-109 Park, R/V ...........................................................A-34
Fuel Tank Selector Switch, Diesel, Headlamps, R / V ............................................... A-36 Instrument Panel Lamps (Suburban and Metri-Pack C o n ne ctors .......................................... 8
Auxiliary Fuel Tank and, R / V ..........................A-81 Hazard Lamps, Front Park, Marker, Roof Utility), R / V ........................................................ A-110 Operation, C irc u it.................................................... 3
Fuel Tank Selector Switch, Gasoline, and, R /V ............................................................. A-33 Instrument Panel Lamps, P C o m m e rc ia l......... B-72 Panel Doors, Rear Defogger, R / V ..................... A-147
Auxiliary Fuel Tank and, R / V ..........................A-80 Headlamps - Base, R/V ......................................A-25 Instrument Panel Lamps, P Motorhome ......... C-58 Park and Marker Lamps (Fleetside and
Fuse Block, R / V ....................................................A-14 Headlamps - Base, P Commercial ................... B-23 In tro d u c tio n ............................................................. 3 Wideside), R / V ................................................. A-157
Fuse Block, Diesel W/Man Trans, Headlamps - Base, P M o to rh o m e ..................... C-15 Key-ln and Lights-On Warning Buzzer, Park and Marker Lamps (Suburban and
P C o m m e rcial.................................................... B-12 Headlamps With Daytime Running Lamps, R /V ...................................................................... A-113 Utility), R / V ........................................................ A-156
Fuse Block, Diesel W/Auto Trans, R /V ...................................................................... A-26 Lamp, Cargo, R/V ...............................................A-121 Park and Marker Signal Lamps,
P C o m m e rcial.................................................... B-13 Headlamps with Daytime Running Lamps, Lamp (Fleetside and Wideside), License, P C om m ercial.................................................... B-31
Fuse Block, Diesel W/Auto Trans, P C om m ercial.................................................... B-28 R /V ...................................................................... A-159 Park and Marker Signal Lamps,
P M o to rh o m e .................................................... C-9 Headlamps with Daytime Running Lamps, Lamp (Suburban and Utility), License, P M o to rh o m e ....................................................C-22
Fuse Block, Gasoline W/Man Trans, P Motorhome ....................................................C-18 R /V ...................................................................... A-159 Phantom View, R/V ............................................... A-2
P C o m m e rcial.................................................... B-10 Headlamps, Quad Halogen, R /V ........................A-32 Lamps, Turn Signal, R /V ..................................... A-44 Phantom View, P C om m ercial...............................B-2
Fuse Block, Gasoline W/Auto Trans, Heater, Auxiliary, R / V .......................................... A-99 Lamps, Turn Signal, P C om m ercial................... B-34 Phantom View, P M o to rh o m e ............................ C-2
P C o m m e rcial.................................................... B-11 Heater, R/V ...........................................................A-96 Lamps, Turn Signal, P M o to rh o m e ...................C-24 Plugs, Glow, R/V ................................................. A-84

2 GENERAL INDEX
Plugs, Glow, P Commercial .............................. B-60 Powertrain Control Module Pinouts, R / V ......... A -66 Transmission Control Module Pinouts,
Plugs, Glow, P M o to rh o m e ................................ C-44 Powertrain Control Module Pinouts, P Motorhome . ............................................... C-39
Power Brake Booster Vacuum System, R/V . . . A-164 P C om m e rcial....................................................A-49 Transmission Control Module, Diesel,
Power Distribution - Diesel, R/V ....................... A-12 Powertrain Control Module Pinouts, R /V .......................................................................A-72
Power Distribution, Diesel W/Man Trans, P M o to rh o m e ................................................... A-33 Transmission Control Module, Diesel,
P C o m m e rcial......................................................B-6 Pulse Wiper/Washer, R / V ................................... A-50 P C om m ercial.................................................... B-56
Power Distribution, Diesel W/Auto Trans, Radio, AM ETR, R /V ............................................ A-144 Transmission Control Module, Diesel,
P C o m m e rcial......................................................B-7 Radio, Stereo, R / V ...............................................A-145 P M o to rh o m e ......... ..........................................C-40
Power Distribution, Diesel W/Auto Trans, Radio, R / V ............................................................. A-143 Transmission Converter Clutch
P M o to rh o m e ................................................... C-5 Rear Air Conditioning, R / V .................................A-95 Detent Solenoid (5.7L), R /V ............................ A-74
Power Distribution, Diesel Driveaway, Rear Defogger - Panel Doors, R/V ...................A-147 Turn Signal Lamps, R / V ......................................A-44
P C o m m e rcial..................................................... B-8 Rear Defogger, R/V .............................................A-146 Turn Signal Lamps, P .C o m m e rcia l................... B-34
Power Distribution, Diesel Driveaway, Rear Defogger - Tailgate, R /V ............................ A-148 Turn Signal Lamps, P M otorhom e..................... C-24
P M o to rh o m e ................................................... C-7 Rear Exterior Lamps, R / V ................................... A-149 Underhood Lamp, R / V ........................................A-121
Power Distribution - Gasoline, R/V .................. A-10 Rear Hazard Lamps, R/V ................................... A-35 Vacuum Systems, R/V ........................................ A-164
Power Distribution, Gasoline W/Man Trans, Rear Wheel Antilock Brakes, R/V ..................... A-116 Vacuum Systems, P Commercial ..................... B-79
P C o m m e rcial..................................................... B-4 Rear Window, Power, R /V ................................... A-142 Vacuum Systems, P M o torho m e ........................C-64
Power Distribution, Gasoline W/Auto Trans, Rearview Mirrors, Power Outside, R /V .............. A-129 View, Phantom, R / V ............................................... A-2
P C o m m e rcial..................................................... B-5 Regular Production Option (RPO) L is t................ 10 View, Phantom, P Commercial ............................ B-2
Power Distribution, Gasoline W/Auto Trans, Repair Procedures, Circuit W irin g ....................... 6 View, Phantom, P M otorhom e............................ C-2
P M o to rh o m e ................................................... C-4 Roof and Hazard Lamps, Front Park, Views, Component Locator, R / V ....................... A-166
Power Distribution, Gasoline Driveaway, Marker, R/V ......................................................A-34 Views, Component Locator, P Commercial . . . B-81
P C o m m e rcial..................................................... B-9 Roof Marker Lamps, R/V ................................... A-40 Views, Component Locator, P Motorhome . . . C -66
Power Distribution, Gasoline Driveaway, Safety Belt Warning Buzzer, R /V ....................... A-112 Warning Buzzer, Key-ln and Lights-On,
P M o to rh o m e ................................................... C -6 Special T o o ls ........................................................... 9 R /V .......................................................................A-113
Power Door Locks, 2-Door (With Power Start and Charge, Diesel, R /V ............................ A-56 Warning Buzzer, Safety Belt, R/V ..................... A-112
Outside Rearview Mirrors), R / V .....................A-131 Start and Charge, Diesel, P C o m m e rcial......... B-41 Warning System Without Rear Wheel
Power Door Locks, 2-Door (Without Power Start and Charge, Diesel, P Motorhome ......... C-31 Antilock Brakes, Brake, R /V ............................ A-115
Outside Rearview Mirrors), R / V .....................A-130 Start and Charge, Gasoline, R /V ....................... A-55 Weather-Pack Connectors ................................... 8
Power Door Locks, 4-Door (With Power Start and Charge, Gasoline, P Commercial . . . B-40 Windows, Power, R/V . ........................................ A-136
Outside Rearview Mirrors), R / V .....................A-132 Start and Charge, Gasoline, P Motorhome . . . C-30 Windows, 2-Door, Power, R /V ............................ A-139
Power Door Locks, 4-Door (Without Power Symptoms Index, R /V ............................................ A -8 Windows, 4-Door, Power, R /V ............................ A-140
Outside Rearview Mirrors), R / V .....................A-134 Symptoms Index, P Commercial . ..................... B-3 Windshield Wiper/Washer, P Commercial . . . . B-38
Power Door Locks and Power Mirrors, Symptoms Index, P Motorhome ....................... C-3 Windshield Wiper/Washer, P Motorhome . . . . C-28
R /V ...................................................................... A-131 Table of Contents ................................................. 1 Wiper/Washer, Pulse, R /V ................................... A-50
Power Mirrors and Power Door Locks, Tailgate, Rear Defogger, R/V ............................ A-148 Wiring, Camper and Trailer, R / V ........................A-160
R /V ...................................................................... A-131 Tailiamps (Fleetside and Wideside),
Power Outside Rearview Mirrors, R / V ..............A-129 R /V ...................................................................... A-151
Power Rear Window, R / V ...................................A-142 Tailiamps (Stepside), R / V ................................... A-152
Power Windows, 2-Door, R / V ............................A-139 Tailiamps (Suburban and Utility),
Power Windows, 4-Door, R / V ............................A-140 R /V ...................................................................... A-150
Power Windows, R/V ..........................................A-136 Tail, Rear Marker and License Lamps,
Powertrain Control Module Inputs - P C om m ercial.................................................... B-78
Gasoline, R / V ................................................... A -68 T a ilia m p s............................................................... C-62
Powertrain Control Module Inputs - Test Equipment, Electrical ................................... 4
Gasoline, P C o m m e rc ia l................................ B-50 Throttle Body Injection, R/V ...............................A-77
Powertrain Control Module Inputs - Throttle Body -Injection, P Commercial ............ B-48
Gasoline, P M otorhom e...................................C-34 Throttle Body Injection, P M o to rh o m e .............. C-38
Powertrain Control Module Outputs - Tools, Special ........................................................ 9
Gasoline, R / V ...................................................A-70 Trailer Wiring, Camper and, R / V ....................... A-160
Powertrain Control Module Outputs - Transmission Control Module Pinouts,
Gasoline, P C o m m e rc ia l................................ B-52 R /V ...................................................................... A-67
Powertrain Control Module Outputs - Transmission Control Module Pinouts,
Gasoline, P M otorhom e...................................C-36 P C om m ercial.................................................... B-55

GENERAL INDEX 3